International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072
Design, Analysis & Testing of Battery Pack for Off-Road Applications
Shantanu Bamane1 , Om Zaware2 , Rohan Dhaygude3 , Prathamesh Pawar4
Department of Mechanical Engineering, Dr.D.Y.Patil College of Engineering, Akurdi, Pune, Maharashtra, India
Abstract – The increasing demand for safe, effective & sustainablebatterypackshasdrivensignificantadvancements in electric battery technology particularly for off-road applications where the battery pack must face harsh conditions (i.e. high temperature, high vibrations, etc ). This paperpresentsacomprehensivestudyonthe design,analysis & testing of an electric battery tailored for off-road applications.Theprocessinvolvesselectionofbatterycells,bus bar materials, cell holder materials, choosing an effective battery management system, battery casing. For Analysis ANSYS & COMSOL Multiphysics software were utilized & for testing Vibration Test & Ingress Test were performed on the Battery pack. This paper encompasses the battery pack according to AIS 156/048 standards. This includes factors such as safety, performance, durability & environmental impact. The findings demonstrate the potential of the proposed battery pack for off-rode vehicles thus providing a viable alternative to the long-standing use of Internal Combustion Engines.
Key Words: Lithium-ion Battery, Electric Vehicle, Battery Vibration Testing, Ingress Protection Testing
1.INTRODUCTION
Inthisrapidlyevolvinglandscapeofautomotivetechnology, thedesignandanalysisofbatterypackplayapivotalrolein shaping the performance & efficiency of electric battery pack.Off-roadvehicles,suchasall-terrainvehicles(ATVs), requirerobustbatterysystemwhicharecapableofenduring harsh environmental conditions. Lithium-ion battery is favouredforitshighefficiency,highenergydensity&longlifecycle Theprimaryobjectiveistodesignabatteryhaving high energy density and power density while maintaining thermalstabilityandsafety.
1.1 Objectives
1. Selection of cells having high energy density, high powerdensityanddurability
2. SimulationofBatterycellusingMATLABSimulinkto affirmthechargedischargecycleofbatterycell.
3. Structural and Thermal Analysis of Battery pack usingANSYSandCOMSOLMultiphysics.
4. Analysis of bus bar using COMSOL Multiphysics software to check its durability to high temperatures
2.BATTERY DESIGN
2.1
Cell Selection
Followingpointswereconsideredforcellselection
1. InternalResistance
2. CellChemistry
3. FoamFactor
4. Capacity
5. Availabilityinmarket
6. Discharge&chargerate
Table -1: BatteryCellComparisonaccordingtoits technicalspecifications
For designing a battery pack with the given parameters, lithium-ionSamsung48X21700cellswithNMCchemistry were selected due to their high-power density, higher voltage,goodcapacity-to-weightratioandthereliabilityand availabilityassociatedwithSamsungbrand.
2.2 Battery Parameters
The parameters of the battery were chosen to balance voltage,capacity&managecurrentcapabilitiestoensureit meetsperformance,safetyanddurabilityrequirements.
Table -2: BatteryParameters
5. ManufacturingBatteryPack
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072
3. Thermal conductivity and convective rate of heat transfer
4. Manufacturability
2.3 Busbar Material Selection
InourBatterypack,weareusingcopperbusbarsforseries connection between cells and a nickel strip for parallel connectionbetweencells.Weareusingcopperbecauseofits high electrical and thermal conductivity and nickel for its highweldability.
Consideringapackdischargeof7.5Afromeachindividual cell,wehaveselectednickelstripof0.3mmthickness,andfor apeakdischargeof180Athethicknessofacopperbusbaris 2.5mm.
2.4
Battery Casing
The Casing is the outer enclosure of the battery pack that protectsthebatteryfromtheouterenvironment.Itprovides for rigidity and durability to the entire battery pack. The casing can be made of various metallic and non-metallic materialswhichareofhighstrengthandstiffness.Various parameters were taken into consideration while selecting casingmaterialsuchas:
1. TheStrengthofmaterial
2. TheDensityofmaterial
For our battery pack, we are using a T6-6061 grade Aluminum sheet of 3 mm thickness. We are considering aluminumoverothermaterialsduetoitshigherstrength-toweightratioandbetterthermalproperties.
