Project

Given inputs:

Motor Power = 40 kW

Motor Operating Voltage = 110V

Battery Peak Power = 23 kW

i) Considering the 2-Wheeler Power and Voltage requirement, Li-ion battery fits the best to the needs.

Advantages of Li-ion battery:

1. High Energy Density
2. Compact in Size
3. Low Maintenance
4. Low Self Discharge

Thermal Components to be used are:

1. PTC for protection from external shock conditions
2. CID for protection from overcharging conditions
3. PCB for protection from over-discharging conditions
4. Fuse for protection from over-current conditions

ii) 

Parameter	Value
Nominal Capacity	2200mAh
Dimensions	Height: 65mm Diameter: 18mm
Weight	45gms
Nominal Voltage	3.6V
Current	4A
Internal Resistance	200mOhm

iii) Motor current = Battery Power/Motor Voltage = 23,000/110 = 210 A

Motor current after losses = 250 A

Motor Power = Motor Current * Motor Voltage = 250*110 = 27.5 kW

Travel Factor = Range/Speed = 180/60 = 3

Final Motor Power = Motor Power * Travel Factor = 27.5*3 = 82.5 kW

Battery pack capacity = Motor Power / Efficiency = 82.5/0.85 = 100 kW

No.of cells in series = Motor Voltage/Cell Nominal Voltage = 110/3.6 = 32

No.of cells in parallel = Motor Current/Cell Current = 250/4 = 65

Total Cells of Battery Pack = 32*65 = 2080

iv) Battery Pack Volume: π*r^2*h = 3.14*9mm*9mm*65mm = 16540.5 mm3

v) Battery Pack Weight: Total Cells* Weight of Cell = 2080*45gms = 95kgs

vi) Spot Welding establishes cell to Cell interconnection

vii) Test to be performed are:

1. Safety Tests
   1. Cell Short Circuit Test
   2. Cell Overcharge Test
   3. Cell Nail Penetration Test
   4. Fire Resistance Test
2. Mechanical Tests
   1. Vibration Test
   2. Shock Test
   3. Waterproof Test

viii) Recycling Process includes:

1. Pryo Process: Recycling at the Refining Stage
2. Hydro Process: Recycling at the Production Stage
3. Direct Process: Recycling at the Assembly Stage

ix) Thermal Runaway Causes:

1. Cell manufacturing defects
2. Extreme High or Low Temperature
3. Overcharge
4. Short Circuit
5. Charge-Discharge cycles

Thermal Runaway Prevention:

1. Good BMS
2. Avoid Overcharging
3. Avoid Overheating
4. Good Storage