Steps Convert Watt nour or battery mito Ampere hour Or bartery WKT — Power= Voltage X Current Also Watt hour = Voltage X Ampere hour 1875 = 48 X Ampere hour Ampere hour = (1875/48) = 39.06 Ampere hour (say 40 AH) Therefore, to run the 1500 Watts motor for 1 hour, 48V 40 AH lithium ion battery is needed. If the electric bike is running at an average speed of 35 km/hr, 48V 40 AH provides 35 km mileage. ie Ifyou want 35 km mileage (range), 48 V 40 AH lithium ion battery is needed. It you want 70 km mileage (range), 48 V 80 AH lithium ion battery is needed. Step:t Find out the current (in amps) consumed by the motor to run. We know that, Power = Voltage X Current 1500 = 48 X Current Current = (1500/48) =31.25 Amps (theoretically) ‘Step:2 Find out the Watt hour of the battery. To run the 1500 Watts motor for 1 hour, Simply multiply (1500 Watts X 1 hour) = 1500 Watt hour. Take efficiency of 80% for battery. ie (1500 / 0.8) = 1875 Watt hourHOW TO CALCULATE RANGE OF LITHIUM ION BATTERY (AMPERE HOUR) FOR AN ELECTRIC VEHICLE? Let us take an example, To run an electric bike with 48V 1500 Watts BLDC motor, how much ampere hour of lithium ion battery is needed. ‘Step:1 Find out the current (in amps) consumed by the motor to run. We know that, Power = Voltage X Current 1500 = 48 X Current Current = (1500/48) =31.25 Amps (theoretically) Summary — Electrical Design busbar shoul be desed with + ieagecaret est o5 Ree. 1 See coin re conacten. 1 Seymonfecnleytasenay Bushes joing methods prefered with: ‘Cameroon, + Hahn swt Lect Systems shoulhave; + Ewe + Manat age ep where pase. + Satie cleave mater open ee tan + Maney Standards and Testing + esa en by compost wid eb inveeac ater waded shay le. Fecelaplesh tat he veel peperdetr trp orenaion ‘Tete caepermdetbe rane ec + Achar eee the tne + Shes pt sant and adgezcson te ned. + Thee anbeagpes mana oa meenaLaser welding + newer apeens aber gs ae megane ota wag co + federico uroeieeecla tenn been Assignment Question ne sari a rere a ae ‘opnetoand ny nicest age ne (eid ed a ALS ei tl entice en en ct ‘emcog me pee lem dare vse a maemun eR Wt ay TE Busbar Joining Methods ae = vine" Sie Toe wei Current Equalization in Parallel Path henacarert some pale pete pn ‘sauce maddy be toveas neh cecal Inshonrepesenaion ts 18 perience hier este ‘ange? 43 ew be atdton aranrtecaret ons \Whenthepalel pats mst epee equal cre fom, cae tnerence ep Preis santo ge pais hipachegsane ‘esate ta tte th Fetesstese 8 = Speed estos ne ah =A, = Significance of the Voltage Drop Camder lon pecans es the eu ameter: 2085/8 (eth: are Tecoeiprdnp eee ane DOIN er ope cence WAR mean caret tra eu ewe, Vaiage Dap = 002 «001 = 0.00027 Tsim bea pica 84 whenmany sth rs a pestini wa vot cep euler sie. ee, iresecion2 nla hanes iste be ee cig Banta,Significance of the Voltage Drop Conse on specs hares ie: re suet: 200NG/ OBI lege ae ‘Teceresprdig ween wo OO ope oar Wh meee caret 2m tether Valage Drop = 02001 = .a0ear ‘sway ates sian. 84 when may sich sess apres nis, ore \otage ep weber sie. ez he ire seo ana te hasnt Sele eigenen e shor ar Contact Resistance econ stance can be abn at: Serine ean? Contac, Streamline esse: carer ores rdw fir yt ‘Nee ta Tore seule eine ate Sb Enedinewe ora cite Mason stn repre sete cece veo! Siete Cosette cron mince Example: Busbar Sizing for 2? Cells Siwapene tn tee hceeenscr sa 8M Ao fence ae Sgn ee peel be oo ane toes US ecg Boba Example: Busbar Sizing for 2P Cells Coude Ps cetprno eC ar ne Sane fess heb be ales ge be eget Siem ote 208 Decten ni ea 08 ‘tert 9 eS a to ete. Voltage Drop in Sensor Harness Ferrata pein tagcat {enpeatre nang ese Theres re 3 eal pay reais, Tehama ter doaealeracar age dg mse screeds eal hen hae: meses ee tics Tele concrete ep ee, some neuter. Sensng sensed ung 1 este ope pic. 2 taboeen(egartnc net ateuen ie Example: Busbar Sizing ary esac 1 Te eg Burs sha an osoto stereo 0 edt, Scott bub Mtl Papert Cae =DODIIEC', pre = 17°10 ove =ores(64 Fy) = (072410914 ODENG0-20) = 190-404 sie Cope be R= 1 