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Mechanical Design of Battery Packs - I — Lesson 1

This lesson covers the mechanical design of battery packs, starting with a review of the electrical design and the issues that can arise. The lesson also explains the calculation of capacity, voltage, and current requirements, and the potential issues such as voltage drop and thermal aspects. It further delves into the mechanical design aspects, including the weight of the battery, the forces acting on it, and the material selection for the base plate. The lesson uses the example of designing a battery pack for an electric bike to illustrate these concepts.

Video Highlights

00:20 - Introduction
04:00 - Mechanical design of a cell
16:00 - Concept of stress and strain theory
19:45 - Forces that can act on a battery pack
22:01 - Design of the base plate of a battery pack
23:18 - Example problem and solution on base Plate thickness
24:34 - Overview of material selection for battery pack

Key Takeaways

- Battery pack design involves considering electrical, mechanical, thermal aspects and the Battery Management System (BMS).
- Mechanical design considerations include the weight of the battery, the forces acting on it, and the material selection for the base plate.
- The design process involves considering the depth of discharge (DOD), the operating voltage, and the energy consumption per kilometer.
- Different types of forces, including compressive, tensile, shear, torsion, and bending forces, can act on the battery pack.