Project 1 Mechanical design of battery pack
Prepare a detailed battery pack drawing along with its enclosure. :
To ensure this project is a sucessful project we have to keep in mind a mny things like:
1.kind of battery we using ,it's chemistry,structure,voltage.
2.Amount of cell and how many cels connected in series and parallal so that we complete the demand.
3.Motor toeque.
4.Regenaration brake torque.
5.range of vehicle.
5.weight of vehicle.
6.Average energy consumption on a driving cycle.
7. price of the vehicle.
SPECIFICATION OF BATTERY:
calculation:
volume of single cell=3.14*.13^2..65=0.03451 m^3
single cell energy=single cell capacity *single cell voltage
=2.5*3.3=8.25 wh
Volumetric energy=single cell energy/volume of each cell
=8.25/0.03451 =239.06wh/m^3
Gravimetric energy=single cell energy/single cell mass
=8.25/0.076=108.55 wh/kg
Now we have assume that the voltage need to run the motor is 220 v.
Given that the battery pack capacity is 18 kwh.
So ,Energy=voltage *current
18000=220*current,
current=18000/220=82(near about).
So,cell connected in series =Total voltage/nominal voltage
=220/3.3=67(near about)
cell connected in parallal=total current/cell capacity
=82/2.5=33(near about)
Total no of cell=cell in series*cell in parallal
=67*33=2211
The total value of energy=(no of cell in series*nominal voltage)*(no of cell in paralal*cell capacity)
=(67*3.3)*(33*2.5)
=18.240 kwh
So, we can complete the demand of 18 kwh.
Total weight of the battery pack=no of cells*weight of single cell
=2211*0.076=168.036 kg
Total volume of the battery pack=no.of cells*volume of single cells
2211*0.03451=76.27 m^3
Energy Density=volume*battery pack eergy
=76.27*18.240=1391.1648 kwh/m^3
PHYSICAL MAUFACTURING OF THE BATTERY PACK:
DIMENSION OF A CELL
BATTERY PACK HOLDERS:
WELDING AND CONNECTION OF CELLS:
ADVANTAGE OF NICKEL STRIPS:1.here we use sopt welding ,so no damage to cell.
2. It is very efficient and easy to use.
3.It is corrosion resisitant.
4.we have to use 100% pure nickel ,so that electricity can flow very quickly.
BATTERY ENCLOSURE:
BATTERY ENCLOSER SPECIFICATION:1.Material that we use to made this is very light weight,but as strong as to handle vibration ,mechanical damage.
2.cost efficient.
3.Not so chemically engaged with environment.
BMS AND THERMAL MANAGMENT: Last but very important thing is Battery managment system and the thermal protection equipment .we have to use BMS for proper saftey and maintain a good cell life.
Thermal managment done through special kind of enclosure system (use in tesla) for air cooling system but if we use coolant or any liquid for cooing than we have to done proper lining of this coolant and proper differance from electric line.
Next we have to attached sensors like current,voltage,thermal sensing devices,that connected to BMS so that bms can track all the saftey poarameters.
BATTERY COOLING SYSTEM IN TESLA
FINAL FORM BATTERY:
