EV Battery Boxes Explained

Summary

In this episode of Electric Classic Cars, sponsored by Mouser Electronics, Richard discusses the intricacies of designing and building battery packs for electric vehicle conversions. He emphasizes the importance of considering space, weight, voltage, and current capacity to optimize performance. The video showcases the process of assembling battery packs, selecting appropriate connectors for safety and quality, and the fabrication of battery boxes. It also highlights the integration of coolant systems and electrical components, providing insights into the complexities within battery boxes.

Takeaways

• 🔋 Designing a battery pack involves balancing space, weight, voltage, and current requirements.
• 🚗 The available space in the vehicle dictates the size and shape of the battery pack that can be accommodated.
• 🏋️‍♂️ The battery pack should not exceed the weight that was removed from the vehicle to maintain handling and legal compliance.
• ⚡ A typical voltage target for most electric conversions is around 400 volts to ensure sufficient power for the motor.
• 🔌 The battery pack must be able to provide the necessary current, which can be up to 1,000 amps for large Tesla Drive Units.
• 🔩 The battery pack needs to be securely mounted within a protective battery box, which also serves as a mounting point for the vehicle.
• 🔌 High-quality connectors from Mouser Electronics are crucial for safety and professionalism in electric vehicle conversions.
• 💧 The battery box must manage both electrical connections and coolant lines to ensure efficient operation and cooling.
• 🔧 Fabrication is key to protecting the batteries and ensuring they are securely mounted within the vehicle.
• 🛠️ The battery box includes safety features like blast vents to release pressure in case of thermal runaway.
• 🔄 Cable management is essential for organizing the connections within the battery box for efficient and safe operation.

Q & A

What is the main focus of the video episode sponsored by Mouser Electronics?

The main focus of the video episode is discussing battery packs, including how to build them and the design considerations necessary for electric vehicle conversions.

What are the four main considerations Richard mentions when designing a battery pack?

The four main considerations are available space, available weight, voltage, and amps. These factors are crucial for ensuring the battery pack fits within the vehicle, does not exceed the weight removed during conversion, provides sufficient voltage to power the motor, and can handle the required current.

Why is available space important when designing a battery pack?

Available space is important to ensure the battery pack fits within the vehicle without compromising handling or legality. It also determines the physical dimensions of the battery pack and how many batteries can be included.

What role does available weight play in battery pack design?

Available weight is crucial to ensure that the battery pack does not exceed the weight that was removed from the car during conversion. This is important for both handling and legal reasons, as the car was designed to carry a specific weight.

Why is voltage a critical factor in battery pack design?

Voltage is critical because it determines the power output of the battery pack. A typical electric motor used in conversions requires around 400 volts, so the battery pack must be designed to achieve this voltage to effectively power the motor.

How does the requirement for amps in a battery pack affect its design?

The requirement for amps affects the design because the battery pack must be able to supply the maximum current that the motor can draw, especially in high-performance applications. This ensures the motor operates at its full potential.

What is the significance of using OEM EV connectors in the battery pack build?

Using OEM EV connectors ensures a professional and OEM-like appearance to the build. It also contributes to the safety and quality of the electric conversion, as these connectors are designed for high-voltage applications.

Why is fabrication an important part of the battery pack building process?

Fabrication is important because it not only protects the batteries but also ensures they are securely mounted within the battery box. It also involves creating a safe enclosure with proper mounting points and ventilation for the battery pack.

What is the purpose of the blast vent mentioned in the script?

The blast vent is a safety feature designed to release pressure in case of a thermal runaway event within the battery. If the battery overheats, the vent will pop, allowing gases to escape and preventing further damage.

How does the coolant system interact with the battery pack within the battery box?

The coolant system interacts with the battery pack by circulating coolant through lines that run into and out of the battery pack. This helps regulate the temperature of the batteries, ensuring they operate efficiently and safely.

What are some of the electrical components found inside a finished battery box?

Inside a finished battery box, you can find components such as contactors, pre-charge contactors, main fuses, auxiliary fuses, charge controllers, and isolation monitoring systems. These components are essential for managing the flow of electricity and ensuring the safe operation of the battery pack.