Pel, bel 22+10* 86 pat, eh ar oe Sem mato 2 a ierttnm tbatConductor Insulation Intonation iden erg may eee era Connor etc raters tea mat atm, ‘par eae ng py poet Teles olin shu be optima: ‘rnc dense > oemsedane “onanee er pts tne et ‘horesaa bein eknterns tae Short Circuit Scenarios heat erate ung sharers her tmoee | ail Thespecha best cede on temper Compr essty vas y OR astemgee stm 20 ‘wo0re Ince pete usar ats Hesupeber ‘omponets mat Design Criteria "Eden rata Dy) = ae nt heh) dice Ra etna tn aetna i ea a ie De mth wos radar pe: Gd Opt) cum cmyiysbae hittin cern be et ae ey se sn weet P OBS SMT ae Tae ‘sea misusing ty Aes e Sac in Electrical design of battery pack babar seven 1 ance on 5. Mahal ns 2D rapt © Goan raion 1 Sgro ema esi 2. mre tr se, age op, ‘Crest ecualaton sr onagethods Mechanical Considerations cra eaiyrast seers gel Comper ey ond Marne de we ap Story sgnrneo po vein depot Aig ata taerdatbth ends onde sudan teen debated orhactonlstcten, Enfoten pat comet cancers inde oreo ence Example: Busbar Sizing 10°40 henge brs moet 5% Co, IME", ppg = 1 Solution: } ‘pec orco(1 4060 —Ty) = (12 10% +N) 20) = aso A= 1 6 Bele, DoE ARROWS i Piha na tt Re ett! | Ane br oben, ees tac I use 5 2201092 em i Conductor material selection esc rtel al ea pane, mca fetal ie ‘Tera eset ptm ein arene exes eto uk ee aces hr ma: Mw wecrcdod eran Staelin, 2p mci gh en, these cen tenposos rien anon ox eet ip nee, ‘comma ow eer et tae, ope abi ate. Te restate ane, aru sioner an oon 8 esug ease bb ese ste mor ht. Electrical design of battery pack yeu Den imgetn) Teastesiganceocarert iow. An improperly designed busbar an Temperature rise de tocurent —_»ngaisystem operation, flow Result in ocr efficiency. Shortcut cuentstressesand—_. Qyereat sl & nearby component protection. Pose safely Blaby ses, i A aE. Inc structural daage ering meth nd performanceForces acting on the battery pack -~aos Base plate dimension calculations Inca eee on 9 Certucoheargir pact es Sepraprsee se Forces acting on the battery pack Introduction to Stress-Strain theoryBuilding the battery pack... ne imiinccmeiapingarme dis crmcsinartanentoeae 3 Coming th depth ofa x0) ta be 80%, desig abate packal nil a? crete R ccoraonen erro Connecting Cell Together Important Considerations usc scored, Ute poste onc tice, uate ct option ute ce den oa tote g eta tema susie Merwe tne es Importance of... Importance of... Mechanical dese: ane ‘ae: Thermal designBattery Pack Development Process Electric desir 2 Thermal > Ue 1 Duratity 5 Performance & Safety Assignment 4.8 1. Thearfabe 0) Tel vate sane Softer wh ch 0) Tent age ota mes cf a ater he dachagng )ALICrate of charging in CCC mode Lon Battery gets ful charged to 100%ia thous Bates are recommended tobe charged fistrto prolong thee In EV Batteries Constant caer followed b constant vote charg cormeiy wed (ter cattle camescate wih Cage incarnation teas ‘het dag ta en tea end hrs testoey ose Ce Fast charging gts the voltage close tothe peak col vtae, much before the tater isfy charged ete pt wt bated rs To Sum up Lion Batries (Cand NCA) dominates EV mare todoy HDi era upre aan wher ee cy va) xm om nda ences eae Cost ofbattery is ots the inti catal sts aca aft ees, i al eens gon og ce cha ca pd evra sen te ent et ened Aso te tends rae be me vere Basic Charging Methods ee pert try nacen orien ome ONITEL ae umainpen ier cen woven front bw Se nN fesneeioea aCharging Techniques \ ee ee a To Sum Up atery Usage Cots depends nt just on Capital Costs of ater, but ais fice ie Archeaon tens ate preity Baty Use Contos s compare leet Bateries with diferent opt Costsand feces, gen aninterest te are ae ere bees an Ve et yt es Sone unease ies al spends ber onpaescompaions Enhancing fe cycles and reduce Capital Costs more important in nto make Es afdate Impact of Interest wt e one Toundersn the inpc ees, we tae wo bates it cot gs Lee a pot nn EO, eepeeay nodiatiecnmaon = age seoenpxtieet fe ‘suo SE =| cane = resieonremmaticientaien zy 14008 002 Ah Examples of some