Module Configuration

Owned by Eric Zhao
Last updated: Sept 04, 2023 by Kostubh Agarwal
4 min read

https://docs.google.com/document/d/1__XgN5KwcSGN4PDO7op1BnbrN98TiNxS-JX0baDGL14/edit?usp=sharing

What is the ideal pack configuration?

Rectangle (Packing Density: 0.785)

Honeycomb (Packing Density: 0.907)

  • More space in between batteries for cooling/other equipment

  • Extra space reduces probability of combustion in event of crash

  • Higher packing density 

  • Less space taken 

  • Less materials needed

2S vs 4S Modules

  • An even number of cells in series required to keep the gusset plates on top.

 

Area = 0.23928 m2

PROS:

  • More gap area between modules, possibly better airflow and cooling for batteries

  • Reduced complexity per module, only one busbar connection on bottom

  • Module arrangement has positive and negative terminals on same side

  • Area in top center for hardware components

  • More modules means damage is more isolated and cheaper to fix

CONS:

  • More module to module connections, greater contact resistance and possibly greater energy loss in connections compared to 4S?

  • Have to create and assemble “double” the modules

  • Takes up more area

 

Area = 0.22403 m2

PROS:

  • Module arrangement has positive and negative terminals on same side

  • Area in top right for hardware components

  • Only have to create “half” the number of modules

  • Less energy loss in module to module connections

CONS:

  • More complex modules, need 5 busbar connections

  • Very long (86.7 cm)

 

Area = 0.20163 m2

PROS:

  • Smallest area required

  • Only have to create “half” the number of modules

  • Less energy loss in module to module connections

CONS:

  • Positive and negative terminals on opposite sides.

  • More complex modules, need 5 busbar connections

 

Cell Arrangement

What to do with empty spaces?

 

kinda sus

 

 

Layouts vs Chassis Concept

(for a sense of scale)

Seems to be more of a matter of where we want to put the pack, rather than if we can put the pack in the car.

Front and back placement concepts

NOTE: We would want “easy” access to the pack for removal of the battery pack every night and for module replacements.

Maybe we can consider having the pack at a bit of a slant if it helps with creating an aerodynamic aerobody? Not sure how this would affect the physical properties of the modules though (if they can withstand the shift in weight).

Individual Module Mass Estimate:

  • 44 batteries => 2112g

  • 2 acetal plates => 2 x 117g = 234g

  • other parts tbd