Battery Pack Design of Cylindrical Lithium-Ion Cells and Modelling of Prismatic Lithium-Ion Battery Based on Characterization Tests

Abstract

With increasing research on lithium batteries, the technology of electric vehicles equipped with lithium battery packs as the main energy storage system has become more and more mature, and the design and testing of lithium ion battery packs are becoming extremely important. As the battery system becomes more complex, it is necessary to optimize its structural design and to monitor its dynamic performance accurately. This research considers two related topics. The first is the design of a battery submodule made up of cylindrical lithium cells. The objective of this design is to improve its energy density and optimize the heat dissipation performance according to the installation position and space constraints in Ford Focus EV 2013, and, produce a submodule prototype based on this design; The second objective is to derive and verify an equivalent circuit model for a prismatic lithium battery cell of high energy capacity based on experimental results. In terms of mechanical structure, the basic structure of a battery pack is determined by the desired performance as well as cell characteristics. In this research, the Samsung 35E 18650 cylindrical cells are chosen. 20 battery cells are connected in parallel to form a battery submodule, and 13 battery submodules are connected in series to form a battery pack. The battery pack design process mainly includes positioning and connection of battery cells, heat dissipation mechanism, cabling and inside the pack. The above considerations were applied to prototype battery submodule with an energy density of 216.87 Wh/kg. Some key considerations in the design of the battery pack include checking the conductivity and the welding connection. Chemistry of lithium-ion batteries are constantly evolving with industrial demands which call for higher energy storage capacity. Therefore, this research selected a new high-capacity prismatic cell to establish an equivalent circuit model using characterization and experiments, followed by verification. A 280 Ah Lithium Iron Phosphate (LFP) prismatic battery cell was selected and characterized by testing under various operating conditions for validation, the Urban Dynamometer Driving Schedule (UDDS) was used.