A Project Seminar on

DESIGN AND ANALYSIS OF INTERCHANGEABLE BATTERY

CONTAINER
Submitted by
1. Akhil.V (160117736075)

2. Sai Bhuvan.R (160117736101)

3. Tarun Sai (160117736108)
Under The Guidance Of
Dr .CH.INDIRA PRIYA DARSHINI
Assistant Professor, MED

Submitted To
Department of Mechanical Engineering,
Chaitanya Bharathi Institute of Technology
(A)
Hyderabad,5000075
 ABSTRACT

 Battery container is the energy source of the conventional electric vehicle

 This energy source gets depleted and has to be recharged.
 The recharge process takes 4-5 hours for a two wheeler there by reducing
the available time of the vehicle per day.
 The swapping/interchanging concept was introduced to increase the
available time.
 The objective is to a design a battery container with interchangeable
feature
 The design will be done in the solidworks software.

 The Dynamic analysis will be performed in the Ansys mechanical.

 The thermal analysis will be performed using a 2D cfd model in the Ansys
Fluent software.
 INTRODUCTION

INTERCHANGEABLE BATTERY CONTAINER

 The main function of battery container is to provide a rigid structure to

the cells.

 The Interchangeable container is the one where the exhausted

battery/cell can be replaced with a fully recharged one.

 The swapping/interchanging is basically done at two levels, one is at

whole pack level and the other is at module level.

 The other main function of battery container is to provide uniform

thermal distribution by means of cooling system.
 METHODS OF SWAPPING

• The swapping can be done at two different levels. The first one is
swapping the whole container with a new one. The other is where the
swapping of modules present in the container and it is called as
swapping at module level.
The main advantage with the swapping at module is the cost involved in the
concept and it can be applied to any kind of electric two wheeler.
 Disadvantages of swapping at container level

Disadvantage due to variation in the design of battery container

Stack of modules of an electric 4 wheeler

 LITERATURE REVIEW

 Rahul et al [1] have done design analysis for the electric bike which includes frame analysis,
calculation for the performance of the vehicle and test run result of the same. These initial
calculations are needed to determine the size of the battery pack.

 The detailed information regarding the different types of batteries available for automobile
application is mentioned the technical report submitted by Stephens et al [2]. From the report
it is observed that the 18650-lithium ion cell is suitable for our application
 Shashank et al [4] have applied robust design methodology to identify crucial requirements of a battery
pack. It is observed from the methodology that the structural and thermal aspects of the container are the
most important aspects.

 The main function of battery container in thermal aspect is to provide uniform thermal distribution. Aihua
et al [5] have designed a parallel-series combined liquid cooling system for a 288V Ni-MH battery pack.
This type of cooling system is found to be suitable to apply along with the swapping concept.

 Na yung et al [7] have done dynamic analysis on a battery container of a 4 wheeler. They have done
vibration analysis starting from 20hz to 100hz in 40 steps with 1g amplitude. These conditions are taken
from real time study on external vibrations of an electrcic vehicle.

 Rajib Mahamud [8] has designed Thermal Management For electrical-drive vehicles using reciprocating
cooling flow. The analysis is done using 2D cfd model in the ansys fluent.
 RESEARCHERS GAPS

 Most of the research was done on the battery packs suitable for the 4
wheeler vehicles. These designs cannot be applied on a two wheeler
because of the gaps in the research.
 The gaps are because the design of battery container for the two
wheeler is limited with the space available on its chassis which leads to
limited range of the vehicle.
 The limitation in the range of the vehicle can be eliminated by
introducing the interchangeable feature in the container. Hence it is
proposed to design an interchangeable battery container.
 Battery Container Design
 The initial design process includes the selection of the cell, calculation
of size of modules and their arrangement, calculating the space
available in a two wheeler chassis.
 From the above values a basic CAD model will be created in the
solidworks.

Software for our Design.

 We have selected 18650 type lithium ion cell for our design.

18650 cell from Panasonic

Advantages of a standard 18650 cell [2]

 Cooling System
 The main objective of a cooling system is to maintain uniform thermal
distribution within the permissible temperature.

Uneven thermal Distribution

 Design of cooling system
 The design of cooling system includes the selection of coolant, design of
coolant flow channel and flow parameters.
 The liquid cooling was found to be more effective than the air cooling.

Cooling ability of air, water-glycol and oil [6]

Coolant flow with respect to cell.

Liquid cooling by means of cooling plates in Ni-MH battery

pack [5]
 Analysis

 We will be performing dynamic analysis on the cad model and optimize it

from the data retrieved from the results.
 The simulation software Ansys mechanical will be used to perform the
dynamic analysis.
 Thermal Analysis

 A 2-dimensional CFD model will be created for the thermal

analysis.
 The analysis will be performed in Ansys Fluent which uses the
Finite difference Method.
 CONCLUSION

The main objective is to design a interchangeable

battery container for a two wheeler which is strong enough
to be certified from ARAI and equipped with a thermal
management system.

This helps in increasing the range of the electric

vehicle, ultimately helping the society from our side.
References

• [1] Rahul B. Gupta, Parth C. Patel, Azlankhan A. Pathan, Viranchi Shastri : “Design and Development
of Electric Two Wheeler”, International Journal for Scientific Research & DevelopmentVol. 6, Issue
02, 2018 | ISSN (online): 2321-0613.

• [2] Stephens, D., Shawcross, P., Stout, G., Sullivan, E., Saunders, J., Risser, S., & Sayre, J. (2017,
October) “Lithium-ion battery safety issues for electric and plug-in hybrid vehicles”(Report No. DOT
HS 812 418). Washington, DC: National Highway Traffic Safety Administration.

• [3] Samuel Reineman : “ Design and Analysis of a Battery for a Formula Electric Car” thesis
submitted at MIT 2013.

• [4] Shashank Arora , Ajay Kapoor and Weixiang Shen : “Application of Robust Design Methodology
to Battery Packs for Electric Vehicles: Identification of Critical Technical Requirements for Modular
Architecture” article submitted at MDPI.

• [5] Aihua Ch , Yinnan Yuan, Jianxin Zhu, Xiao Lu and Chenquan Zhou : “The Design and
Investigation of a Cooling System for a High Power Ni-MH Battery Pack in Hybrid Electric Vehicles”
article submitted at MDPI.
• [6] Gi-Heon Kim and Ahmad Pesaran : “Battery Thermal Management Design
Modelling” The World Electric Vehicle Association Journal, Vol. 1, 2007.

• [7] Na Yang, Rui Fang, Hongliang Li2 and Hui Xei : “Dynamic and static analysis
of the battery box structure of an electric vehicle”IOP Conference Series: Materials
Science and Engineering.

• [8] Rajib Mahamud : “Advanced battery thermal management for electrical-drive

vehicles using reciprocating cooling flow and spatial-resolution, lumped-
capacitance thermal model” thesis submitted at University of Nevada, Reno May
2011.

• [9] “ Automobile India Standards” published by Automobile Research Association

of India.
Thank you