International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 03 | Mar 2025
p-ISSN: 2395-0072
www.irjet.net
Design, Analysis & Testing of Battery Pack for Off-Road Applications Shantanu Bamane1, Om Zaware2, Rohan Dhaygude3, Prathamesh Pawar4 Department of Mechanical Engineering, Dr.D.Y.Patil College of Engineering, Akurdi, Pune, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------5.
Abstract – The increasing demand for safe, effective &
sustainable battery packs has driven significant advancements in electric battery technology particularly for off-road applications where the battery pack must face harsh conditions (i.e. high temperature, high vibrations, etc.). This paper presents a comprehensive study on the design, analysis & testing of an electric battery tailored for off-road applications. The process involves selection of battery cells, bus bar materials, cell holder materials, choosing an effective battery management system, battery casing. For Analysis ANSYS & COMSOL Multiphysics software were utilized & for testing Vibration Test & Ingress Test were performed on the Battery pack. This paper encompasses the battery pack according to AIS 156/048 standards. This includes factors such as safety, performance, durability & environmental impact. The findings demonstrate the potential of the proposed battery pack for off-rode vehicles thus providing a viable alternative to the long-standing use of Internal Combustion Engines.
Manufacturing Battery Pack.
2.BATTERY DESIGN 2.1 Cell Selection Following points were considered for cell selection 1. Internal Resistance 2. Cell Chemistry 3. Foam Factor 4. Capacity 5. Availability in market 6. Discharge & charge rate Table -1: Battery Cell Comparison according to its technical specifications Cells
Voltage
Capacity
Weight
18650 CYL LFP
3.2 V
3200 mAh
46 g
Key Words: Lithium-ion Battery, Electric Vehicle, Battery Vibration Testing, Ingress Protection Testing
21700 CYL NMC
3.6 V
5000 mAh
70 g
Prismatic LFP
3.2 V
100 Ah
2210 g
1.INTRODUCTION
32600 CYL LFP
3.2 V
6 Ah
145 g
Samsung 48X 21700
3.64
4.8 Ah
67.9 g
In this rapidly evolving landscape of automotive technology, the design and analysis of battery pack play a pivotal role in shaping the performance & efficiency of electric battery pack. Off-road vehicles, such as all-terrain vehicles (ATVs), require robust battery system which are capable of enduring harsh environmental conditions. Lithium-ion battery is favoured for its high efficiency, high energy density & longlife cycle. The primary objective is to design a battery having high energy density and power density while maintaining thermal stability and safety.
For designing a battery pack with the given parameters, lithium-ion Samsung 48X 21700 cells with NMC chemistry were selected due to their high-power density, higher voltage, good capacity-to-weight ratio and the reliability and availability associated with Samsung brand.
2.2 Battery Parameters The parameters of the battery were chosen to balance voltage, capacity & manage current capabilities to ensure it meets performance, safety and durability requirements.
1.1 Objectives 1.
Selection of cells having high energy density, high power density and durability.
2.
Simulation of Battery cell using MATLAB Simulink to affirm the charge discharge cycle of battery cell.
3. 4.
Table -2: Battery Parameters Configuration
14S 24P
Structural and Thermal Analysis of Battery pack using ANSYS and COMSOL Multiphysics.
Peak Voltage (V)
58.8
Nominal Voltage (V)
50.4
Analysis of bus bar using COMSOL Multiphysics software to check its durability to high temperatures.
Cut-off Voltage (V)
37.8
Peak Discharge Current (A)
180
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