Future of mobility is Electric Vehicles. By switching to EVs, India will curb its CO2 emissions by one Giga tons by 2030. This feat will translate into less air pollution in metros and mini metros and will keep the present and future generations healthier.

Electric vehicles are the future! The manufacturing companies are putting more effort into moving from traditional vehicles to electric cars. There are plenty of benefits to owning an electric vehicle with the right amount of functionality and infrastructure.

While other internal combustion engines derive energy from burning fuel, electric vehicles receive their power directly from a large battery assortment. In EVs , The Lithium-Ion Battery Used & Compared with traditional battery technology, lithium-ion batteries charge faster, last longer and have a higher power density for more battery life in a lighter package.

Secondly, lithium is considerably lighter than other elements utilized in cells, such as lead, necessary for small devices such as phones and cars with several batteries. Finally, since lithium ions and electrons quickly move back into negative electrodes, the lithium-ion batteries can get recharged.

When it comes to applications of lithium-ion batteries, they are very good electricity storages, The Li-ion battery (LIB-LFP) functions in the same way as other batteries. The electrodes, on the other hand, are not as highly influenced by chemical processes. While draining, Li-ions move from the negative anode to the positive cathode, and likewise when recharged.

It is an example of one of the Automotive Model is a midsize sedan manufactured in Automotive Industries. The main power source for the vehicle is Lithium-ion battery. It has a battery capacity of 62 kWh. The Battery is manufactured by LG CHEM, Poland. It provides an approximate range of 263 miles.

The High Voltage (Henceforth Called HV) Battery is located between the front and rear axles at the bottom of the vehicle and provides effective weight distribution and low center of gravity. The battery pack used in the Model has improved protective structure which enables significant structural strength and torsional rigidity to the vehicle.

The battery modules used in the HV battery are placed in the integrated structure made up of Aluminum. This enables a space-efficient battery module distribution in the battery tray and protects the battery modules in case of any collision.

Lithium-ion battery used in Models made up of 9 battery modules. Each battery module has 24 high energy density Lithium-ion cells. Battery modules are connected in series and each cell is connected in series-parallel combination.

Each battery module is thermally and electrically monitored and controlled. Battery module is encased with an aluminum housing. The battery mass is 376 kg. It had advanced safety systems for the HV Battery Pack consisting of Pyro fuse, Shunt Assembly, the Battery Management System, Battery Sense Module, contactors, fuses, busbars, temperature monitoring (cell monitoring strips) for protection.

The battery is a part of the vehicle chassis, mounted low in the vehicle to provide a lower center of gravity. It is housed in a lightweight aluminum structure that is bolted to the body of the vehicle, helping to improve rigidity.

The battery modules of the vehicle may have either prismatic cells or pouch cells. Prismatic lithium-ion cells made by LG will be used. Battery modules with different cell types will not be used in one battery. For the 62-kWh battery, the modules are arranged as 12 in series and 2 in parallel.

Formation of 6S2P (6 In Series & 2 In Parallel) Module Assembly for Generating 21.5 volts Battery Module, further to this, it will form 350 volts Battery Power Pack With 39.5 kWh Energy, which will be used for SUV 4W Cars.

Having Cell Capacity ≥ 56Ah & Nominal Voltage range Approx 3.65 V ~ 3.68 V, Also Operating Voltage Range 2.8 V ~ 4.25 V at constant & 2.5 V ~ 4.25 V at peak, this cell will get converted in to 21.5 V Capacity Module Formations.

This Module will get converted in to 350 V System with Battery Power Pack 96S2P (96 In Series & 2 In Parallel) With Nominal Pack Voltage 351.5 V & Maximum Voltage of 398.5 V & Minimum Voltage of 288.5 V

By Assembly Total 16 Nos of Modules of 21.5 V, This Battery Power Pack will form a Pack Capacity of 112 Ah at 1 C Rate of Charging Capacity & Which will generate the Total Energy of 39.5 kWh.

This Entire Battery Power Pack Is Nothing but Lithium-Ion Cell Rechargeable Electrical Energy Storage System (RE-ESS) of 350 V @ 39.50 kWh.

To take decisions on C-rates or power for battery pack in various modes, temperature for battery pack (T_Batt) needs to be defined.

The operating temperature limit of the battery in drive mode should be between -20°C to 55°C.The maximum discharge current and regeneration current are functions of temperature and SoC also needs to be defined.

In drive mode, the battery can be charged with regenerative current. Since the magnitudes of these currents are expected to be high, these might affect the warranty life of battery. Hence, the C- rates of regeneration currents are limited. The operating temperature limit of the battery in drive mode should be between 0°C to 45°C.

Also, all the Testing Parameters Including EoL End of Line Testing of Battery Power Pack Along with Battery Module will be Defined. This Includes Functional Testing, Safety Testing, Performance Testing & Electrical Checks considering high voltage systems.

Thermal Resin Dispensing in Battery Module & Battery Power Pack will also be analyzed to study the behaviors aspects of battery power pack in case of high voltage systems, Thermal Runaway Analysis will also be considered the part of this project.