With the development of electric vehicles and energy storage systems, battery pack design has become a key technical link. This article will deeply analyze the design process of 100kWh battery pack, including design objectives, selection considerations, structural design, thermal management and other aspects to help readers understand the key steps and technical points of battery pack design.

1. Design goal setting

1.1 energy density

• set the energy density target of 100kWh battery pack, that is, store more electric energy in a limited space and increase the mileage by battery pack.

1.2 Security

• set battery pack safety indicators to ensure that no safety problems such as thermal runaway or explosion occur battery pack under various working conditions.

1.3 cycle life

• set a cycle life target of battery pack, that is, it can still maintain stable performance and prolong the service life of battery pack after several charge and discharge cycles.

2. Selection considerations

2.1 battery type

• according to the design goal, select the appropriate battery type, such as lithium ion battery, sodium sulfur battery, etc., and consider its energy density, cycle life, safety and other parameters.

2.2 battery monomer

• select the appropriate battery specifications and voltage to match the total capacity and voltage requirements of battery pack.

2.3 battery management system (BMS)

• select a BMS system suitable for 100kWh battery pack to ensure the charge and discharge balance and temperature control of each monomer of the battery pack.

3. Structural design

3.1 Layout design

• design the layout structure of battery pack, including the arrangement of battery cells, heat dissipation structure, cable wiring, etc.

3.2 shell design

the shell structure of battery pack is designed to ensure the safe fixation of battery components and the isolation of the external environment.

3.3 cooling system

• design battery pack cooling system, including fan cooling, liquid cooling system, etc., to ensure that the battery keeps the appropriate temperature when working.

4. Thermal Management

4.1 Temperature Monitoring

• design a temperature sensor layout scheme to monitor the internal temperature changes of battery pack in real time to ensure that the battery works within a safe temperature range.

4.2 heat dissipation design

• design heat dissipation structure and cooling system to effectively dissipate heat and prevent battery overheating from causing performance degradation or safety problems.

5. Test verification

5.1 charge and discharge test

• battery pack the charging and discharging performance test of the system verifies that its energy density and cycle life reach the design goal.

5.2 security testing

• conduct security tests to simulate battery pack performance under various abnormal conditions to ensure that its security meets the requirements.

Through the analysis and implementation of the design process, the design of 100kWh battery pack can meet the preset design goals such as energy density, safety and cycle life, providing reliable power sources for electric vehicles and energy storage systems. I hope the content of this article can help readers to have a deeper understanding of the key steps and technical points of battery pack design, and provide reference for practitioners in related fields.