Design and manufacturing of battery pack for Formula Student car

Cilj ovog rada je istražiti tržište ćelija, sustavno ih usporediti i odabrati pravu ćeliju za primjenu u bolidu FSB Racing Teama - FSBRT06e. Pritom je bilo potrebno simulirati vožnju bolida po stazi korištenjem softvera za dinamiku vozila kako bismo dobili iznos potrebne energije za završetak trke i profil snage za testiranje ćelija. Nakon sužavanja odabira ćelija, preostale dvije ćelije su se intenzivno testirale kako bi se potvrdio odabir. Nakon što je izabrana ćelija, krenulo se u proračun hlađenja korištenjem ciklusa snage dobivenog iz simulacije. Razmatrane su dvije opcije: zračno hlađenje te hlađenje nevodljivom polimernom tekućinom. Za opciju zračnog hlađenja napravljena je CFD simulacija koja je bila potrebna za odabir odgovarajućeg ventilatora. Za hlađenje polimernom tekućinom evaluirane su karakteristike dostupnih tekućina, te je odabrana najbolja opcija. Također, modelirani su različiti koncepti baterijskog paketa, te je odabran najpovoljniji koji je dodatno razrađen. Modelirani su i validirani mehanički nosači, odabrani su pripadajući konektori, te je modelirano kućište. Istovremeno je izrađen testni baterijski segment čija je svrha dodatna provjera i testiranje prije izrade konačnog baterijskog paketa.The aim of this paper is to explore the battery cell market, systematically compare them and select the right cell for use in the FSB Racing Team - FSBRT06e. It was necessary to simulate the car driving on a race track using the vehicle dynamics software to determine the amount of energy required to complete the race and the power profile for the cell testing. After narrowing the cell choice, the remaining two cells were intensively tested to confirm the selection. After the cell was selected, the cooling calculation began with the use of the power cycle obtained from the simulation. Two options have been considered: air cooling and liquid cooling. For the air cooling option CFD simulation is made to select the appropriate fan. Liquid liquid characteristics were estimated for the polymer liquid coolant and the best option was selected. Different concepts of battery packs have also been modeled, and the best choice was selected, and further developed. Formers which hold the cells were modeled, the connectors were selected and the casing for the whole battery pack was modeled. At the same time, a test battery segment was manufactured for the purpose of additional testing before the final battery was manufactured