This post walks through what pack simulation involves and where it is applied, from electric vehicles to medical devices.
What Does Battery Pack Simulation Cover?
Pack design simulation usually combines several domains:- Electrical simulation: Series-parallel configuration, voltage and capacity targets, current distribution, busbar and interconnect resistance, and cell-to-cell imbalance.
- Thermal simulation: Heat generation in cells and joints, cooling plate or air-flow performance, and temperature gradients across modules.
- Electrochemical (cell-level) modelling: How electrode design, chemistry and operating conditions affect performance and aging.
- Structural and mechanical simulation: Vibration, shock, crush and drop behaviour of the enclosure, module supports and mounting.
- Safety and abuse simulation: Thermal runaway propagation, venting paths and short-circuit scenarios.
- Aging and life prediction: Capacity fade, resistance growth and swelling over thousands of cycles.
- BMS and system-level simulation: Testing state-of-charge estimation, balancing logic and drive-cycle or load-profile behaviour.
Tools range from detailed 3D field simulations to reduced-order models that run fast enough for control development.
2-Wheeler EV battery simulation report:
Battery Pack Design & Simulation Report
IST Li-ion Battery Simulator V-10.0.1 · Module & Pack Engineering
Rev. 00
23-Oct-2026
23-Oct-2026
| Document No. | IST-BDR-IST-ATH450X-LFP-16S2P-R1-20261023 | Revision | 00 — Initial issue | Date | 23-Oct-2026 08:29 |
| Status | Design review | Classification | Confidential | Pages | see footer |
1. Project Details
| Model No. | IST-ATH450X-LFP-16S2P-R1 | Company Name | IST Skill |
|---|---|---|---|
| Contact Person | not specified | Design Engineer | not specified |
2. Application Context
| Application Type | 2-Wheeler EV | Target Duty / Drive Cycle | IDC / MIDC (India), Ather 450X city + highway |
|---|---|---|---|
| Target Vehicle / System Mass | 108 kg kerb + 75 kg rider | Target Range / Runtime | ~53 km IDC / ~40 km real |
2.1 Design targets (Define Application)
| Voltage window (V) | 43.2 – 58.4 | Ambient temperature (°C) | -10 to 50 |
|---|---|---|---|
| Nominal pack voltage (V) | 51.2 | Energy (kWh) | 1.536 |
| Continuous discharge (kW) | 4.6 | Peak power (kW) | 5.1 |
| Peak duration (s) | 10 s (BMS 150 A / 10 s limit) | Continuous charge (kW) | 0.58 |
| Charge time | 0-100% in ~3.3 h | Charging standard | Other / Multiple |
| IP rating | IP67 | Cooling | Passive |
| Heating | None | Cycle life target | 2000 cycles to 80% SOH |
| Calendar life target | 8 years | Allowable DoD | 90% |
| Max cell temperature | 55 | Allowable ΔT | <=5 |
| Envelope | Cell block 280 x 140 x 174 mm (fit Ather 450X battery bay) | Weight budget | 18.5 kg |
| Functional safety | QM (no ASIL) | Cell-to-cell barrier | 2 mm aerogel pad |
Notes: Ather 450X class 48 V LFP pack - FINAL: K2 Energy LFP26650UE (3.7 Ah, 15 A continuous / 30 A pulse, 1C charge), 16S8P = 128 cells, 51.2 V 29.6 Ah 1.52 kWh, 16.7 kg est.; JBD UP16S-series 150 A smart BMS with the project parameter set (115 A continuous / 150 A 10 s discharge, 25 A charge, OVP 3.65 V, UVP 2.70 V, discharge OT 60 C, charge OT 45 C, 4 external NTC); 2 mm aerogel sheets between cells; nickel strip series links 4.8 mm2 per cell (3 A/mm2); passive cooling through the aluminium case; pack < 60 V DC (voltage class A). Cells lie flat, two end-to-end, 7 hex rows across the 280 x 174 mm face (tight fit - confirm in CAD).
