Analysis of a Battery Pack Module for a Formula Student Car

Year : 2025 | Volume : 13 | Special Issue 05 | Page : 320 339
    By

    Advait Jadhav,

  • Shubh Dodia,

  • Ved Chavan,

  • Hari Vasudevan,

  • Vinayak H. Khatawate,

  1. UG student, Department of Mechanical Engineering, SVKM’s Dwarkadas J. Sanghvi College of Engineering, Vile Parle, Mumbai, Maharashtra, India
  2. UG student, Department of Mechanical Engineering, SVKM’s Dwarkadas J. Sanghvi College of Engineering, Vile Parle, Mumbai, Maharashtra, India
  3. UG student, Department of Mechanical Engineering, SVKM’s Dwarkadas J. Sanghvi College of Engineering, Vile Parle, Mumbai, Maharashtra, India
  4. Professor, Department of Mechanical Engineering, SVKM’s Dwarkadas J. Sanghvi College of Engineering, Vile Parle, Mumbai, Maharashtra, India
  5. Associate Professor, Department of Mechanical Engineering, SVKM’s Dwarkadas J. Sanghvi College of Engineering, Vile Parle, Mumbai, Maharashtra, India

Abstract

This research aims to evaluate the development of a high-voltage accumulator system that meets established standards of safety and operation. It examines key components, protocols, and techniques used in its creation while assessing performance in electronic cooling and structural integrity. Polymers, serving as electrical insulators and flame retarders, have found an interesting application in EV battery packs. This study focuses on polycarbonate materials’ ability to withstand thermal and structural loads for safe battery operation and aims to exploit polycarbonate’s high strength to weight ratio to function as cell holders. This test of modular assembly using polymers as an intermediate structural member helps to identify their potential applications in dynamical systems. The system includes the use of polycarbonate sheets for constructing the 64-cell battery pack module as part of an 8-segment setup, featuring 512 Molicel P42A Li-Ion cells with a capacity of 16.8Ah and a peak voltage of 537.6V. As there is a considerable loss of power to heat due to the high-voltage configuration, this study also explores forced air convection as a method for battery pack cooling, assessing its performance under normal operating conditions. The work guides battery pack design and cooling system optimization using Finite Element Methods, aligning with Formula Student 2023 regulations before vehicle integration.

Keywords: Electric vehicle, battery pack, thermal analysis, structural analysis, CFD, cooling, accumulator, finite element analysis

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

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How to cite this article:
Advait Jadhav, Shubh Dodia, Ved Chavan, Hari Vasudevan, Vinayak H. Khatawate. Analysis of a Battery Pack Module for a Formula Student Car. Journal of Polymer and Composites. 2025; 13(05):320-339.
How to cite this URL:
Advait Jadhav, Shubh Dodia, Ved Chavan, Hari Vasudevan, Vinayak H. Khatawate. Analysis of a Battery Pack Module for a Formula Student Car. Journal of Polymer and Composites. 2025; 13(05):320-339. Available from: https://journals.stmjournals.com/jopc/article=2025/view=225034


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Special Issue Subscription Original Research
Volume 13
Special Issue 05
Received 16/01/2025
Accepted 08/04/2025
Published 22/07/2025
Publication Time 187 Days
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