ABSTRACT:
The methodical process of developing an E-bike battery pack that complies with UK laws is presented in this dissertation. The process begins with determining the energy requirements depending on the chosen route and the characteristics of the rider. This information then informs the selection and specifications of a suitable battery type. During the design stage, careful CAD modelling is created using CATIA V5 to produce an effective enclosure. A FEA, or finite element analysis, examines how the battery enclosure reacts to different impact situations in order to guarantee strength. At the same time, thermal analysis uses analytical methods to examine heat loss from cells inside the pack. Through compliance, efficiency, as well as technical breakthroughs, this integrated methodology seeks to create an E-bike battery system which not only satisfies regulatory criteria but also outperforms expectations in terms of performance
AIM
This dissertation’s primary aim is to create an E-bike battery pack which will meet the growing need for economical and ecologically responsible modes of transportation. Complying with UK E-bike laws, the battery pack is intended for E-bikes with a maximum motor power output of 250W, a maximum aided speed of 15.5 mph, as well as pedal-assisted motor control capability. The objectives include complex spreadsheet calculations and sophisticated CAD modelling with a focus towards the battery pack’s mechanical and thermal design. Furthermore, the study explores bicycle dynamics to accurately determine motor power and torque under many riding circumstances, and Simulink models are going to be employed to represent the pack of batteries and motor’s performance. The ultimate goal is to provide a high-performing, compatible battery system that supports sustainable transportation initiatives.
OBJECTIVES
1. Develop a compliant E-bike battery pack, adhering to UK regulations.
2. Calculate the Energy requirements of battery pack based on route choice and cyclist profile.
3. Size the battery pack and select type of battery
4. Perform design process for the battery pack enclosure
5. Employ CATIA V5 to generate CAD model of the battery-pack enclosure
6. Conduct an FEA study on the battery housing under different impact events. 7. Analyse the thermal load experienced by the battery pack and calculate, through analytical means, the expected heat dissipation from the cell within the pack.
Fig: Battery support case.
Figure : FEM model of battery pack
Fig: Temperature distribution for SS304.
Fig: Thermal deformation for SS304.
Fig: impact on side of battery pack.
Fig: case 2 crash test deformation.
Fig: case 3 crash test Stress.