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Do you know what are the main components of an EV power pack?

2023-03-27

Power packs are the only source of power for purely electric vehicles and the range that an electric vehicle can travel depends on the power of the pack. The market is using high capacity cells or using more cells as a way of boosting the power pack electrical energy, however this can drive up the cost of the pack, so the focus needs to be on optimising the structure of the pack during the design process of the power battery, so what are the main components of an EV power pack?

1. Power Cell Module

The role of the power battery module in the power pack is to store and release energy, which is the power source of the electric vehicle. The power battery module can be understood as the power battery monomer combined into multiple PACKs through series-parallel connection, PACK is a single component, which means packaging, encapsulation and assembly, and its process procedure includes three major parts: processing, assembly and packaging.

After the power battery module has been structurally designed, it can be combined with the power battery management system and thermal management system to form a more complete power battery pack. The power battery pack is designed in a fixed position with the help of technology and structure, and together they play the function of electrical energy charging and storage. The fundamental role of the module is to fix, connect and secure the pack.
Power battery cells and batteries are divided by positive materials, including lithium cobaltate, lithium manganate, lithium iron phosphate and lithium nickel cobalt manganate ternary materials. The structure of the power battery module should be fixed, supported and protected by the battery cells, which can be summarised into 4 major items: mechanical strength, electrical performance, thermal performance and fault handling capability.
Power battery modules can be divided into three types according to the structural shape of the cells: cylindrical cells, square cells and soft packs, whose respective advantages and disadvantages are also obvious. To a large extent, the performance of the cells determines the performance of the power cell module, which in turn affects the performance of the entire power pack. Therefore, when designing a power pack, the material and shape of the cells must be considered in accordance with the design requirements of the vehicle.
The ability of the power battery module to hold the cell in place and avoid performance-damaging deformation, to meet current-carrying performance requirements, to control the temperature of the cell, to cut off power in the event of a serious abnormality and to avoid the spread of thermal runaway are all criteria for assessing the merits of the power battery module.
2. Structural System
The structural system includes the power battery PACK cover, tray, various metal brackets, end plates and bolts, which can be regarded as the "skeleton" of the power battery PACK, playing the role of support, resistance to mechanical shock, mechanical vibration and environmental protection (waterproof and dustproof). The power battery pack is loaded on the electric vehicle, the mechanical characteristics must be fully considered first, the product must have a certain strength and stiffness, in order to avoid deformation and functional abnormalities under mechanical loads such as vibration and shock, safety protection against collision, extrusion, tumbling, falling and other accident conditions.
3. Electrical System
The electrical system mainly consists of high-voltage jumper or high-voltage harness, low-voltage harness and relays. The high-voltage harness can be regarded as the "artery and blood vessel" of the power battery PACK, which continuously transports the power from the heart of the power pack to each required component. The low-voltage harness can be seen as the "neural network" of the power pack, transmitting detection and control signals in real time.

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