Project 1 Mechanical design of battery pack

Aim:- Mechanical Desigen Of Battery Pack.

Objective:-

Battery pack capacity:18kwh

Cell:ANR 26650M1-B

Prepare a detailed battery pack draw along with its enclosure.State your assumptions.

Theory:-

Battery pack capacity:18kwh

Cell:ANR 26650M1-B

They bring a lot high power due to their use of patented Nanophosphate battery technology. Based on Lithium iron phosphate chemistry LiFePO4cells are naturally safe at a wide range of temperatures and conditions. Whether the app requires outstanding cycle life or stable floating reliability, Lithium Werks ’26650 cells are suitable for a wide range of strengths pulse or pending applications. Nanophosphate Technology 26650 Lithium Ion Power Cell Provision of Nanophosphate battery technology thermal-stable chemistry, fast charging, consistent output, low volume loss over time, and total cost of ownership (TCO). It provides the basis for secure applications while meeting the most demanding customer requirements. Most layers of protection are employed in chemistry, cell and system the level of acquisition of energy storage solution with high security and tolerance of harassment in comparison in chemical compounds metal oxide lithium-ion The highly efficient A123 battery technology of Nanophosphate lithium iron phosphate LiFePO4 delivers high power and energy combined with excellent safety performance and wide range of health cycling with a lightweight, compact package. Our cells have low volume losses and growth disruption over time and high usable energy in a wide range of charging SOC, allowing our systems to meet the end-of-life energy and energy needs with minimal packing obesity.

Cell:ANR 26650M1-B Specification:-

Charactestics:-

Applications for ANR 26650M1-B:-

Government uses:-

i.Soilder power.

ii.Military power grids.

iii.Military vechiles.

Commercial uses:-

i.IT Backup.

ii.Autonoums guided vechicle.

iii.Telecome backup.

iv.Industrial robotics and material handling equipment.

Transportation solutions uses :-

Hybrid vechicle and electric vechicle

i.Off-highway vechicles.

ii.Passenger vechile.

iii.Commercial vechicle.

Grid solutions uses :-

i.Frequency regulation.

ii.Renewables integration

iiiReserve capacity

Mechanical Desigen Of Battery Pack:-

A high-power battery is one of the most important parts of an electric car battery. Battery parameters have a significant impact on some parts and features of the car.

Cell Interconnects:-

Cell size is linked to the maximum expected current management In order to obtain reliable welded connections in terminals, In addition, some alloys pay for both heat, strength, and low resistance, which are all desirable features of good wiring. value.Incompatible tabs can overheat, leading to even higher resistance resistance.Cellinterconnects should not be sold on storage caps or attached at high temperatures. recommends that the tabs resist or be laser-burned at both ends of the cells. Resistance welding provides unchanging power over time by using an important feature on the welding tab. These parameters can be specified and controlled by constant high quality constant temperature.

Insulated gasket:-

Solid insertion pad of 18650 batteries Poor and good point. protecting and preventing interference, providing high electrical insulation mechanical strength softness and elasticity.Barley Paper is pure cellulose, which is why it is used in a variety of materials, and has many applications. The electrical properties of these implants made it possible to use them in portable lithium-ion batteries. The best thing about cellulose is that it is a good protector while polar.

Battery welding:-

They are two types:-

i.Spot welding

ii.Laser welding.

i.Spot Welding:-

One of the oldest methods of welding resistance spot welding was invented by Elihu Thomson in 1877. This method usually uses a dual pulse. The first pulse eliminates impurities and oxides, and the second pulse comprises the active components. The temperature rises in the affected area, visible, and eventually reaches the point of melting. Forms of weld nugget in the affected area after cooling. This is a small amount of molten material that has been mixed together.

Laser Welding:-

Laser beam welding or is a welding method in which the laser beam provides a fixed heat source that binds objects together. The lasing medium, the lasing cavity, and the source pump all the main components in the laser welding machine as shown in Figure 3. The cavity design determines the type of outgoing beam and the light lenses used to focus on the laser. The level of beam produced can vary and when heated, a beam with low diffraction is required to create a stable heat source with a small local size.

