Project 4

For a vehicle of gross weight 300 kg, the motor ratings are 1200Wh, 65V. The range is 225km and the maximum speed is 60kmph. Calculate the capacity of the battery pack required and the number of series-parallel connections. Give a stepwise discussion on how a battery pack is built.
Note: Choose any relevant lithium ion datasheet

For a vehicle of gross weight 300 kg, the motor ratings are 1200Wh, 65V. The range is 225km and the maximum speed is 60kmph. Calculate the capacity of the battery pack required and the number of series-parallel connections.

Here i have attached the excel for stepwise calculation how calculate the capacity of battery pack required and number of series and parallel connections are required. Please refer the attached excel

2. Give a stepwise discussion on how a battery pack is built.

The Battery Cell is a small, rectangular component roughly the geometry of a paperback book. These battery cells are assembled together in frames to form Battery Modules. These modules are then linked together via a myriad of electrical connections and enclosed in the Battery Pack which is assembled directly to the automobile frame.

Battery Cells -> Battery Modules -> Battery Pack

Process:

RAW MATERIAL TO AUTOMOBILE PLANT:

Battery fabrication abrication process using the battery cells as the “raw material” in the battery pack fabrication process. These small individual cells are typically manufactured at other, specialized facilities and arrive at the automobile fabrication plant as completed products

LITHIUM-ION BATTERY:

The individual battery cells are simply metallic cartridges that contain an anode, cathode, and separator immersed in an electrolyte fluid.

LEAK CHCEK & EV Battery Assembly Fixture:

Before the cells can be assembled into modules, each cell undergoes checks within a specialized fixture. This process is essentially a “leak check” process to ensure that the electrolyte isn’t leaking from the cell and to ensure that no moisture intrusion occurs over the entire operational life of the battery. This step is vitally important to ensure that the cells are properly functioning, and future battery capacity won’t be compromised.

Assemble the battery cells into battery modules:

Typically, there are about 12 battery cells per battery module, but this varies across automotive make and model

Final_Step:

The last step in battery pack fabrication is assembling the modules into the battery pack housing. This step involves a significant number of electrical hookups and fine-tuning. For example, the Nissan Leaf EV contains 48 battery modules which are all connected together via electrical monitoring equipment. These modules are typically picked and placed by an automated robotic assembly arm into the battery pack housing. After all the modules are placed into the housing they are manually connected together by an automotive technician. After all connections have been made, the battery pack housing cover is placed manually; finally, an automated robot arm is typically used to drill all screws thus completing the battery pack fabrication process.

Note: Choose any relevant lithium ion datasheet:

Here i have attached Battery Model LIR18650 2600mAh

Data sheet helps to findout below mentioned points for customer uses:

1. Characterstics of cell

2. Test conditions

3. Apperance & Electrical performance

4. Safety performnces and Enviourment tests

5. Packing and warrenty information

6. Dimension and performance of cell

Available Requirements:

1. Cylindrical Lithium Ion Rechargeable Cell