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Mechanical Design of Battery Pack

Method · August 2023

DOI: 10.13140/RG.2.2.18172.92808

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 Mechanical Design of Battery Pack

Battery pack capacity: 18 kWh

Cell: ANR26650M1-B

Prepare a detailed battery pack drawing along with its enclosure. State
your assumptions.

Introduction
The high-voltage battery is a crucial component in an electric vehicle (EV),
holding immense significance in influencing various aspects of the vehicle's
performance. These include the maximum traction motor torque, maximum
regeneration brake torque, vehicle range, total weight, and price.
A battery is composed of one or more electrochemical cells (battery cells) that
convert chemical energy into electrical energy during discharging and vice
versa during charging. The specific elements and chemical reactions within
the battery during these events define its chemistry.
To create a single functional unit, individual battery cells are grouped together
into a battery module, which serves as both a mechanical and electrical unit.
These modules are then electrically connected to form the complete battery
pack.
While there are various battery types used in hybrid and electric vehicles, we
will focus on Lithium-ion (Li-ion) cells due to their superior specific energy
[Wh/kg] and specific power [W/kg] compared to other types.
In the mechanical design of batteries, the widespread adoption of electric
vehicles faces two major challenges: safety and reliability. Current Li-ion
battery packs are susceptible to failure due to factors such as continuous
transmission of mechanical vibrations, exposure to high-impact forces, and
the possibility of thermal runaway. Implementing robust mechanical design
and effective battery packaging can provide better protection against these
issues, allowing for safer and more reliable large-scale electrification of the
road transport sector.
Cell Parameters (ANR26650M1-B)
To select the battery cells for our pack, we will conduct an analysis of various
battery cell models available in the market. After careful consideration, we
have opted for the ANR26650M1-B battery model for our battery design.
Battery Datasheet: [Link]

Specifications of the battery model are as follows:

Nominal capacity: 2.5Ah at a 0.5C rate
Minimum capacity: 2.4Ah at a 0.5C rate
Nominal voltage: 3.3V
Charge end voltage: 3.6V
Standard charge current: 2.5A (1C)
Fast charge current: 10A (4C)
Maximum continuous discharge current: 25A (10C)
Maximum pulse discharge current (10 sec): 60A (24C)
Discharge cut-off voltage: 2.0V
AC impedance at 1KHz: 6mΩ
Weight: 76g
Length: 0.065m
Diameter: 0.026m
C-rate (cont.): 10C
C-rate (peak): 24C

The advanced Nanophosphate lithium iron phosphate (LiFePO4) battery

technology provides exceptional power and energy density, along with
outstanding safety performance and a long lifespan, all packed into a lighter
and more compact design. These cells demonstrate minimal capacity loss
and impedance growth over time while offering a high usable energy range
across various states of charge (SOC). As a result, systems utilizing these
batteries can effectively meet end-of-life power and energy needs without
requiring significant pack oversizing.
Battery Pack Calculations
To determine the battery pack specifications using the ANR26650M1-B
battery cells, we will utilize the provided information about the battery cell
and conduct the necessary computations. We will assume that the battery pack
is composed of multiple strings connected in parallel.
Battery Cell Specifications
Nominal capacity: 2.5Ah at 0.5C rate
Nominal voltage: 3.3V
Battery Cell Geometrical Features
Battery cell diameter (Dc) = 0.0262 m
Battery cell length (Lc) = 0.065 m
Battery Pack Requirements
Battery pack total energy (Eb): 18 kWh
Battery pack voltage (Ub): 300V
Calculations
1. Volume of battery cell (Vc):
Vc = π * (Dc) 2 * Lc /4
Vc = π * (0.0262) 2 * 0.065 /4 = 0.034510 m3
2. Battery cell energy (Ebc):
Ebc is calculated by multiplying battery cell capacity (Cc) with battery cell
voltage (Uc):
Ebc = Cc * Uc
Ebc = 2.5Ah * 3.3V = 8.25 Wh
3. Number of battery cells connected in series (Ns):
To find Ns, we divide Ub by Uc:
Ns = Ub / Uc
Ns = 300V / 3.3V ≈ 91
4. Energy content of a string (Es):
Es is calculated by multiplying Ns with Ebc:
Es = Ns * Ebc
Es = 91 * 8.25Ah = 750.75 Wh
5. Number of battery cells connected in parallel (Np):
To determine Np, we divide Eb by Es:
Np = Eb / Es
Np = 18000Wh / 750.75Wh ≈ 24 (rounded to the nearest integer)
6. Battery pack total energy (Eb):
Considering the number of strings (Np) and the energy content of each string
(Es), Eb is obtained by multiplying Np with Es:
Eb = Np * Es
Eb = 24 * 750.75 Wh = 18.018 kWh ≈ 18 kWh
7. Battery pack capacity (Cb):
Cb is calculated by multiplying Ns with Cc:
Cb = Ns * Cc
Cb = 24 * 2.5Ah = 60 Ah
8. Total number of cells in the battery pack (Nb):
To find Nb, we multiply Np with Ns:
Nb = Np * Ns
Nb = 24 * 91 = 2184 cells
9. Battery pack mass (mb) considering only the cells:
mb is obtained by multiplying Nb with mc:
mb = Nb * mc
mb = 2184 * 0.076kg = 165.98 kg
10. Volume of the battery pack (Vb) considering only the cells:
Vb is calculated by multiplying Nb with Vc:
Vb = Nb * Vc
Vb = 2184 * 0.034510 m3 = 75.37 m³
These calculations consider only the battery cells and do not account for
additional components like electronics, cooling systems, casing, etc., which
will influence the final size and mass of the battery pack. The above
calculations yield the battery pack specifications based on the ANR26650M1-
B battery cells for the specified requirements.
Summary of Results
Volume of the battery cell (Vc) 0.034510 m3