batteries “le pest atries _2LWh Battery without agin acount temperature / wage pattern (Crate) anew cast ofr 0 yes wh; DD an 156 al ge at 2 Pet xt fr 2c wh OCD th ene sce a3 Pet cost cm ome wth 35060 an 2 cae / ce Bat eth cost 0 fr Kes wih S05 Dank hag ere we te Assignment 4.7 1 Use Battery ith Capital Cost 10000 with ie of 300 cycles, use oF cycle per dy se 0 DoD and hae BOX ol Battery Capacity 10KWh and Incest ate 28, 9) WeFUTinacls angling ct per Al atey 2) Ute appoemate onsed compute ung ph 5) New ase teletype ya Conga corp h Sse tice sere fete vn nyt dns cerita Pet Staion easy ana ere as epctn nee at (ong ng lorie PT parent) Prosper near taeseyorung Ost neg OS lebmeyCnycm D4 00 in) tas 859 1099 Sevcatet nasis_c 640115308 are i arth yee eh te atts casa dows cot Teen societies mt Effective Battery Costs per kWh of usage ees REARIAERAR rr of o/ ves ete on ety epeatin = B= Ue ee 8) ‘Usable ster Capacty perce = ap =C* De® AL/2 KH ert ay wth oe os ane 7) cacy eps vase ‘fect Baty Cons per yar gan eet at] an be caine fom Exel Shee BatCostY = PTR Balt Capa) (Bee tc eho ges ae = ae CPO ‘ae ts aioeCapital Costs into Operational Costs Conia Methito aue ot eres ot an facet nhc een wl ped naa etm tee dp cr hg gil ol prea ce franc re sw eden mete pea Bc ‘ea EB et ti Given thes data (fe-cycles, cycles used per day, interest rate and capital costs) nea compte eee ote USAGE Baer pr ith Wha na ano ap pre ‘eiOnetanen deh neta pcre om ved plu diacey Nga ere nator ae ent cea angen ne re eae imaptate i opceap ears Battery Pack Capital Costs Costs depends on Capac Wh) name of els used and Cost pe Cel ost pr el dees gn chet od eye sed insta onion ‘tet uh ge tenprne ested es (tery P cot at depend ae KN it 2 24 4 aN type cote ae tery Capt Coss: Cleo BMS ast paging cots Coating costs cotage Const BUS ad pcg BABA acy tery eterna penser: Bagster one ae Cougs dens ones ela tes ed a Battery is a container of electrical energy Conceptually similar to a petro! (gasoline) tank ‘ut, ne petol tank, Ebates expense high Cap Cns hhc sot ei, tt Wien pase Cece, ere nape tel ake gM ‘om peepti cak fe weed perce enn ter en wth hrc es) {odicep nto Bome peta at) ane Convert igh Capt cos of tery ito Operational ots ‘ether net ec SE i Assignment 4.6 (contd) 5. Truwor Fake Packs made with cdi ces ned rit pressure tobe apie on cls to moid bling Pn contiuration imps fet mabe series of m els and then tach such series npr ) Inamodule of pale of 3.654, 4h each one cl alsin open. The resultant capacity of module then reduced to 128, 4) SoHo hater pack isthe Sd ofthe strongest collin the pack ©) SaCestnation is independent of SH estimation Battery is a container of electrical energy Conceptually similar to a petrol (gasokne) tank ut, unlike petro tank, EV battery expensive High Capital Costs__ ‘Ortecerhndhe te pete eee eect Weve pc wl pce apn per ep eg oemne oben Fer 0 we edt puter aera wth gh otal cs) dle ry one ey ser ower open 8) ane Convert high Captal cost of Battery rt Operational Costs! ‘estas ina et ee RRAssignment 4.6 (contd) 4. Abn pack 354 220i be ade paver a Ore bat eee aah Sno ao 8, sma 2 age oS catpstots wh cosine bee eres 1 feteteaeer ernboacaes © ealgmcaue nal abe ecient ae “AB pak of fran 214 made wth 25, 12ANU on eto typed he packa cs rome tesa stra "Rebeca on tha aah scc ets imo nce eo byt a etn, © Whatsiemni ep at ote act, att ale clot pt ret ieee citi reo tuted Assignment 4.6 1. Need 15 Wh battery with nominal votape at 350V The cel that one has 1: 365,24 AhUlon cel How wil one us cls to bul the best Confgrato forte batery? What wl be the battery vokage when ts Sot is 10h and votage when ti 00? 