Li-Ion Battery Pack Design for Electric Vehicles (2023)


The Exclusive Guide to Battery Pack Design for Electric Vehicles: Mechanical, Thermal, Electrical and Systems Approach

What you will learn

Gain a comprehensive understanding of different lithium-ion cell chemistries and make informed decisions in battery selection and design

Master the principles of mechanical design of battery module and pack, enabling you to design robust and reliable battery systems.

Learn how Li-Ion battery behaves at various temperatures and how to define the operating temperature requirement to maintain safety, performance and life.

Learn the importance of thermal management systems in EV battery packs and explore various types and methodologies for battery cooling

Develop an understanding of the electrical components in an EV battery pack (BDU, contactors, sensing, fuses, etc) and their selection criteria.

Learn about the Battery Management System and the crucial role it play with respect to safeguarding the battery pack and extending cycle life.

Gain knowledge about battery pack testing including functional and abuse testing.

Dive into the world of EVs and understand their history, growth, common terminology and sizing requirements.

Gain insights into the future trends of lithium-ion batteries and electrification, allowing you to anticipate and adapt to emerging technologies and advanc

Description

Welcome to an unparalleled learning experience in the realm of battery pack design for electric vehicles. This course, the first of its kind, is exclusively dedicated to the intricate world of Li-ion battery pack design. It offers an all-encompassing guide that meticulously covers every facet of this critical subject, from fundamental terminology to the most advanced design concepts.

The course is designed to provide an in-depth understanding of the pivotal role that battery packs play in the operation and performance of electric vehicles. We delve into the selection of materials, the intricacies of mechanical packaging design, the complexities of thermal management, and much more. This isn’t merely an educational journey; it’s an invitation to become part of the electric vehicle revolution.


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The current decade signals a paradigm shift in transportation with the rise of electric vehicles (EVs) and Li-ion battery technology. Propelled by advancements in battery efficiency, global sustainability goals, and shifting consumer preferences, EVs are poised to dominate the automotive industry.

Whether you’re a student seeking to broaden your knowledge, a professional aiming to specialize in this field, or an enthusiast with a keen interest in electric vehicles, this course offers a unique opportunity to gain expertise in a field that is shaping the future of transportation.

English
language

Content

Introduction

Course Introduction
Course Structure

The Journey of Vehicle Electrification

From Early Electric Vehicle Development to Modern Vehicle Electrification

Understanding the Language of Electrification

Vehicle and Industry Terminology
Battery Terms and Definitions
Recap of Battery Pack Terminology

Introduction to Battery Pack Design

Translating Customer Requirements into Battery Pack Designs
Exploring Battery Comparison Ratios such as $/kWh, kWh/kg, etc
Battery Pack Benchmark Ratios

Exploring Lithium-Ion and Other Cell Chemistries

An Overview of Lead Acid Battery
Understanding Lithium-Ion Cells
Sodium and Nickle Based Cells
Alternate Battery Technology: Li-S,Li-Air, Polymer, Solid State, etc.
Lithium-Ion and Other Cell Chemistry Recap

Mechanical Packaging and Material Selection for Battery Packs

High-Level Overview of Battery Pack Components
Exploring Different Cell Form Factors
Module Design Basics
Module Structure Design
Use of Plastics in Modules
Understanding the Role of HV Bus Bars
Other Module Components: TIM, Mica, LV Harness, Etc
Integration into the Battery Pack Design

Thermal Management in Battery Systems

The Importance of Temperature Regulation in Battery Systems
Passive Thermal Management Systems
Active Thermal Management Systems
Li-Ion Battery Pack Operation In Temperature Extremes
Li-Ion Temperature Behavior and Thermal Management System

Mastering Battery Management System Controls

Fundamentals of Battery Management Systems (BMS)
Types of BMS and Hardware
Understanding Cell Balancing Techniques
Exploring Additional BMS Functionality & Software Controls
BMS and Cell Balancing Recap

Electrical Design and HV Components

HV System Overview and 400V vs 800 V Architecture
HV Components Overview
HV Component Details: Contactors
HV Component Details: Fuses
HV Component Details: HVIL
HV Component Details: Connectors
HV Component Details: Battery Disconnect Unit
HV Component Details: Charging System
HV Components in an EV: A Quick Recap

Understanding Battery Pack Testing

Li-Ion Failure Causes
Performance & Characterization Testing
Certification Standards

Looking Ahead: The Future of Lithium-Ion Batteries and Electrification

Major Trends in Battery and EV Technology

Course Summary

Course Overview & Summary

Bonus Section

Bonus Video