The use of battery systems in electric drive systems plays a crucial role in environmental protection. However, the disassembly, reuse, and recycling of these battery systems currently pose significant challenges. Typically, the battery cells are welded together, making the non-destructive replacement of individual cells within the pack difficult or even impossible. Although there is existing knowledge about the properties of detachable electrical contacts, there are currently no approaches that enable such detachable connections while considering the specific challenges of battery packs with multiple cells and their design. In particular, the disassembly of the pack is problematic concerning a design that aligns with circular economy principles. The greatest challenge in realizing a detachable cell connection is to ensure a low and uniform contact resistance across the pack while simultaneously guaranteeing the safe and reliable operation of the battery pack. The authors therefore present the design, configuration, construction, and testing of a battery pack with detachable cell connections for a light electric vehicle (LEV). The test vehicle “eVee” from the Innovation Campus Mobility of the Future (ICM) serves as the example vehicle. Initially, the requirements for the battery system are analyzed to subsequently select the cells and design the packaging. Various concepts for integrating functional components, such as the contact system or battery management system, are then compared concerning assembly and manufacturing effort, weight, size, and cost. The challenge lies in optimizing the design for material and cost efficiency while ensuring reliable electrical connections. In the next step, the authors detail the design and construction of the individual functional components and their integration into a complete system. Finally, the battery system is manufactured and assembled using prototyping methods, and the necessary interfaces for integrating the battery pack into the vehicle are analyzed and designed. In the final stage, the battery pack is tested regarding its electrical properties and functionality showing a working battery pack solution with easy to dissemble subsystems and cells and therefore increasing the battery packs potential for circular economy.

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Light Electric Vehicle Battery Pack Design for an Improved Circular Economy Using Detachable Cell Contacting

  • Theo Seiler,
  • Jan Markowetz,
  • Philip Müller-Welt,
  • Katharina Bause

摘要

The use of battery systems in electric drive systems plays a crucial role in environmental protection. However, the disassembly, reuse, and recycling of these battery systems currently pose significant challenges. Typically, the battery cells are welded together, making the non-destructive replacement of individual cells within the pack difficult or even impossible. Although there is existing knowledge about the properties of detachable electrical contacts, there are currently no approaches that enable such detachable connections while considering the specific challenges of battery packs with multiple cells and their design. In particular, the disassembly of the pack is problematic concerning a design that aligns with circular economy principles. The greatest challenge in realizing a detachable cell connection is to ensure a low and uniform contact resistance across the pack while simultaneously guaranteeing the safe and reliable operation of the battery pack. The authors therefore present the design, configuration, construction, and testing of a battery pack with detachable cell connections for a light electric vehicle (LEV). The test vehicle “eVee” from the Innovation Campus Mobility of the Future (ICM) serves as the example vehicle. Initially, the requirements for the battery system are analyzed to subsequently select the cells and design the packaging. Various concepts for integrating functional components, such as the contact system or battery management system, are then compared concerning assembly and manufacturing effort, weight, size, and cost. The challenge lies in optimizing the design for material and cost efficiency while ensuring reliable electrical connections. In the next step, the authors detail the design and construction of the individual functional components and their integration into a complete system. Finally, the battery system is manufactured and assembled using prototyping methods, and the necessary interfaces for integrating the battery pack into the vehicle are analyzed and designed. In the final stage, the battery pack is tested regarding its electrical properties and functionality showing a working battery pack solution with easy to dissemble subsystems and cells and therefore increasing the battery packs potential for circular economy.