Designing Future Smart Battery Enclosures

Sammanfattning

The aim of this project was to explore battery enclosures, specifically for e-scooter batteries, and whether additive manufacturing can be used to enhance existing designs. Furthermore, FEM and topology optimization were explored as tools for optimizing these designs. A modified Double Diamond approach was used as a guideline for the project. The modified version enters a prolonged optimization phase after the ”discover”, ”define” and ”develop” steps. The optimization phase consisted of exploration, testing and iteration. Developed concepts were subjected to FE analysis based on UN regulations and IEC standards. Topology optimization was utilized for establishing design principles, which were applied in the iterative ”Master” and ”Maestro” series. In the end, the ”Master 13.7” model was infused with various lattice structures. These latticed models were tested and compared using comparative values. Models for demonstration were ultimately printed using SLS and FDM. Throughout the project, the only model that narrowly passed all tests was ”Master 13.7”. All ”Maestro” models performed significantly worse. In addition, none of the latticed versions outperformed the original ”Master 13.7”. Nevertheless, the comparative values indicated that the gyroid lattice showed the most promise. The study concludes that an AM battery enclosure can be designed to pass relevant tests and standards. However, real-life tests are needed in order to determine the validity of these results. Moreover, a business perspective is required in order to evaluate the viability of such a product. The proposed method of incorporating topology optimization was judged as having questionable usefulness. FEM was, on the other hand, deemed essential to the process.