2 han homey Wit ov nb ceofguato? To Sum up Wehavelakedat Conceal Oe of Bar Paks far holed cy oral Dg lg ee raton ut Then {eign homebrew Se) Cntr nema et (selenite in pie ad perornnce Coniwete eames ree nro en Celsereraize pense cesarean Sg etn tineeour aot desoaneenieacers sae Failures in Battery Pack | Vacations pac (neal ray eee open cet -(n cesta ten elects A ae acon eh cnt PS (ne ofapualcestecone su crete nde hs age rye ibe hei Crcrtorta cof hat it ae tg perce pn wince eure tae nostic eget pnp) Fepuemet cca fet Fa sei conection between module fs: ater fas Gene aera —mayeie bub reicemet Failures in Battery Pack II Fale in BMS. replace BMS MOSFET in MS heated: desig se Temperature sensor fare: detect and replace fae dec apace anceeg eS wane ce al capacy deterioration: atery Pack Capcty deterioration Unban cls modes te Pat Capit denen Inca Sol or S¢ estimation ‘isa eater and heey hee of en ure caret on weg ipo eg p4 onrret Electrical Design Ashcan ane, conduct nate vaage op ‘nde restedtvec be oe sn ee ‘Shgop oot tonnon sn ab cbc bts \nemgfonet monies brome ered set d'etat ae Cetmanecel acount nadd hapa rete cl aca fom onecellb —p mtu abe sma asc ott ton ree Apick wth ontracus imbalance wl quily detest mCapactyCells to Module and Modules to Pack dhl Celspacedin pare tofrm2 Cel equation dig Chang Cal.an be comet in paral to form MODULES fou Sanelipreanetue das eworcagysaaperet Giana sane nae Sites paises sro! 2004 Ceeeabssesbeen — Kagpehonrcd ipa) staan 7 a Modules can now be connected in series to make a Miiedpsdcinwistims —— agtimemetrsttaees ——_bateyelhiherotge ‘battery Pack wae ‘fee connect M4 mods of 0 th four 15 A ce in paral) see jouprgmosieny agave here aan ate ee hl Serreammeseemgusis — Segsneat ‘statin age iebapat ‘reser Mieuied sia sieibecamyesNi et (adda Hace dene Nommajor balancing sue here: Auto-balancing between cells in a mode ll the time ast % ONrTEL aha at Building mSnP battery pack ; (elscan be comeced nee aor STING f oveconcint ote Baden ‘ict bcey Reatinneate ee Sse tacoma lta cacy Seteigen crea" coy sic none Sextet ERR tet, het hv once uegunahe hoe Tiree aon ot yg ag stoner patty Building Packs from cells Cell voltage typically 3.7V (usage voltage varying from 3.1V to 4.1V) Cell Capacity is 3.4 Ah (cylindrical to 50 Ah (prismatic / pouch) ‘Requires cells connected in Series to get higher voltage: 14 cells in Series is 51.8 ‘Required cells in Parallel for higher Capacity: 8 cells (50 Ah) in parallel gives 400 Ah Generally cells has tobe connected in series and parallel to make a pack 'mPnS implies m cells in paraliel to form modules and then connecting n modules in series. "SP implies nels in sviesto frm sings and then connecting m tingsin pra, 4P14S pack with 3.7V cylindrical cells of 3.4Ah gives a capacity Capacity in Ah is 4°3.4 Aho 13 6a; voltage is 143.7V or S84 Total Capac in wh = 13.6°51.8 Wh = 7045 Wh;Battery Pack Design: Electrical Battery-pack required certain Voltage and Capacity (in Ah and Wh terms) Voltage chosen based on requirement of drivetrain component and ttl battery Capacity Wah Cartes ge ric ses tick cables ermal tet 200 Amps Therefore depen gon ner) of storage, eta wt peered dal yo > ow £880 72V for sal batteries for 2/307 and small 4W 100 Who SKM: Kh eques 21 Ah cos ose wth prismatic nd tical 3540 for medium sted batteries for larger cars and pet ups Wh to 70 Wh batteries 1 Ah ater reques< 3h pose oy wth ia 750V for motors for buses and trucks ters of 6 Wh to 300K: a0 mary cel if cynical sed Design considerations for Pack Thermal design must remove the heat generated from the pack immediately Cal hourtint pet stad Mechanical design should include safety considerations Right Pressure needs to be applied to cells, eve they wil bulge Battery Management System (8MS) Only balanced cells used in a pack: requites voltage/curtent/temperature monitoring of each cel and balancing cessing charging 2s well as shoring ack should get cut ofthe temperature increases: ey to safety Communicates with charger to decide caring strategy What makes a Battery Pack? Number of cells assembled to form a battery-pack for required voltage and capacity Safety sues Cell Balancing Careful electrical design so that every el get equal charged / discharged Calls: Chemistry evolves continuously bringing costs down Materials: depends on chemistry Quantity used depends on Whig Cost of material and Availity