Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and...
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Transcript of Midsize Lithium Ion Battery Pack Patrick Montalbano © 2012 RIT Winter 11-12 Student Research and...
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Introduction
Design, Construction, and Applications of a Midsize Lithium Ion Battery Pack
Patrick Montalbano, KC2SAE
Rochester Institute of Technology, 2012College of Applied Science and Technology
Mechanical Engineering Technology
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Battery Technologies
Lead Acid (Pb)•Very low cost, mass produced, highly scalable•Worst energy density: very heavy
Nickel Cadmium (NiCd)•Low cost, mass produced•Poor energy density, limited scale
Nickel Metal Hydride (NiMH)•Good energy density, good shelf life•Limited current
Lithium Ion (Li+)• High Energy density: lightweight• High cost, additional safety considerations
Energy Density
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Form Factor
Rectangular Cells• Customized Shape• IC Protection
Cylindrical Cells• Standardized• Flexible Platform• Highly Scalable• Hardware Protection• Limited in Size
Model 18650• Highly Commercialized• Commodity Pricing
• Require additional voltage/circuit protection •Constant current/constant voltage charging
IntroductionBattery Technology
Form FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Nissan Leaf Battery
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Lithium Applications
Integrated into personal electronics
Lithium is well suited for portable electronics:• Size Limitations• High power demand• Lightweight• Rechargeable
All-electric EV’s
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Battery Backpack
Battery On-Frame Backpack
To be used for extended use of Amateur (ham) radio on hikes-Easily adaptable in military or commercial applications
Battery
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Flat Midsize Pack
•Easy to Carry• 5.5 lbs
•Common voltage (14.4v)•High Capacity• 354 Wh
•Highly configurable
An innovative solution for midsize powered devices
• Carbon Fiber Composite• Load bearing
• Sealed against water/dust
•1.75” Overall Thickness
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery Backpack
Midsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
“Level 1” Assembly
Level 1: Parallel assemble providing cell level over-current protection
Level 2: Series elements producing operating voltageLevel 3: Power Control Board to load
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Mold Making
1. Plug constructed from wood is 1:1 representation of
finished part
2. Fiberglass mold cavity is inverted for carbon fiber layup
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” Assembly
Mold MakingLayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Layup
3. Carbon reinforced epoxy laminate is compacted using vacuum
4. Part is removed and finished
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold Making
LayupPrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Final Prototype
•(2) Anderson Power Pole terminals
•State of Charge ‘fuel’ LED gage
•Developer pass-through DB-9 (voltage and 1-wire
temperature)
Shown with UHF/VHF transceiver
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayup
PrototypeSummary
Midsize Lithium Ion Battery PackPatrick Montalbano
© 2012 RIT Winter ‘11-’12 Student Research and Innovation Symposium
Project Summary
Special thanks to battery cell sponsor, Tesla Motors.
IntroductionBattery TechnologyForm FactorLithium ApplicationsBattery BackpackMidsized Pack“Level 1” AssemblyMold MakingLayupPrototype
Summary
•Packs can be built using rejected automotive cells
Development Expenditures
14.4v, 22Ah @ 30A354 Wh13 x 9 x 1.75 inches5.5 lbs
Battery Specs.
Composites & tooling; $300Electrical connectivity & PCB; $80
Cells; $150 - $240Housing & hardware; $130
Commercialization Estimate