Pdf mechanical design and packaging of battery packs for. Chemistry, components, types and terminology offers to the reader a clear and concise explanation of how liion batteries are designed from the perspective of a manager, sales person, product manager or entry level engineer who is not already an expert in liion battery design. Battery tech electric vehicle news and trends insideevs. New fascinating details emerge on rivian battery pack design. Individual battery cells are grouped together into a single mechanical and electrical unit called a battery module. Battery pack voltage volts pack voltage has a big impact on pack capacity. Functional requirements are established for the pack. Battery pack design, validation, and assembly guide using. Transformation from the horsedrawn carriage to horseless transportation took its time when new technology arrived. General motors electric vehicle battery production ansys simplorer predictions for a 24cell battery module in blue as compared to experimental data in red measured using the us06 driving schedule for overall pack. Development of battery pack design for high power liion. Some systems will show approximately constant power consumption no matter what the battery voltage is, and some will have a sweet spot where the power is lowest.
The development of a publicly available model that can project benchscale results to real world battery pack values would be of great use. Design of a lithium ion battery pack for 400 mph electric. An ev battery pack accounts for up to 46% of this cost 35. Better battery packs made possible with cooltherm materials. Application of robust design methodology to battery packs. Unfortunately, we can not use all of our battery pack or we will kill our batteries extremely fast.
Several patented mechanical design solutions, developed with an aim to increase crashworthiness and vibration isolation in ev battery pack. Pack level actions battery pack structure vent management sys pack cooling sys battery controls sys power limits temp, age, others over temp over chargedischarge ens control cell balancing battery sensors v, i, t fusing cell level actions. Range per charge miles using an average of 300whmile. Battery manufacturers design ev battery packs for specific vehicle models, and.
Batteries, ev west electric vehicle parts, components, evse. Accelerate ev adoption power of battery energy storage. The battery pack will be designed for an average energy consumption of 161. Design and optimization of lithiumion batteries for. With over 30 years of experience our engineers can provide design solutions for your product. As you can see the battery pack, battery management system bms controller, motor and the transmission unit forms the major components in an ev. Chapter 5, summary of battery pack testing describes performance, abuse, and compliance testing. Nissan li battery history we started lithium battery research in 1992, beginning with a cobalt type battery in a cylindrical cell package. Shen, a hybrid thermal management system with negative parasitic losses for liion battery packs. To extend the life of the battery pack, we do not want to discharge the batteries more than 80%. Challenges in battery pack design for electric vehicles with special. Lucid picks lg chem as cell supplier for lucid air standard version. We developed the compact battery pack with structural safety and high cooling performance based on numerical simulation for hybrid electric vehicle hev.
Mckinsey center for future mobility trends in electricvehicle design 3 archetypes of battery heating. With a simple series chain of cells, the battery capacity in amphours is the same as the capacity of the individual cells since the current flows equally through all the cells in the chain. Design and optimization of lithiumion batteries for electricvehicle. Custom battery pack design, 30 years of battery packs designing. Vital parts of an electric car the battery pack is the fuel source of the car, since there are hundreds of cells arranged to form a battery pack a special circuit is required to monitor these cells. Update on electric vehicle costs in the united states through.
The supply chain for electric vehicle batteries usitc. Product design takes time to adjust to new technology. Challenges in battery pack design for electric vehicles with special emphasis on stateofcharge soc estimation by dr. In the late 90s, we started developing a mntype cell and in the early 2000s developed a laminated cell. A guide to understanding battery specifications mit electric vehicle team, december 2008 a battery is a device that converts chemical energy into electrical energy and vice versa. Electric vehicle battery chemistry and pack architecture.
Global annual electric vehicle sales by company in 2014 and 201510 figure 10. In this report we focus on the first four steps, which make up the manufacture of battery packs for use by oems. The modules are electrically connected to form a battery pack there are several types of batteries chemistry used in hybrid and electric vehicle propulsion systems but we are going to consider only lithiumion cells. The range per charge is 300wh per mile which is typical of a normal car. There is usually little difference in a batterys 10ah and 20ah rating so it doesnt have a big impact on the pack size. Battery pack calculator electric vehicle conversions.
There is usually little difference in a battery s 10ah and 20ah rating so it doesnt have a big impact on the pack size. Leading li ion battery provider for commercial vehicle segment. The native ev battery pack, by contrast, can take a simple, rectangular shape, giving native evs up to twice the rangeover 300 kilometers per charge and up to approximately 400 kilometers for the best performers, according to the environmental protection agencywithout forcing up. The pack uses a carbon composite shell and a ballistic shield to protect the battery pack in case of accident or foreign object penetration. They are a stayinplace solution and cure as a gel, easing the stresses caused by thermal differences and flex. The purpose of this paper is to present the philosophy and methodology behind the design of the battery pack for mits 20 formula sae electric racecar. This project reports on and builds upon work on the development of this system from.
