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Review of mechanical design and strategic placement technique of a robust battery pack for electric vehicles

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  • Arora, Shashank
  • Shen, Weixiang
  • Kapoor, Ajay

Abstract

In an electric vehicle (EV), thermal runaway, vibration or vehicle impact can lead to a potential failure of lithium-ion (Li-ion) battery packs due to their high sensitivity to ambient temperature, pressure and dynamic mechanical loads. Amongst several factors, safety and reliability of battery packs present the highest challenges to large scale electrification of public and private transportation sectors. This paper reviews mechanical design features that can address these issues. More than 75 sources including scientific and technical literature and particularly 43 US Patents are studied. The study illustrates through examples that simple mechanical features can be integrated into battery packaging design to minimise the probability of failure and mitigate the aforementioned safety risks. Furthermore, the key components of a robust battery pack have been closely studied and the materials have been identified to design these components and to meet their functional requirements. Strategic battery pack placement technique is also discussed using an example of Nissan LEAF battery packaging design. Finally, the disclosed design solutions described in this paper are compared with the Chevrolet Volt battery pack design to reveal the basic mechanical design requirements for a robust and reliable battery packaging system.

Suggested Citation

  • Arora, Shashank & Shen, Weixiang & Kapoor, Ajay, 2016. "Review of mechanical design and strategic placement technique of a robust battery pack for electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 60(C), pages 1319-1331.
    • Handle: RePEc:eee:rensus:v:60:y:2016:i:c:p:1319-1331
    DOI: 10.1016/j.rser.2016.03.013
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    References listed on IDEAS

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    1. Rao, Zhonghao & Wang, Shuangfeng, 2011. "A review of power battery thermal energy management," Renewable and Sustainable Energy Reviews, Elsevier, vol. 15(9), pages 4554-4571.
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    Cited by:

    1. Ruiz, V. & Pfrang, A. & Kriston, A. & Omar, N. & Van den Bossche, P. & Boon-Brett, L., 2018. "A review of international abuse testing standards and regulations for lithium ion batteries in electric and hybrid electric vehicles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 1427-1452.
    2. Yang, Chen, 2022. "Running battery electric vehicles with extended range: Coupling cost and energy analysis," Applied Energy, Elsevier, vol. 306(PB).
    3. Jianwen Cao & Bizhong Xia & Jie Zhou, 2021. "An Active Equalization Method for Lithium-ion Batteries Based on Flyback Transformer and Variable Step Size Generalized Predictive Control," Energies, MDPI, vol. 14(1), pages 1-25, January.
    4. Tao, Laifa & Ma, Jian & Cheng, Yujie & Noktehdan, Azadeh & Chong, Jin & Lu, Chen, 2017. "A review of stochastic battery models and health management," Renewable and Sustainable Energy Reviews, Elsevier, vol. 80(C), pages 716-732.
    5. Anton Kersten & Manuel Kuder & Torbjörn Thiringer, 2021. "Hybrid Output Voltage Modulation (PWM-FSHE) for a Modular Battery System Based on a Cascaded H-Bridge Inverter for Electric Vehicles Reducing Drivetrain Losses and Current Ripple," Energies, MDPI, vol. 14(5), pages 1-19, March.
    6. Lixing Chen & Xueliang Huang & Zhong Chen & Long Jin, 2016. "Study of a New Quick-Charging Strategy for Electric Vehicles in Highway Charging Stations," Energies, MDPI, vol. 9(9), pages 1-20, September.
    7. Mahmoudzadeh Andwari, Amin & Pesiridis, Apostolos & Rajoo, Srithar & Martinez-Botas, Ricardo & Esfahanian, Vahid, 2017. "A review of Battery Electric Vehicle technology and readiness levels," Renewable and Sustainable Energy Reviews, Elsevier, vol. 78(C), pages 414-430.

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