Battery cell energy (Ebc) 8.25 Wh

Number of cells in series (Ns) 91

Energy content of a string (Es) 750.75 Wh

Number of cells in parallel (Np) 24

Battery pack total energy (Eb) 18 kWh

Battery pack capacity (Cb) 60 Ah

Number of cells in the pack (Nb) 2184 cells

Battery pack mass (mb) 165.98 kg

Volume of the battery pack (Vb) 75.37 m³

Battery Module
The required battery for this system is an 18KWh battery pack, which should
be configured as 91 series and 24 parallel (91S24P), resulting in a total of
2184 cells in the battery pack.
To simplify the management, optimization, and protection of the battery, the
battery pack is placed into a battery module. This approach reduces
complexity and minimizes the risk of battery damage.
Consequently, the configuration is transformed from 91S24P, 2184 cells to a
setup involving multiple 7S4P cell modules. Here are the details of this
configuration:
 Total Cells in the Battery Pack: 91 * 24 = 2184 cells
 Number of Cells in a Single Battery Module: 7 * 4 = 28 cells
 Number of Modules Required: 2184 / 28 = 78 modules
 Configuration of Modules: 13 rows of 6 modules each, totaling 78
modules
 Cell Configuration in Each Module: 7 series and 4 parallel (7S4P)
Cell Dimensions

Diameter 25.85±0.30 mm
Length 65.15+0.05 mm
Weight 0.076 Kg
Cell Holder
Every individual cell holder has the capacity to accommodate a maximum of
four battery cells. By connecting multiple holders together, the battery pack
can be securely held. This arrangement enhances the stability of the battery
pack and mitigates vibrations.
Actual Battery Pack

2D and 3D Views (Drawing)

Front and Bottom Views (Drawing)