The shape, size and number of cells in each module combined with the design of the enclosure contribute to maintaining safe cell temperatures and cell integrity during a crash. Phev rex battery packs ev battery packs innovative battery systems. The fourth episode in our ev basics series addresses how to calculate the battery pack size. Hyundai is three years into its ioniq program, which includes 3 versions hybrid, plugin hybrid, and allelectric, and today, it unveiled a refresh version with the allelectric version getting. The native ev battery pack, by contrast, can take a simple, rectangular shape, giving native evs up to twice the rangeover 300 kilometers per charge and up to approximately 400 kilometers for the best performers, according to the environmental protection agencywithout forcing up the price exhibit 1. Introduction to electric vehicle battery systems technical. Challenges in battery pack design for electric vehicles with. Batteries for electric cars boston consulting group. Design and optimization of lithiumion batteries for electricvehicle applications by nansi xue. Pack level actions battery pack structure vent management sys pack cooling sys battery controls sys power limits temp, age, others over temp over chargedischarge ens control cell balancing battery sensors v, i, t fusing cell level actions cell chemistry cell design cell manufacturing. Angelique janse van rensburg, northwest university. Chemistry, components, types and terminology, 2015 263pp. Introduction recently, a hybrid electric vehicle hev that utilizes an internal combustion engine and an electrical. Get the best performance out of your batteries by filling in surface imperfections with a thermally conductive gap filler designed with electric vehicle applications in mind.
To protect ev batteries, some packs include a heating blanket to warm the battery. An overview of cell chemistry, pack size and configuration selection process to meet these requirements is given. Battery cells come in fixed voltages and capacities. Because a vehicle battery pack may contain hundreds or even thousands of cells that exhibit tightly coupled electrochemical and thermal behavior, one particular challenge is to maintain an optimum range of system operating conditions to minimize material degradation and loss of capacity. Lithium ion battery pack, cooling system, finite element analysis, computational fluid dynamics 1. Design and optimization of lithiumion batteries for electricvehicle applications by nansi xue a dissertation submitted in partial ful. However, they all incorporate combinations of several simple mechanical and electrical component systems which perform the basic required functions of the pack. Hyundai upgrades ioniq electric with significantly bigger. October 2017 what did we learn from a teardown and. All high voltage battery packs are made up from battery cells arranged in strings and modules. Chapter 4, battery pack design describes the various stages of battery pack design, covering aspects of a123 energy cells, which may be different from other cells. Battery pack design series and parallel integration of cells to achieve required. Battery pack design considerations and construction details.
Battery pack cost at given annual production volume forvarious battery electric vehicle bev and plugin hybrid electric vehicle phev battery types 9 figure 9. In order to meet your power requirements a battery pack may need to be used. Ucem high voltage battery design for electric vehicle. Trend in battery thermal management from desirable to must by both vehicle oems and battery manufacturers from simple to complexeffective active rather than passive parallel rather series air cooling use of liquid as cooling medium from pack thermal design to module thermal design for high temperature batteries such as. Sep 30, 2019 the idea is that you want to design your pack so that the voltage swing of the batteries see below is adequate, and where the power consumption is the least. High current wiring was connecting the battery, and providing a main output line, also connected with relays for overcurrent protection. Heres an overview of some of the specifications, safety considerations, and management systems that go into ev battery design.
An overview of cell chemistry, pack size and configuration selection process. Excell design expertise we have a world class design team comprised of electrical and mechanical engineers. Where a lithium battery cell has a nominal voltage of 4. The main reason is that liion batteries have higher. Design and optimization of lithiumion batteries for electric. In this work, the integration of lithiumion battery into an ev battery pack is investigated from different aspects, namely different battery chemistry, cell packaging, electric connection and. An electric vehicle battery is often composed of many hundreds of small, individual cells arranged in a seriesparallel configuration to achieve the desired voltage and. In addition, because an ev will discharge the batteries faster than the manufacturer tested and rated, we get an. Modularityindesign of battery packs for electric vehicles evs is. Battery tech gives tesla an edge, and the situation is improving. The selected batteries arrived, and the high voltage battery pack was assembled.
The handbook of lithiumion battery pack design sciencedirect. Design optimization of battery pack enclosure for electric. Design and analysis of a battery for a formula electric car. Over time salvage companies will have battery packs and modules available for sale. The type of battery, the number of cells, the shape of the pack, and the components of the pack will be determined by the voltage and load current of the device being powered. A battery cell can be regarded as the smallest division of the voltage. Hybrids, full electric 3 battery pack architecture. Electric vehicle ev discover alternatives to fossil fuel in batteries. Excellence in automotive engineering and production deep knowledge of international safety standards. The bms was configured to the battery, and tests were conducted to determine the bms was working correctly. Some dedicated resistive heating units use energy from the battery and work only when the vehicle is.
The architecture and seating arrangements stayed the same for a while on early cars. Update on electric vehicle costs in the united states through 2030 working paper 201906 international council on clean transportation 3 cell materials like cobalt, battery cell design to achieve greater energy density, battery pack improvements designed for further density improvements, and lower assembly costs that. The idea is that you want to design your pack so that the voltage swing of the batteries see below is adequate, and where the power consumption is the least. This summary provides an introduction to the terminology used to describe, classify, and compare batteries for hybrid, plugin hybrid, and electric vehicles. The tesla model 3 battery pack represents a bottomup redesign of the battery pack, starting first and foremost with the battery cells used in the pack. Request pdf design optimization of battery pack enclosure for electric vehicle lithiumion battery pack which is comprised of assembly of battery modules is the main source of power. How to design battery packs, tutorial for design engineers. Dmc battery testing platform inside an ev battery pack battery pack designs for evs are complex and vary widely by manufacturer and specific application.
620 218 445 190 498 1389 1537 154 1056 966 973 1021 186 1368 1213 761 1525 404 1246 561 166 860 233 47 631 475 899 1046 882 1147 1371 80