Project 1 Mechanical design of battery pack

Li-ion cell (ANR 26650M1-B):

This Li-ion cell is manufactured by Lithiumwerks. They deliver very high power due to their use of patented Nanophosphate battery technology.

Based on the Lithium iron phosphate chemistry (LiFePO4), the cells are inherently safe over a wide range of temperature and conditions.

For outstanding cycle life stable float reliability this cells are suitable for a wide varity of power,pulse and stand by applications

Nanophosphate battery technology offers thermal stable chemistry.fast charging.consistent output law capacity loss

over time.

It provides extremely safe conditions for while meeting most demanding customers requirements Multiple layers of protections are employed on chemistry.cell and system

level to acheive an energy storage solution with superior safety

Dimensions:

Cell Specification:

Assumptions:

We are assuming the overall voltage required to operate the motor and other acessories of electric vehicle as 400v. So we have construct the battery pack of 18KWh for a 400 V input voltage motor.

Construction of battery pack:

To construct a battery pack initially we have to estimate the voltage requirement of the overall load of vehicle.

We had assumed as 400V as mentioned above.

Then the battery modules should be created in such a way that the overall voltage is matched with the load requirement voltage

The modules can be created in series/parallel connections of individual cells. Then every modules should be connected in series/parallel to construct final battery pack

In series connection-Voltage added and Current remains same.

In Parallel connection-Voltage remains same and Current gets added.

Here in our case single cell voltage is 3.3V and a capacity of 2.56Ah Energy provided from sigle cell is give 8.25Wh

So for 18KWh battery pack we need approximately(18000/8.25=2182 cells)

We have to create a single module to produce 400V for our load requirement.

So to obtain 400 V output cells are connected in series where voltage become added and current remains same

To obtain 400V,no of cells required is approximately (400/3.3=122 cells).

Thus single module gives as 400V from 122 cells but energy of one module is not enough to run the vehicle as motor
power rating is higher. The energy generated from

single module is (122 * 8.25Wn=1006.5Wh).

So to construct a battery pack with 18KWh with not exceeding 400V the modules are connected in parallel in this parallel connections the currents are getting added and

voltage remains same as 400V As current increases the power of battery pack increase to run the motor load of high power rating.

Now we have to find how many similar modules should be connected in parallel to acheive 18KWh battery pack

This can be calculated as (18kWh/1006.5Wh =17.88) which gives as nearly 18 similar modules should be connected in pararallel to acheive 18KWh battery pack

Thus the battery model is said to be 122S18P configuration(122 series and 18 parallel connections),which gives us (122*18=2196 cells) From this we have created overall capacity of battery pack as (2196*8.25Wh=18117Wh) which is slightly higher than 1BKWh

The overall Capacity(Ah) of battery pack is given as (2.5Ah * 18=45Ah).

Which means it provided 45 A of current continuously for one hour to full discharge

Thus 18 modules should be arranged in a way as battery pack to fit in an EV chasis

Enclosure construction:

To find overall enclosure volume we have to find the volume of single module volume consist of 122 cells in series connection and multiplied with 18 parallel connected module volume,
Single module,

Let as assume 122 cells(single module) are divided into 2 modules of 61+61 cells

The length of the module No.of cell in row (Cell dia. Margin at both side of cells) + clearance at side(2(cell dia margin)).

=61*(26+4)+60=1890mm

The breath of the module = (cell dia +Margin of both side of cells + clearance)

=26+4+60=90mm

Height of the module = Height of cell connecting strip thickness wires say 35mm

=65-35-100 mm

Thus the volume required for single module is 1.8 0.09 0100162 m3

Total number of modules assumed are 18°2=36 modules,since single module is divided into two modules.

Therefore total volume required for battery pack of 122518P configuration construction is 0.016236-0583 m3

Thus from the above results it is assumed approximately Im3 of volume should be used for EV battery pack with additional ventilation spaces for pack

We can assume that two modules are combained into one cabinet. So 18 cabinets should be connected to form

final battery pack.

Materials and process in battery pack construction:
Battery pack constructions consist of three major levels of processings namely cell level,module level pack level constructions.

The electrodes are combined with electrolyte to various cell models as cylindrical prismatic pouch type cells

After case sealing cells are combained to form module level construction Finally these modules are combained to form pack level constructions.

Joining technologies of cells:

The interconnections between cells/modules are practised by various welding techniques Some of them are,

• Ultrasonic metal welding.
• Resistance welding.
• Laser beam welding.
• Wire bonding.
• Mechanical Jooining.

Ultrasonic metal welding:

Ultrasonic metal welding or UMW, is a solid-state welding technique which forms a band by applying moderate static pressure and an ultrasonic oscillation of about 20 kHz between two

parts of metal. The solid-state weld is formed through the high frequencymotion between the parts causing continuous shearing and plastic deformation, while also removing any oxide layers

or contaminants

Most metals can be ultrasonically welded and the method is excellent for welding together thin foils, as well as
thicker sheets with spot or seam welds and also wires.

The four types of materials welded in this process can be seen as,

a) Aluminium wire welding on copper.

b)Copper and aluminium welding.

c)Multilayered copper foil welding.

d)Ultrasonic seam welding.

Resistance spot welding:

One of the oldest welding methods is resistance spot welding (RSW) RSW is a technique where two or more metal sheets are welded together through the application of an electrical current

and pressure between two electrodes. The electrical resistance of the material at the interface results in the generation of heat and melts the materials together without the use of

filler material or gases.

The temperature increases in the affected area, the interface, and eventually reaches the material's melting point. A weld nugget forms in the affected area after cooling.

This is a small volume of the material which has melted and then fused together.

Laser beam welding:

Laser beam welding or LBW is a welding technique in which a laser beam provides a concentrated heat source that fuses the materials together.

LBW is commonly performed using keyhole mode welding in which the extreme power density of the laser beam causes the metal to melt and evaporate.

As the metal atoms evaporate from the surface, forces in the opposite direction of the evaporation causes a local

vapor pressure. The vapor pressure creates a hole which is known as the

keyhole by depressing the molten metal.

Here below shown the welding of busbars to cylindrical battry cans.

Enclosures:

Cells in series connection

When you connect cells together in series, it doesn't change the amps or the capacity, it only raises the voltage of the pack. Hooking them up in series means that you connect the positive end

of one cell (or P-group) to the negative end of the other as shown below,

Cells in Parallel connections

If you take several cells and connect their same-type electrodes in parallel, they all will act as though they are one large cell. Also, when you first connect them to each other,

they must be at the same level of charge,

Cell houlders

These houlders are used for houlding the individual cells in a better posture without mis-assemble. The connections can be made accordingly to make series connections and

parallel connections to form the required module dimensions

After installind the cells in a individual module the entire maximum positive terminal and maximum negative terminal are made under single pair of

terminals as shown below,

Here shown the cells are arranged and welded without using cell houlders as

safety concerns.

They are just covered by polimer sheet after the interconnections are made. Mostly connections with cell holders should be recommanded for better

Battery Cabinet arrangements

Each modules are interconnected in series or parllel according to the requirement and packed as a single large cabinet pack as shown below,

Battery pack arrangement:

Finally the overall battery pack after the arrangement of all cabinet connections with enclosure looks like this as shown below,

Vents holes are present with enclosure for cooling/heating the battery pack temperature according to its environment conditions.

Different cell types are used by different manufacturers of EV such as Cylindrical Prismatic,Pouch types The pack constructions are different for every manufacturers.

Below shown the battery pack constructios process of Tesla,BMW and Nissan Leaf.