Project 4

Q) 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

SOLUTION;

GIVEN DATA;

Vehicle of gross weight = 300Kg

MOtor ratings = 1200Wh,65V

Range = 225Km

Maximux speed = 60mph

TO FIND;

Calculate the capacity of battery pack required

and

the number of series-parallel connections

SOLUTIONS;

BATTERY PACK ESTIMATION
INPUTS
Vehicle Weight	300Kg
MotorRatings	1200Wh,65V
Range	225Km
Maximum Speed	60Kmph
CURRENT CALCULATION
Power	Voltage*Current
1200W	60V*Current
Current	1200/65=18.5
Current by an Motor	18.5 Ampere
Currrent Loss	1-10%
New motor current	18.5*1.05
New motor current	18.9 Amp
POWER REQUIRED AT MAX SPEED
At 60Km/hr	Voltage*Current
At 60Km/hr	60*18.9
At 60Km/hr	1134Watt
TRAVEL FACTOR
Travel factor	Total Range/Total Speed
Travel factor	225/60
Travel factor	225/60
Travel factor	4
POWER BASED ON TRAVEL FACTOR
Power required	Power*Travel factor
Power required	1134*4
Power required	4536 Watt
Power required	4.5 kW
BATTERY PACK CAPACITY BASED ON EFFICIENCY
Battery pack efficieny	85%-95%
efficiency	85%
Required battery pack capacity	4.5/0.85
Required battery pack capacity	5.29Kw
BATTERY PACK CAPACITY BASED ON MOTOR EFFICIENCY
Total Battery pack capacity	5.29/0.85
Total Battery pack capacity	6.22Kwh

SERIES-PARALLEL CONNECTION
Series_Connection
Motor Voltage	220V
Cell Nominal Voltage	4
No. Of series Connection	250/4
No. Of series Connection	62
Parallel Connetcion
Motor Current	160A
Cell Current	4A
No of parallel connection	40
Total Cells are required	2480

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 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 in the battery pack which is assembled directly to the automobile frame..

1)Battery cells

2.Battery Modules

3.Battery Pack

PROCESS;

RAW MATERIAL TO AUTOMOBILE PLANT;

• Battery fabrication process using the battery cells as the 'raw material' in the battery pack fabrication process
• These small individual cells are typically manufactured at others , specialized facilities and arrive at the automobile fabrication plant as completed products

LITHIUM-ION BATTERY;

• The individual battery cell are simly metallic cartridges that an anode
  cathode
• and
• separator immersed in an electrolyte fluid

LEAK CHECKING AND EV BATTERY ASSEMBLY FIXTURE;

• Before the cells can be assembled into modules,each of the cell undergoes checks within a specialized fixture
• This process is essentially a 'leak check' process to the 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 the step is vitally important to the ensure that the cells are properly functioning and future battery capacity wont be compromised...

ASSEMBLY THE BATTERY CELLS INTO THE BATTERY MODULES;

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

FINAL OR LAST STEP;

• The last step in the battery pack fabrication is the assembly of the modules into the battery pack housing
• This is the step involves in a significant number of electrical hookups and fine-tuning
• For example of Electrical vehicles in Nissan Leaf EV its contains 48 Battery modules which are all connected together via electrical monitoring equipment

• These modules are the typically picked and placed by an automated robotic assembly arm into the battery pack housing
• the battery pack housing covered by placed manually
• finally an automated robot arm is typically used to drill all screws thus the completing the battery pack fabrication process

NOTES;

I choose lithium ion datasheet model(LIR18650 2600mAh)

Data sheet helps to findout below mentioned points for customer uses are;

• Characteristics of cell
• Test conditions
• Apperance & Electrical performance
• Safety performances
• Environment tests
• packing and warrenty information
• Dimension and performance of cell