18650 Battery Module Design and Simulation

Overview

This project features a 60-cell 18650 battery module designed in SolidWorks. It includes 3D modeling, exploded view, dimensioned drawings, and FEA stress testing to validate the lid and wall under uniform bolt pressure using real-world materials.

Table of Contents

1. CAD Models
2. Engineering Drawings
3. Simulation Results
4. Exploded View & Assembly
5. Materials Used

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CAD Models

SolidWorks .SLDPRT files for:

• 18650 Li-ion Cell (reference geometry for layout)
• Lid (top enclosure with bolt clamping features)
• Base Plate (bottom foundation with alignment holes)
• Side Walls (vertical enclosure pieces)
• Busbar (copper conductor strip)
• Cooling Plate (Aluminum thermal base)
• Terminal Block (external power output)
• Terminal Strip (internal busbar connector)
• Dowel Screw (custom fastener for assembly)

Engineering Drawings

Includes dimensioned and toleranced drawings for each part, using ANSI standard with real manufacturing tolerances (e.g., ±0.1 mm on hole locations, +0.13/0 mm on bolt diameters).

Simulation Results

• Static stress simulation under 5000 N/m² uniform pressure on the lid.
• Max von Mises stress: ~9.7 kPa (well below Aluminum 6061-T6 yield of 55 MPa)
• Displacement plot confirms minimal flex at bolt hole regions.

Exploded View & Assembly

An exploded view animation illustrates the full stack-up from base to lid, with proper part order and bolt hole alignment.

Materials Used

• Lid & Casing: Aluminum 6061-T6
• Busbars: Copper (annealed)
• Battery Shells: Stainless Steel 304