Design presentation

Design of 12 Volt starter battery
Srikanth 12.05.15
Design concepts for the demonstrator

Summary
Srikanth | 12.05.152
 Introduction
 Requirements
 Proposed combinations
 Goal
 Model 1: Kokam and LSMtron
 Model 2: Kokam and Maxwell
 Model 3: Toshiba
 Question

Requirements
To design and fabricate 3 battery systems which must withstand the forces acting on the batteries while
testing on various situations.
The size of our battery system must be similar to the normal lead acid batteries.
Weight is reduced by using fiber glass, thin wall battery boxes, small screws and trimming off extra
material where ever possible.
Avoiding metal for the construction and using fiber glass for insulation will decreases the chances of
short circuiting.
All the connections, constructions, attachments must be electrically insulated.
Low weight, rigid & easy to construct.
Compact, robust & nice presentation.
The construction must with stand the G-forces acting on our battery during testing on roads.

Proposed combinations: Why these combinations?
The eight best combinations tested from the flexible prototype were preselected and ranked
according to several features:
Volume
Weight
Compactness
Assembly difficulty
Vmin battery
Vcellmin
Imax lithium cells block
Imax capacitors block
Power lithium cells block
Power capacitors block
V: voltage; I: current
The two best ranked were selected for the Demonstrator
The third battery (Toshiba) was selected after the market research carried out for the
Demonstrator, being the most promising lithium battery for performing the cold cranking test
without using capacitors
The smaller, the better
The simpler and easier, the better
The higher, the better

Proposed combinations: Ranking for the 8 best combinations of the flexible prototype
3 points --> the worst; 10 points --> the best
Heter 40 Ah
Maxwell 1500 F
Heter 40 Ah
LSMtron 1500 F
Lumos 67.5 Ah
Maxwell 1000 F
Lumos 90 Ah
Maxwell 1000 F
Kokam 60 Ah
Maxwell 1000 F
Kokam 60 Ah
LSMtron 1000 F
A123 40 Ah
Maxwell 1500 F
A123 40 Ah
LSMtron 1500 F
Volume 3 4 10 9 7 8 5 6
Compactness 7 8 5 6 9 10 3 4
Assembly difficulty 4 3 6 7 9 10 8 5
Vmin battery 8 10 3 4 5 7 6 9
Vcellmin 5 7 6 9 4 3 8 10
Imax lithium cells
block
6 5 7 9 10 8 4 3
Imax capacitors block 7 9 5 3 4 6 8 10
Power lithium cells
block
7 5 6 9 10 8 4 3
Power capacitors
block
4 6 8 7 9 10 3 5
Weight 5 3 10 7 8 6 9 4
56 60 66 70 75 76 58 59 TOTAL
 The ranked eight combinations from the flexible prototype are:
 According to these results, the selected combinations are:
 Kokam 60 Ah – Maxwell 1000 F
 Kokam 60 Ah – LSMtron 1000 F

Proposed combinations: Spider graph for the 8 best combinations from the flexible prototype
3
4
5
6
7
8
9
10
Volume
Compactness
Assembly difficulty
Vmin battery
Vcellmin
Imax lithium cells block
Imax capacitors block
Power lithium cells block
Power capacitors block
Weight
Best combinations from the flexible prototype
Heter 40 Ah
Maxwell 1500 F
Heter 40 Ah
LSMtron 1500 F
Lumos 67.5 Ah
Maxwell 1000 F
Lumos 90 Ah
Maxwell 1000 F
Kokam 60 Ah
Maxwell 1000 F
Kokam 60 Ah
LSMtron 1000 F
A123 40 Ah
Maxwell 1500 F
A123 40 Ah
LSMtron 1500 F

Goal
Model 2
Kokam 12 Ah Pouch cell
Maxwell EDLC 3000 F
20 Kokam Cells 4S5P
12 Maxwell BSCAP 6S2P
Model 1
Kokam 12 Ah Pouch cell
LSMtron 3000 F EDLC
20 Kokam Cells 4S5P
12 LSMtron 6S2P
Model 3
Toshiba 10 Ah Prismatic cell
20 Toshiba Cells 5S4P
Capacitors are not required in
this model
To design and construct 3 start up batteries with following
combination:

Model 1: Kokam & LSMtron
Kokam cells with LSMtron Capacitors

Srikanth | 12.05.1510
List of main components used in Model-1 including Kokam cells & LSMtron
capacitors:
BMS
RelayFuse
Current sensors
Cabels
Copper Bars

Srikanth | 12.05.1511
List of main components used in Model 1 including Kokam cells & LSMtron
capacitors: Top Plate
Kokam cells
Insulation
Plates
Battery Box
Fiber Glass
L-Shape Plates
LS Mtron
Capacitors

Srikanth | 12.05.1512
 Using L- shape fiber glass materials, Kokam cells & LS Mtron capacitors are holded
together and to reduce weight slots are made wherever possible.

