Case Study A: Wing shape battery

Customer requirements:

  • 8mm max thickness of over 700mm length of a battery pack,

  • Hard case.

  • Power + Balance connectors – from the center line of the case.

The problem:

Wiring problem.  In order to achieve max capacity the cells where designed to fill the all volume of the wing.  In this case, at the battery center line pass 2 high power wires + all the balancing harness + 2 connectors – one for power and one for maintenance + balance.  All in very narrow volume.

Solution:

Fiberglass super slim case.

Designing of 3D printing part that separates the harnesses to 3 levels (all in <7.5mm) and include internal tunnels for wiring.

Power & Balance in minimum volume