Unveiling the Dynamics: Research and Analysis of Performance Accumulators
- The "performance accumulator" improves battery pack design for vehicles by analysing their specs and energy needs to find the best match with the right components.
- We customize the cell choice and potting for perfect encapsulation based on these needs. Working with the CPP program, we used vehicle data to meet battery pack requirements, excluding the battery itself.
- We defined details like weight, cooling, connectors, BMS, mounting, enclosure size, material standards, and thickness to meet these needs.
- By tackling common battery pack reliability issues, we aim to create custom solutions within the same segment to meet specific requirements effectively.
Energizing the Future: Leading the Way in Battery Pack Design
- Our design respects client space needs, incorporating cooling methods like liquid cooling to manage heat. Adhesive potting helps transfer heat efficiently, improving battery performance.
- Inside, we use connector-based cell modules with Redlock 350 Amp connectors in an aluminium enclosure, ensuring secure and compliant assembly.
- For EFaR's 1.4 joules/module requirement, we created a 20S-20P, 5-stack battery with 4 series and 100 Ah per module (about 40.8V, 100A), totalling 5 modules.
- For EFaR's 1.4 joules/module requirement, we created a 20S-20P, 5-stack battery with 4 series and 100 Ah per module (about 40.8V, 100A), totalling 5 modules.
Installed energy
7.3
kWH
Installed capacity
100
Amp. hours
Optimizing Prototypes for Efficiency and Longevity
- We assess if battery pack designs meet client standards and specifications.
- The enclosure, about 2mm thick, had 304 gates. After adding the cell stack and securing the mountings, we began the connection work, including compliant contactors for the 12-volt system.
Maximum Cont. Discharge
300
Amps. at 3C
Precision Testing: Validating Performance, Ensuring Safety
- We use data to flag errors and prevent cost increases. Fans provide 6-8 CFM of airflow, cooling the cells through inlets and outlets, supported by 4mm-thick mounting points for an insulated enclosure.
- We integrated a genuine Orion BMS with an IMD circuit and various lug inputs for insulation management. The BMS allows for data transmission, reception, and optimal use of the battery pack.
Maximum Charging time
30
Mins
Fast Charging upto
198
Amps.at 2C
Empowering the Future: Advancing Battery Pack Engineering and Development
- Cells were placed in holders with thermal and electrical insulators for safe spot welding during assembly.
- We connected the cells with 0.15mm nickel strips in 8mm-10mm segments and positioned terminals accurately for the Battery Management System (BMS) connection.
- A bus bar bridges the nickel strips and Redlock connectors, covering 50% of the span to ensure even heat distribution and reliable module connections.
Maximum Cont. Discharge
500
Amps.at 5C
Sustaining Power: Mastery in Battery Pack Deployment and Maintenance
- After manufacturing, we test the battery pack by charging and discharging it 5-10 times to ensure it works well.
- We verify the BMS functionality and accurate data reception through detailed calculations. Once confirmed, the battery pack is sent and installed in the vehicle.
- Post-installation data checks confirm the battery pack is working optimally and correctly.
Life cycle support charging
50
Amps.at 0.5C
Baud Rate
500 k