Srikanth | 12.05.1513
 BMS, Fuse, Relay, Current sensors & the main poles (Positive & Negative terminals) of the
battery are screwed to the two insulation plates. The insulation plates are supported by fiber
glass cubes to provide adequate support to the small components.

Srikanth | 12.05.1514
Fiber
Glass
 In our design we have used Fiber Glass wherever posible to decrease the weight and
to keep all the components electrically insulated.
Fiber
Glass

Srikanth | 12.05.1515
Battery box
Top Plate
Clamping Side
Plates
How LSMtron Capacitors are mounted to the bottom of the battery box

Srikanth | 12.05.1516
 Clamping Lithium Cells & Capacitors to the bottom of the battery box using small M6 screws which
increase rigidity and reduce weight.

Srikanth | 12.05.1517
 Size of model 1 with Kokam cells & LS Mtron capacitors is L=440mm, H=190mm,
W=175mm
 Size of standard H9LN6 lead acid battery housing is L=394mm, H=190, W=175mm
 Length of the model 1 is increased by 46mm compared to standard H9LN6 lead acid
battery housing.
 So we are constructing new housing which fits our requirements

Srikanth | 12.05.1518
Volume of H9LN6 Lead acid battery housing = 13.1liters
Volume of Model 1 = 14.63 liters
Volume of Model 1 is 1.53 liters larger than H9LN6 Lead acid battery housing volume.

Srikanth | 12.05.1519

Srikanth | 12.05.1520
Model 2: Kokam and Maxwell
Kokam cells with Maxwell capacitors

Srikanth | 12.05.1521
List of main components used in Model-2:
Fuse
Relay
BMs
Maxwell
Capacitors
Current
Sensor
Kokam
cells
Terminals
Copper Bars

Srikanth | 12.05.1522
Fiber
Glass
Fiber glass components provides the necessary support & help to reduce
the weight of the battery

Srikanth | 12.05.1523
 Using L- shape fiber glass materials, Kokam cells are glued together and assembled
 Maxwell will be providing the holder caps to assemble the capacitors
Maxwell
Caps
Fiber
Glass

Srikanth | 12.05.1524
 BMS, Fuse, Relay, Current sensors & the main poles (Positive & Negative terminals) of the battery are
screwed to the two insulation plates.
 The insulation plates are supported by fiber glass cube blocks to provide adequate support to the
small components.

Srikanth | 12.05.1525
Clamping Cells & Capacitors to the bottom of the battery box with using
small M6 screws.

Srikanth | 12.05.1526
 Size of model-2 with Kokam cells & Maxwell capacitors is L=394mm, H=248.5mm, W=175mm
 Size of standard H9LN6 lead acid battery housing is L=394mm, H=190mm, W=175mm
 Height of the model-2 is increased by 58.5mm when compared to standard H9LN6 lead acid battery
housing.
 So we are modifying the H9LN6 lead acid battery housing which fits our requirements.

Srikanth | 12.05.1527
Volume of Model 2 = 17,2 liters
Volume of Model 2 is 4.1 liters larger than H9LN6 Lead acid battery housing volume.

Srikanth | 12.05.1528

Model 3: Toshiba
Srikanth | 12.05.1529
 In this model we are only using Toshiba cells, no capacitors are required.
 The size of the Toshiba battery box is less than H9L/N6 lead acid battery housing.

Model 3: Toshiba
Srikanth | 12.05.1530
Relay
BMS
Current Sensor
Fuse
Main poles
Toshiba Cells
List of main components used in Model-3:

Model 3: Toshiba
Srikanth | 12.05.1531
Toshiba
Cells
Clamping
Plates
 In this model we are using similar technique to assemble the toshiba cells. Fiber glass with screws
at the bottom will hold the assembly together.

Model 3: Toshiba
Srikanth | 12.05.1532
Screws & nuts to hold the cell
assembly to the battery box

Model 3: Toshiba
Srikanth | 12.05.1533
 Toshiba cells and the assembly will be screwed to the bottom of the battery box using M8
screws to withstand the vibration during testing

Model 3: Toshiba
Srikanth | 12.05.1534
 Size of model-3 with Toshiba Cells is L=368mm, H=152mm, W=175mm
 Size of standard H9LN6 lead acid battery housing is L=394mm, H=190, W=175mm
 Lenght and Height of the model-3 is reduced compared to standard H9LN6 lead acid
battery housing.
 So we are constructing new housing which fits our requirements.

Model 3: Toshiba
Srikanth | 12.05.1535
Volume of Model 3 = 9.78 liters
Volume of Model 3 is 3.32 liters smaller than H9LN6 Lead acid battery housing volume

Question
Srikanth | 12.05.1536
Open for suggestion

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