The design of the holder ensures a sufficient space between each cell, allowing
for the incorporation of thermal management strips or plates if needed.
Dimensions
Dimensions:
Length: 198.66 mm
Width: 113.52 mm
Height: 69.71 mm
Weight:
Weight of Cells: 0.076 * 28 = 2.13 Kg
Electric Connection
Nickel Tabs/Strips:
 Conductive metal strips are affixed between each cell within the electric
bicycle battery pack through spot welding. Nickel is the chosen material
due to its low relative resistance and its suitability for spot welding.
 Pure nickel strip is exceptionally suited for battery construction. Its
substantial resistance to corrosion, efficient compatibility with spot
welding and soldering, as well as its effective conductivity paired with low
electrical sensitivity, empowers battery systems to perform optimally, even
within extremely corrosive conditions.
 The options of resistance spot welding, micro TIG welding, and laser
welding processes all facilitate high-quality large-scale production. The
preference for a specific technology is typically determined by the
particular requirements of the application and how well the chosen
technology aligns with those requirements.
 A nickel tab is employed for linking the cells to assemble the battery pack.
This tab features four indicators, facilitating its spot welding placement
between the battery and the strip through various spot weld methods.
 The strip has a thickness of 0.3 millimeters, with dimensions measuring
38.7 millimeters in length and 10.7 millimeters in width.
 Connections are established through the process of linking in parallel and
in series.
BMS (Battery Management System)
 Regarded as the battery pack's central intelligence, a Battery Management
System (BMS) is akin to its cognitive center. This electronic system
encompasses monitoring and overseeing the battery's complete
performance spectrum. Crucially, its primary function is to prevent the
battery from functioning beyond its designated safety limits.
 Should it identify any precarious conditions, the BMS takes measures to
deactivate the battery, thereby safeguarding both the lithium-ion cells and
the user. Moreover, the BMS monitors the remaining battery charge.
 Consequently, the BMS constitutes a fundamental component of the
battery pack, necessitating a dedicated BMS for each module within the
pack to supervise and ensure the protection of the cell assembly. Hence,
ample space should be allotted for BMS within the battery module design,
and the necessary connections should be established to facilitate its
required functions.
Battery Thermal Management System (BTMS)
 For accurate battery thermal modeling, a reliable thermal model of the
battery is indispensable. By commencing from the heat generated within
the battery, the thermal management system can be formulated by applying
precise boundary conditions. The creation of battery thermal models
involves the integration of the battery's electrical and electrochemical
characteristics with its thermal behavior. The heat generation within the
batteries is governed by intricate electrochemical reactions that are
contingent upon temperature and the battery's state. Models of the battery,
whether coupled, uncoupled, or partially coupled, can be actualized.
 Sufficient spacing between cells in our design allows for the integration of
thermal strips or fins.
Battery Pack Enclosure
 The lithium-ion battery pack, composed of assembled battery modules,
serves as the primary power source for electric vehicles. Throughout the
operational life of an electric vehicle, the battery packs and their enclosures
are exposed to rigorous environmental conditions, including external
vibrations and shocks arising from varying road inclines. Consequently,
these conditions lead to varying degrees of stress and deformation.
 The safety of the vehicle is closely intertwined with the security of the
battery pack, which, in turn, relies on its mechanical attributes, such as its
capacity to withstand deformation and vibration-induced shocks.
Additionally, the preference for a lighter-weight vehicle is driven by its
potential to extend the vehicle's range and the battery pack's life cycle.
 The enclosure necessitates meticulous design, involving extensive
structural analysis and optimization procedures. A recommended wall
thickness of 3 millimeters, requiring a 1.5-millimeter gap, is advised due
to the flush alignment of the battery compartment with the wall surface.
Adjustments to the required gap or screw length should be made for greater
wall thickness.
Identification
Incorporation of manufacturer details, cell chemistry, voltage, capacity, and
country of origin is essential within the pack design. Many manufacturers also
include a date stamp and possibly a serial number to facilitate traceability in
the event of issues. This information is typically presented on a label, although
it may also be directly printed onto the battery casing.
Battery Pack Specifications
Configuration of Modules in Battery Pack: 13 rows by 6 columns
Length of Each Module: 198.66mm, plus BMS (PCB), resulting in 200mm
Battery Pack Length: 13 * 200mm = 3600mm, with an additional 2 *
(3+1.5) for a total of 3610mm, equivalent to 3.61 meters
Battery Pack Width: 6 * 114mm = 684mm, with an additional 2 * (3+1.5)
for a total of 695mm, equivalent to 0.695 meters
Battery Pack Height: 70mm, with an additional 2 * (3+1.5) for a total of
80mm, equivalent to 0.08 meters
Overall Design Results
Battery Cell Battery Module Battery Pack
Package 1S1P Unit 7S4P Unit 91S24P Unit
Capacity 2.5 Ah 10 Ah 60 Ah
Voltage 3.3 V 23.1 V 300 V
Weight 0.076 Kg 2.13 Kg 165.98 Kg
Power 8.25 KWh 231 KWh 18.02 KWh

Conclusions
Utilizing the technical specifications provided in the individual cell's data
sheet, I have formulated a battery pack tailored for the electric vehicle,
delivering a cumulative power of 18 kWh. This configuration is established
with a total of 2184 cells, organized in a 91S/24P layout.
The resulting series connection yields a nominal voltage of 300V, while the
capacity is derived from the parallel configuration of 24 cells, amounting to
60 Ah. The entire vehicle design is optimized to achieve a projected range of
200 km, which serves as a foundational assumption for the battery pack
calculation.
The entirety of the battery pack is segmented into 78 modules, each
accommodating 28 cells. This structural arrangement is tailored to seamlessly
accommodate the 91S/24P cell configuration of 915 cells in each module.
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