Pouch Cell Module Design
Pouch Cell Module Design
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With accumulator's architecture move to a 13ah Cosmx pouch cell (thanks Tesla!) from LGHE2 18650's, I am in charge of leading the module and enclosure design. Our team is still in the process of deciding between a 96s1p and 144s1p configuration, but I went ahead and started on the module design. It's mostly parameterized and fully equation driven so we can swap between segments configuration easily in the future and auto calculates cell spacing given a metal plate thickness, foam thickness, and foam compression % target. My goal is to keep the top down design throughout the development of the module to allow for easily configuration change for both this coming year and future years.
This project is a work in progress and has yet to be completed.
Photos & Technical Documentation
Photos & Technical Documentation
Completed Design
Completed Design
Finalized 6x 28s1p module design for 144s1p 600V Accumulator.
cell compression
all tab connection hardware
module control board integration
handles for easy removal
Some of the design analysis work includes:
Static analysis of cell compression stack up across life span to hit compression targets
FR4 PCB was statically loaded to produce the loads seen by the spring loaded voltage taps on the bottom side of the board to ensure it was sufficiently stiff.
Appropriate pull up resistor was chosen for the isolated thermistors used to monitor cell temperatures
Prototype Models
Prototype Models
Early construction of a test module to check fitment and component tolerance stack ups
Early Module Design
Early Module Design
Very early module design. Allows for easy adjustment of:
module configuration
cell spacing
foam thickness
foam compression
metal cooling plates thickness
tab angle and bends
tab gaps
and more. Future design work to follow.
Potential Chassis Changes (96s1p)
Potential Chassis Changes (96s1p)
Some preliminary packaging exploration with a 96s1p configuration to align with VD's goals of shrinking our wheelbase to the minimum allowed by the rules and moving CG more centrally. Slight chassis tilt would allow for aero improvements with refined under tray design. These changes are pending more investigation.
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