Assignment 5.

1
End plate & side strip calculation

For the below battery pack, End plates and Side strips are required to be designed. Material selected
for this purpose is Aluminum 6061 T6.

Aluminum 6061 T6 Young’s Modulus - 68900 Mpa Yield strength - 290Mpa

(a) Estimating that the pressure applied on End plates is

14Psi and boundary conditions are as defined. Calculate
the thickness of End plate (in mm). Consider maximum
deflection at center of top edge. (Take 1Psi = 0.00689476
N/mm2)

(b) For same pressure, evaluate the cross-sectional area of

side strips & find the thickness (in mm), to restrain the
expansion. Consider maximum allowable deflection to be
1mm & side strip breadth is 14mm.

Analytical Formula and boundary conditions

Rectangular plate.
Boundary condition: Three edges fixed; one edge free
Answer (a):

1. Force calculation on end plate:

Force applied on end plates = Reaction force applied on side strip

Pressure applied on end plate = 14 Psi = 0.09652664 N/mm2

Area of end plate = 124.8mm * 132.8mm = 16573.44 mm2

Force on end plate = 1599.77N

Material Aluminum 6061 T6
2. Material Selection:

ABS has been marked best for base plate but for end Young’s Modulus 68900 Mpa
plates higher strength is required.

Also, there is no need for the material to be insulator. Poisson’s Ration 0.3
Thus, aluminum is chosen here to provide higher rigidity
as compared to ABS. Yield strength 290Mpa

3. Result on Calculation using analytical formula:

𝑎 132.8
= = 1.06 ~ 1 Thickness Max bending stress
𝑏 124.8
(Mpa)
From table:
1 389.38
𝛽1 = 0.321 𝛽2 = 0.259 𝛽3 = 0.511 1.2 270.4
1.4 198.66
𝛾1 = 0.457 𝛾2 = 0.510
1.6 152.1
Max. allowable deflection occurs at x = 0 & z = b.
Calculating stress using σa at x = 0 & z = b,

Thickness of end plate comes out to be 1.2 mm which gives a maximum tensile stress of 270.4MPa.
Answer (b):

Force on Side strips = Force on End plates

𝐅𝐨𝐫𝐜𝐞 𝐨𝐧 𝐄𝐧𝐝 𝐩𝐥𝐚𝐭𝐞
= 1599.77𝑁
𝐒𝐢𝐝𝐞 𝐬𝐭𝐫𝐢𝐩
𝑪. 𝑺 𝑨𝒓𝒆𝒂 = 𝑏 ∗ 𝑡
Calculation - Longitudinal Deformation

Using general formula for Longitudinal strain.

F∗L 1599.77∗272 6.54
∆𝐿 = A ∗ E ∆𝐿 = 𝑏∗𝑡∗68900
∆𝐿 = 𝑏∗𝑡 2
Breadth Thickness Area (mm )
Assuming maximum allowable deflection to be 1 mm,
10 mm 0.7 mm 7
𝑏 ∗ 𝑡 = 6.31𝑚𝑚2 ~ 7𝑚𝑚2
11 mm 0.63 mm 7
A single strip of dimension 14mm X 0.5mm can be used.
Multiple strips (X3) of same dimension can be used to provide 14mm 0.5 mm 7
proper stability.

Stress Calculation
𝐹
σ=
𝐴
1599.29 1599.29
σ= = = 228.47Mpa
b∗t 7

I.e. Below allowable Tensile Strength

Valid Answer:

(a) End plate thickness: 1.1mm to 1.4mm

(b) Side strip thickness: 0.35mm to 0.6mm

Assignment 5.2
Free vibration

An electric vehicle battery weighing 90 kg is

supported on four springs with linear characteristics.
Each of the front two springs have stiffness 15kN/m
and stiffness of each rear spring is 30 kN/m. Find the
natural frequency of the battery.

(a) 2 Hz
(b) 4 Hz
(c) 5 Hz
(d) 16Hz

Answer:

K1 and K2 -> Front spring

K3 and K4 -> Rear spring

All the springs are arranged in parallel connections

Thus, K = K1 +K2 + K3 + K4

K = 15 +15 + 30 + 30 = 90 kN/m

𝑘 90 ∗ 1000 𝑟𝑎𝑑
𝜔𝑛 = √ = √ = 31.6
𝑚 90 𝑠

31.6
𝑓= = 𝟓𝑯𝒛
2𝜋

Valid Answer: (c) 5Hz

 Assignment 5.3
Forced vibration
A Low voltage battery pack is designed for the application in
Electric Bike. Mass and stiffness of the battery pack is 10 kg and
49 kN/m respectively. Battery is considered to be a spring mass
system with single degree of freedom subjected to sinusoidal
acceleration of 3g along the vertical axis of the system. Find the
amplitude of acceleration at the end of 33 seconds.

(a) 23.58m/s2
(b) -14.72m/s2
(c) -23.58m/s2
(d) 25.48m/s2

Answer:

Given,

m = 10Kg

k = 49000N/m

Ao = 3g = 3*9.81 m/s2

t = 33s

𝑘 49000
Thus, 𝜔𝑛 = √ =√ = 70 rad/sec
𝑚 10

A(t) = Ao Sin 𝜔𝑛 t

A(t) = 29.43 * Sin (70*33)

A(t) = -23.58 m/s2

Valid Answer: (c) -23.58m/s2

Assignment 5.4:
MOSFET thermal management

A MOSFET + Heat Sink arrangement with below Specifications is arranged as shown. Find the
MOSFET Junction Temperature (in °C) using Thermal Network Approach

Answer:

Hence, the MOSFET junction temperature is 61.4°C.

This can be automated in Excel for DOE & parameters in Green can be varied to make initial
estimations of what Thermal Management method will be sufficient.

Valid Answer: 60°C to 63°C

Assignment 5.5:
Battery pack thermal management

Consider the 2P16S Pack with shown dimensions. The pack

is present at 45°C. Consider 2C discharge & identify suitable
thermal management method to limit the cell temperatures
to 50°C. Assume that Heat is extracted only using the
bottom surface of the pack.

(a) Natural Air Cooling

(b) Forced Air Cooling
(c) Forced Water Cooling
(d) PCM based cooling

Cell Specifications:

Voltage: 3.65V
Capacity: 15Ah
Internal Resistance: 10mΩ
Answer:

Comparing the HTC value to the plot shown, we

conclude (c) Forced Water Cooling is preferred.

Valid Answer: (c) Forced Water Cooling