Design solutions start with defining the overall system architecture of the battery module and pack. This includes determining the arrangement and configuration of individual battery cells, interconnections, thermal management system, electrical components, and safety features. The Acculon design team considers factors such as energy capacity, voltage, form factor, and the specific application requirements provided by our clients.
The electrical design incorporates all the electrical characteristics, features and parameters of the battery pack. This includes selecting appropriate battery management systems (BMS), protection circuits, voltage regulation, current sensing, and balancing mechanisms. The Acculon design team ensures that the electrical design meets our client’s requirements for voltage range, power output, and efficiency.
The mechanical design focuses on the physical aspects and packaging of the battery module and pack. The design team considers factors such as size, weight, form factor, mounting options, and mechanical compatibility with the client’s application. Acculon utilizes computer-aided design (CAD) software to create 3D models and optimize the layout to maximize space utilization, ease of assembly, and thermal management.
A well-designed energy storage solution can enhance user adoption, maximize efficiency and safety, minimize environmental impact, and pave the way for widespread electrification, ultimately driving the transition to clean and renewable energy sources.
By harnessing the diverse expertise of Acculon’s engineers and technicians, our innovative approach to design fosters cutting-edge solutions.
Thermal design is critical for lithium battery packs to ensure optimal performance and safety. The design team incorporates thermal management strategies such as heat sinks, thermal interface materials, cooling channels, and temperature sensors to regulate and dissipate heat generated during battery operation. Maintaining the battery pack within the appropriate temperature range prevents degradation and even thermal runaway.
Designing a safe battery pack is of paramount importance. The design team incorporates safety features such as overcurrent protection, overvoltage protection, short circuit protection, and cell-level monitoring to mitigate potential risks and ensure safe operation. Compliance with relevant safety standards and regulations is a crucial aspect of the design process. Standards, such as UL 2580, UN 38.3, IEC 62133, IEC 62485, UL 1642, ISO 12405, ISO 15194 (and more), and compliance with those standards may vary depending on the specific application, region, and regulatory requirements.
The design team utilizes advanced modeling and simulation tools to optimize the battery pack design. Acculon analyzes various factors such as energy efficiency, power output, cycle life, and thermal performance through simulations. This iterative process helps refine the design to meet the desired performance criteria and application-specific requirements.
Throughout the design phase, the design team creates comprehensive documentation that includes design specifications, schematics, wiring diagrams, component lists, and assembly instructions. Acculon performs design validation activities such as prototyping, testing, and analysis to ensure that the designs meet the specified requirements and performance expectations.