Battery Design: from chemistry to pack

Designed by battery engineers for battery engineers. The site is organized by system and function, thus making it easy for you to find information. When you think about designing a battery pack you think at cell, module, BMS and pack level. However, you need to also rapidly think in terms of: electrical, thermal, mechanical, control and safety. Looking at the problem from different angles will help to ensure you don’t miss a critical element. This is what BatteryDesign.net is all about.

Published

June 2022

Industry

Batteries

Author

BatteryDesign.net

How to select EV Contactors

Contactor selection is an iterative process that includes consideration of system specifications as well as failure scenarios. Most of the contactor manufacturers share necessary information in datasheets. Thus, a wise approach would be making a comparison table to cover basic specifications like thermal and mechanical initially.

A labeled diagram of a contactor. Labels indicate "Fixed Contacts" at the top, "Arc Chamber" on the upper left, "Moving Contact" below the Fixed Contacts, "Return Spring" in the center, "Moving Core" on the lower right, and "Contactor Actuator Coil" at the bottom. — Battery Design from chemistry to pack

https://www.batterydesign.net/how-to-select-ev-contactors/

Battery technology is changing fast, different chemistry, developments in BMS hardware and fundamental changes to how a pack is assembled. Hence you need to be aware of other battery pack designs. Here BatteryDesign.net can help with data, metrics and insights into some of the most interesting battery designs.

2019 Porsche Taycan

An 800V pack design for high power discharge and fast charge times. The battery contributes around 10% of the vehicle’s overall stiffness. The cooling elements are glued on underneath the bulkhead plate using heat conductive adhesive, thus ensuring coolant leaks cannot short the HV system. Overall though the metrics are not leading, 148Wh/kg and cell to pack mass ratio of 56% shows that other than 800V this is a conservative design.