Nickle strip:-

This is because the effectiveness and efficiency of nickel depends largely on its purity. However, there is a small amount of dirt that can get into the product while throwing it away. To avoid this, we try to maintain a very low temperature that prevents contaminants from entering the material.Nickel strips are used as battery connectors because they have a 20-30% higher efficiency than other materials. Manufacturers consider high conductivity because it allows them to produce batteries of different sizes and shapes. Also, without worrying about battery power and heat capacity.

Cell connecting togather :-

The electrically connected at the end (cathode) of the cell. Note that this area is isolated from the electric bus area or mechanical support that may have different electrical strength. Heat shields, such as tapes, shrink wraps, or sleeves, should have a minimum temperature of 150 ° C. This helps to ensure that the cells do not reach each other in height.

Battery connected to the heat sink:-

The required level of cell protection in the battery pack varies depending on the target system. For example, a battery pack designed for use with HEV should have a fenced-in area that separates cells from shock and vibration, protects them from contaminants and debris, and protects them from other environmental hazards, such as salt spray. Unless it is closed properly, even the enclosure is subject to pressure differences between its interior and the surrounding environment, resulting in small amounts of air exchange. So, over time, some moisture may accumulate and condense in the interior.

Battery connected in series and Parallel:-

Series:-

The batteries with a series connection each battery must have the same voltage and capacity batteries together in the series but you can not connect one To connect a batch of batteries to a series you connect a terminal battery with one battery to positive end of each other until all the batteries are connected. You will then connect a connect cable to the first battery terminal terminal in your battery series in your app, then another cable to the positive battery terminal terminal in your series

Parallel:-

The battery together is when you connect two or more batteries together to extend the battery hourly capacity amp. With the connection of a compatible battery the capacity will increase, however the battery The voltage will remain the same. When you connect batteries in a consistent manner, a terminal battery with one battery connected to the negative battery the next end and so on with a series of batteries.

.

Battery connected the cell balancing wire pin management of the battery system:-

Battery Management System:-

BMS will also control the battery charge by re-charging the received power Battery temperature control systems may be inactive or inactive, and the cooling area may be air, liquid, or some other type of phase change. Air cooling has the advantage of its simplicity. Such systems can operate, rely solely on the circulation of air, or operate, using fans for air flow. Commercially, Honda Insight and Toyota Prius both use efficient air conditioning for their battery systems. The biggest disadvantage of cooling the air is your inefficiency. Greater power must be used to apply the cooling method, which is much higher than the effective liquid cooling. Additional components of the cooling system also add weight to the BMS, reducing the efficiency of the batteries used for transport.

Battery pack Desigen Calculations:-

All the Parameter data taken by the data sheet.

Nominal voltage = 3.3V

Cell Radius = 0.013m

Cell Height = 0.065m

Cell Capacity = 2.5/2.4Ah

Weight of cell = 76g

Power = 2600W/kg

1. Cell volume:-

Cell volume = X Cell height X Cell radius

= 3.14 X 0.065 X 0.013

= 2.65 X 10^-3 m^3.

2. Battery Cell energy:-

Battery cell energy = Nominal voltage X Cell capacity.

= 3.3 x 2.5

= 8.25 wh

3. Total Battery Pack Energy = 18000wh

Toatal battery pack voltage = 150v

Battery pack toatal capacity = Total battery pack energy / total battery pack voltage.

= 18000/150

= 120Ah.

4. No cell in parallel = ( Battery pack total capacity) / (Nominal Cell Capacity)

= 120 / 2.5

= 48 cells in parallel.

5. No cells in series = (Battery pack total voltage ) / (Nominal cell voltage)

= 150 / 3.3

= 46 cells ibn series.

Total no cell calculate = 46 X 48

= 2208 cells .

6.Length of the battery pack = (No of cell x Cell dimension)

= 46 X 0.026

= 1.196m

7. Width of battery pack = ( No of cell in parallel ) x ( cell diameter)

= 48 X 0.026

=1.248m

8.Height of battery pack = 0.065m

9.Area of battery pack = (Length of battery pack X Width of battery pack)

= 1.196 X 1.248

= 1.5 m^2

10.Total weight of battery = ( Total no cell X Each cell weight)

= 2208 x 0.076

= 167.808 kg