development of smart battery enclosure

1. February. 2023
Under the Supervision of
Dr. Sunil Anand
Co Guide
Dr. Vipin Pahuja
ASST. PROFESSOR
BHARTIYA SKILL DEVELOPMENT UNIVERSITY JAIPUR
Design and Fabrication of Smart Battery Enclosure
in Electric Vehicle
7th Six Month
Research Progress Report
Submitted by
Deepak Singh

2. Contents
1. Introduction
2. Objectives of the Study
3. Optimization Method
4. Research Activities
5. Outcomes
6. Work Done till Date
7. Work Left
8. Plan for Next Progress Report
9. Semester Wise Schedule of Work
10. References

3. Introduction
Global warming is a major source of concern.
A disadvantage of high-density energy storage systems are:
Elevated temperatures while operating in an electric vehicle,
Primarily due to internal resistance regions,
Thermal flow failure,
Mechanical damage,
Short-circuiting,
Improper electrochemical reaction
As a result,
Extremely high pressure and multiple explosions
Electric vehicle (EV) fire even with minor lapses.

4. Objective of Study
a. To develop an efficient thermal management system for Li-ion batteries used in EVs.
b. To simulate the developed system in order to understand its behavior, effectiveness and
temperature variation across the cells.
c. To test the developed system under different operating conditions.
d. To analyses the developed BTMSs with and without a conventional cooling system to
validate its application.
e. To study the effect of performance parameters with respect to;
1) Cost,
2) Space,
3) Size,
4) Changes in drive range,
5) Life of battery
6) Weight.

5. Optimization is a necessary tool to identify the best possible optimization
methods are:
Continuous
Combinatorial
Classical methods,
Heuristic, and
Metaheuristic
Popular metaheuristic algorithms for optimisation include
Genetic algorithm,
Bee algorithm,
Particle swan optimisation, and
Ant optimisation.
A genetic algorithm (GA) is an evolutionary algorithm used in Optimization.
Optimization Methods

6. RESEARCH ACTIVITY
Battery Pack Specifications
223
125
112
Parameters Specification
Li ion Battery cell type 26650 Grade “A”
Cell Capacity 5000 mAh
Dimensions: 26 mm x 65 mm (+/- 0.5
mm)
Full charge per cell 4.0V
Charging current per cell 1 - 3.5 A
Nominal voltage per cell 3.7V
Cell discharging Cut-off 2.5V
Energy per cell 8 Wh at 23 ºC
Specific Power of the cell 2600 W/kg
Specific heat per cell 978 J Kg-1K-1
Cell Thermal Conductivity
longitudinal directions
23.3 W/m.K

7. Material used for fabrication
Type Tensile strength (MPa) Tensile modulus (GPa) Compressive strength (MPa) Density
Resin 404 isophthalic resin 50 37 88 1100 kg/m3
ATH A 202 561 kg/m3
E-glass fiber Chopped strand mat 2400 73 e 2600 kg/m3
Thickness of Side walls (mm) 3.5
Thickness of Side walls (mm) 5

8. Enclosure Composite Sandwich Wall:
Thermal Management System
Material for Thermal Management
Paraffin phase change material
n-Octadecane microencapsulated phase-change C18H38

9. Battery Thermal Management system in Simulink

10. Simulink output of speed and battery pack
temperature with time in seconds

11. PHASE CHANGE MATERIAL (PCM)
• n-Octadecane is a straight-chain hydrocarbon, also known as stearic
acid, is composed of 18 carbon atoms and has the chemical formula
C18H38.
• A long-chain fatty acid that can be used as a phase change material
(PCM) in battery thermal management.
• Octadecane has a relatively high melting point of around 69.5°C and a
relatively low heat of fusion of around 225 J/g.
• Store and release a significant amount of heat energy over a small
temperature range.

12. Heat released by PCMs
• Latent heat of fusion by transitions from a solid to a liquid state.
• Absorb heat from the cells generate heat during charging and
discharging,
• Keep the cells at a safe temperature.
• Designed to release heat at specific temperatures, through the use of
thermosetting materials

13. Methods to solidify the phase change material
(PCM) in an ENCLOSUE of a battery
• Natural solidification
• Active cooling
• Thermochromic PCM
• Thermosetting PCM: This method involves using a PCM that is
designed to solidify at a specific temperature and maintain its solid
state after cooling. This can be useful for applications where
temperature fluctuations are minimal and a more stable temperature
range is needed.

14. The quantity of phase change material
A common formula used to rough estimate the quantity of PCM
Equation 1: Q_pcm = Qtotal x (T_hot - T_cold) / (ΔH_fusion)
Q_pcm = quantity of PCM required
Q_gen = heat generated by the battery cells
T_hot = the highest temperature of the system
T_cold = the lowest temperature of the system
ΔH_fusion = the heat of fusion of the PCM (the amount of heat required to
melt a given mass of PCM)
Equation 2:
Qtotal=AU ((ΔTx24)/1000)+mCp(ΔT)/3600 kW/hr.+ (No of cell + fan)
(time x wattage/1000)+ Changes x volume x energy (ΔT)/3600

15. Experimental Setup for Functional Test

16. Experimental Setup for Thermal Test

17. The prototype demonstrated that weight using developed overall can result in a 31% reduction. (1.5 kg 1.035 kg).
Cell temperature at different discharge rate with time in seconds
Experimental Results

18. Discharge rate Higher Temperature
measurement in °C
Total Heat Generation in kJ Capacity (Ah)
Experiment Model Experiment Model
2C 43 48 47 46.6 24.08
3C 49 50 54.5 56 24.08
Over discharging Conditions
4C 56 55 60 59.0 24.08
6C 79.5 76.8 79.2 77.0 24.08
Heat generation with different discharge rates

19. Odometer Reading
Start
Stop
Smart tech Battery1572W @45 km/hr
16203
16259
Developed Battery 1440 W @45 km/hr
16259
16321
Range 56 (27.9W/Km) 61 (23.6W/Km)
Result: 16 % power enhancement observed.
On Road Range Test

20. On Road test with Okinawa Ridge+
Range test was also conducted with Okinawa Ridge + Model
scooty and results found competitive.

21. Results Summary on Objective parameters.
Parameter Value
1)Cost,
Cost in Market Enclosure 2000
Cost of developed Enclosure 500
2) Space, Compact and flexible
3) Size,
Steel 230x270x200
Composite 230x270x200
4) Changes in drive range,
Ideatech 56 km
Developed Composite 61 km
5) Life of battery Normal 3000 cycle
Developed 3500 Cycles
6) Weight. Steel 3.5 kg
Composite 2.79 kg

22. PUBLICATIONS

23. PATENT APPLICATION

24. Thanking You
Queries?