Assembling a battery pack for electric vehicles can be quite complex. Often there is a high power demand, while the available space is limited. Think of applications such as motorcycles, race cars and jet skis. In this article we describe the best methods to assemble a battery pack for these types of applications.

Select the right battery for your electric vehicle

When choosing a battery it is essential to look at the continuous and peak discharge current. Power Battery modules, such as the extreme module, are specially designed for such applications. They deliver maximum current output in a compact design.

Connecting batteries in series and parallel

If the nominal and maximum voltage of the application are known, the battery modules can be connected in series to achieve the required voltage. This determines the minimum space you need for your battery pack. If possible, two modules can be connected in parallel, doubling the capacity and power output. Connecting additional modules in parallel increases the range and reduces the voltage drop. This results in a longer life and better performance of the batteries.

Cooling of the battery pack

Cooling is crucial in high power applications. In classic cars and other low to medium power vehicles this is less critical. However, in high power applications maximum power is often required, which is a good cooling system required. Maintaining a low temperature extends the usable capacity of the batteries.

Battery housing for electric vehicles

Weight saving is essential in applications such as racing cars. The design of the battery housing plays a major role in this. Steel and stainless steel are strong but heavy. Aluminum is lighter and strong, but requires thicker walls. A hybrid solution, such as an aluminum housing reinforced with carbon, offers a good balance between strength and weight.

Battery pack insulation

Thermal insulation ensures that the battery slowly rises and falls in temperature, which prevents condensation. Good insulation materials are PVC, Nomex and Kapton tape. These materials are electrically insulating and resistant to high voltages.

Important considerations

1. Choose the correct battery module: High continuous and peak discharge current is essential.
2. Parallel connection: Add additional modules to increase capacity and power.
3. Cooling: Ensure an efficient cooling system.
4. Weight saving: Choose the right materials for the battery housing.
5. Thermal insulation: Prevent condensation by using good insulation.
6. Electrical insulation: Use materials such as Nomex, Kapton and PVC for safety.

At Power Battery we develop, test and manufacture powerful battery packs and modules. Feel free to contact us for questions or a consultation on your project.

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