2.5 Assembly of Battery Pack
1. Busbars were mounted on machined cell holders and then sent to welding of nickel and copper busbars.
2. After welding, cells were arranged in cell holders andwerepackedbetweentwocellholders
3. Themoduleof168cellswassentforlaserwelding
4. After laser welding of both modules, the wiring harness and Battery Management System were connected to the battery (DALY BMS of 14 S configurationwithratedcurrentof200Awasused inourbattery)
Fig -1:CopperBusbar
Fig -2:Nickelstrip
Fig -3:BatteryCasing
Fig -4:SideviewofbatteryCasing
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072
5. InsulationofFR4sheetwascoveredfrombothtop andbottomside
6. Bothmoduleswerestackedoneachotherinseries configurationwiththehelpofcopperwashers.
7. Thewiresareconnectedtothebatteryterminal.
3. SIMULATION
A MATLAB Simulink model was designed to demonstrate variations in cell performance corresponding to C-rate. In thismodel,wehavethecapabilitytoadjustparameterssuch aschargecurrent,dischargecurrentanddepthofdischarge (DOD) over various time intervals. In this simulation, we conductedbothcharginganddischargingcycles.
Results of Simulation Model
The results generated illustrate the variation in key parameters like current, voltage, state of charge, capacity and cell temperature over time. The voltage curve shows typicalcharginganddischargingcycles,whiletheSOCgraph indicates the amount of charge remaining in the cell. Additionally,thetemperaturegraphindicates thethermal behavior of the cell, which is crucial for understanding its performanceandsafety.
4.
ANALYSIS
Thestructuralandthermalanalysisofthebatterypackwas conductedusingANSYSforstructuralanalysisandCOMSOL Multiphysicsforthermalanalysisofthebatterypackaswell asthebusbar.Thisanalysisprovidesvaluablefeedbackon the safety and durability of the battery pack. Structural analysisrevealsthemechanicalintegrityofthebatterypack ensuringthatthebatterypackcanwithstandphysicalstress without failure during off-road applications. On the other hand,thermalanalysishighlightsthethermaldistributionin thebatterypackduringoperation.Thisanalysisiscrucialfor identifying hotspots to ensure thermal management and prevent overheating. The thermal analysis of the busbar ensures that the busbar can handle high loads without overheating.Theresultsofthebatterypackareasfollows:
Fig -5:FinalModelofBatteryPack
Fig -6:MATLABSimulinkmodel1
Fig -7:MATLABSimulinkmodel2
Fig -8:Resultsat0.3CDischargerate
Fig -9:Resultsat0.3CChargerate
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072
5. TESTING OF BATTERY PACK
1. Vibration Test
The vibration testing is used to demonstrate a product’s abilitytowithstandmechanicalstresswithouthamperingits structuralintegrity.Thishelpsinidentifyingpotentialfailure modesandensuringthebatterypack’sperformanceoverits expectedlifespan.Fortestingofthebatterypack,thebattery
pack was mounted on electric–dynamic stator and was subjectedtoasinusoidalvibrationtestinaccordance with AIS048atanaccelerationof3ginbothaxesandafrequency of30-150Hzatasweeprateof1octaveperminute.Testing was carried out for 45 minutes on each axis. A graph of acceleration vs frequency was obtained that showed a straightlinewithoutanydeflection,implyingthatthebattery pack’s structureis stable. The test result was satisfactory, andtheapparatusshowednophysicaldamagetothecasing orothermechanicalpartsandnofireorexplosionafterthe test.
2. Ingress Protection (IP) Test
The IP test was conducted to demonstrate the robustness and reliability of the battery pack for use in challenging environments.IP6XandIP7Xtestswereconductedonthe battery.AnIP6Xratingindicatesthatthebatteryisdusttight i.e.nodustcanenterthebatteryandanIP7Xratingmeans thebatterypackcanwithstandimmersioninwaterupto1 meterfor30minuteswithoutwateringress.Thetestresult of the battery pack was satisfactory, and no water was observedinsidetheenclosureafterthetest.
6. CONCLUSIONS
In conclusion, the developed battery pack for off-road electric vehicles not only meets but exceeds the stringent requirements of automotive applications. The project demonstratedtherobustnessandreliabilityofthebattery packforoff-roadapplicationthroughcomprehensivetesting. TheselectionofNMC(NickelManganeseCobalt)cellsforthe
Fig -10:ResultsofStaticStructuralAnalysisusingANSYS
Fig -11:ResultsofThermalAnalysisofBatteryPackusing COMSOLPhysics
Fig -12:ResultsofThermalAnalysisofBusbarusing COMSOLPhysics
Fig -13:BatterymountedonElectro-DynamicStatorand vibrationplot
Fig -14:BatterypackimmersedinwaterforIPtesting
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025 www.irjet.net p-ISSN: 2395-0072
battery pack provided high energy density and reliability, making them an ideal choice for demanding off-road applications.Thevibrationtestsconfirmedthatthebattery packcanwithstandthemechanicalstressesoftheoff-road environmentwithoutsignificantriskoffailure.TheIP6Xand IP7Xtestsfurthervalidatedthebatterypacksresistanceto dustandwateringressensuringtheirsuitabilityforharsh conditions.Overall,thesatisfactoryresultsfromthesetests indicatethatthebatterypackiswelldesignedtomeetthe demandsforoff-roaduse.
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