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Mechanical design of battery pack To make the battery pack, we have to first finalize the nominal voltage and capacity of the pack. Either it will be in term of Volt, mAh/ Ah or Wh. Total required Battery pack capacity is 18000 Wh. The individual Cell: ANR26650M1-B has Nominal voltage = 3.3 V Current Capacity = 2.5…
Syed Saquib
updated on 21 Sep 2023
To make the battery pack, we have to first finalize the nominal voltage and capacity of the pack. Either it will be in term of Volt, mAh/ Ah or Wh.
Total required Battery pack capacity is 18000 Wh.
The individual Cell: ANR26650M1-B has
Nominal voltage = 3.3 V
Current Capacity = 2.5 Ah
So, let us assume that for 18 kwh battery pack we need supply voltage of 200 V and 90 Ah
200 V = 3.3 * Cell in series
Cell in series = 200/3.3 = 60.60 = 60
Now, as we know that battery pack capacity (Wh) = Total current * Total voltage = (2.5* cell in parallel) * 200
18000 = (2.5* cell in parallel) * 200
Cell in Parallel = 18000/ (2.5*200) = 36
Module capacity
The required battery pack combination is 60S36P
For this we decided to choose 5 series and 3 parallel module connection.
Each 5S3P configuration Module Voltage capacity = 5*3.3 = 16.5 V
Each 5S3P configuration Current Module capacity = 3*2.5 = 7.5 Ah
So, total capacity of 1 module is = 16.5 * 7.5 = 123.75 Wh
Total Cells
Total number of cells = cell in 1 module * 144
Total number of cells = (5*3) *144
Total number of cells = 2160
1 cell capacity = 3.3* 2.5 = 8.25 Wh
So, total cell capacity = 2160*8.25
Total cells capacity = 17820 Wh = 17.82 KWh (almost 18 KWh)
Note: We should always target more KWH then required considering the losses and connection limitations.
Weight of one cell = 76 g = 0.076kg
So, Battery pack cell weight = 0.076*2160 = 164.16 kg
Module Connection
For 18 KWh of total 200 V and 90 Ah battery pack capacity we need 18000/123.75 = 145.45 modules.
For Simplicity of configuration we took 12*12= 144 modules of 5S3P.
We have to connect the cells in parallel to reach the desired capacity (mAh) and connect such parallel group in series to achieve the nominal voltage (Volt).
In this way, to achieve 200 V battery voltage, number of 5S3P configuration in series connected modules are = 200/16.5 = 12.12 = 12.
For 90 Ah battery current, now we connected 12(90/7.5 = 12) times such (series of 12 module of 200 V) in parallel to get 90 A current from this battery pack.
The 5S3P connection of ANR26650M1-B cell is shown below.
A typical bill of materials (BOM) includes the following:
Step 1: Select the ANR26650M1-B Cells for the Battery Pack
Step 2: Check the Cell Voltage
Step 3: Assemble the ANR26650M1-B Cells
Step 4: Choosing the Right Battery Strips and Spot Weld the Nickel Strips
We have two options two connect the ANR26650M1-B cells together:
The best choice is always Spot welding, but Spot Welder is much costlier than a good quality Soldering Iron.
Step 5: Adding the BMS
A battery management system (BMS) is any electronic system that manages a lithium battery pack and the main functionalities are
The battery pack have all around exposed nickel strips, to avoid any accidental shorting an Enclosure used.
Reference:-
https://datasheetspdf.com/pdf/1424845/A123Systems/ANR26650M1-B/1
https://www.instructables.com/DIY-Professional-18650-Battery-Pack/
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