3. Pack Configuration
| Topology | 1 module(s) × 16S8P = 16S8P (128 cells) | Cell | K2 Energy Solutions K226650UE01 (LFP26650UE-1) |
|---|---|---|---|
| BMS | JBD UP16S 150A (LFP 16S) configured for K2 26650 16S8P | Chemistry / format | LiFePO4 / Cylindrical |
| Nominal / max / min voltage | 51.2 / 58.4 / 40.0 V | Capacity | 29.6 Ah |
| Energy nominal / usable | 1.516 / 1.364 kWh (90 % DoD) | Pack resistance | 62.70 mΩ |
| Continuous discharge | 115 A / 5.06 kW | Max charge current | 30 A (BMS 25 A) |
| Mass (cells / pack est.) | 10.9 / 16.7 kg | Volume (cells / pack est.) | 4.6 / 11.5 L |
| Specific energy (pack) | 91 Wh/kg | Voltage class | A (<= 60 V DC) |
| Module envelope | 316 × 344.0 × 82.2 mm | Coolant / reference temperature | 25.0 °C |
3.1 2D Single-Line Schematic
Power path from the battery modules through protection and switching to the vehicle / system DC bus, with the BMS sense, control and communication wiring. Generated from the pack configuration, the selected BMS and the HV/LV sizing.
| Ref. | Component | Rating / setting |
|---|---|---|
| BT1–BT1 | Battery modules (1 × 16S8P) | 51.2 V nominal, 58.4 V max, 30 Ah; series busbar ≥ 38.3 mm² |
| F1 | Main pack fuse | 175 A, ≥ 80 V DC, breaking ≥ pack short-circuit current |
| RS1 | Current shunt (inside BMS) | range ≥ ±173 A, feeds SOC / OCP |
| Q1 / Q2 | BMS discharge / charge MOSFET switch (low side) | 115 A discharge, 25 A charge, 150 A peak |
| X1 | Pack power connector | ≥ 115 A, ≥ 80 V DC; cable 35 mm² Cu |
| A1 | Battery management system | JBD UP16S 150A (LFP 16S) configured for K2 26650 16S8P, 115 A / 25 A |
| F2 | BMS / LV supply fuse | 5–10 A, 12 V aux |
3.2 Module Cell Series / Parallel Connection
Cylindrical cells: connection strips on both faces — top and bottom views. Module 1 shown (16S8P); all 1 module(s) identical. Balance taps B0…B16 and NTC positions are marked.
Module cell connection — top view
Module cell connection — bottom view
3.3 Balancing Wires & BMS Connection
| Pin | Signal | Function | Connects to |
|---|---|---|---|
| J1-1 | B0 | Cell 1 − (sense reference) | M1 busbar 0 |
| J1-2 | B1 | Cell 1 + / cell 2 − | M1 busbar 1 |
| J1-3 | B2 | Cell 2 + / cell 3 − | M1 busbar 2 |
| J1-4 | B3 | Cell 3 + / cell 4 − | M1 busbar 3 |
| J1-5 | B4 | Cell 4 + / cell 5 − | M1 busbar 4 |
| J1-6 | B5 | Cell 5 + / cell 6 − | M1 busbar 5 |
| J1-7 | B6 | Cell 6 + / cell 7 − | M1 busbar 6 |
| J1-8 | B7 | Cell 7 + / cell 8 − | M1 busbar 7 |
| J1-9 | B8 | Cell 8 + / cell 9 − | M1 busbar 8 |
| J1-10 | B9 | Cell 9 + / cell 10 − | M1 busbar 9 |
| J1-11 | B10 | Cell 10 + / cell 11 − | M1 busbar 10 |
| J1-12 | B11 | Cell 11 + / cell 12 − | M1 busbar 11 |
| J1-13 | B12 | Cell 12 + / cell 13 − | M1 busbar 12 |
| J1-14 | B13 | Cell 13 + / cell 14 − | M1 busbar 13 |
| J1-15 | B14 | Cell 14 + / cell 15 − | M1 busbar 14 |
| J1-16 | B15 | Cell 15 + / cell 16 − | M1 busbar 15 |
| J1-17 | B16 | Cell 16 + (pack +) | M1 busbar 16 |
| J2-1 | T1 | NTC 1 — module 1 cell surface | |
| J2-2 | T2 | NTC 2 — module 1 busbar | |
| J2-3 | T3 | NTC 3 — MOSFET / power stage | |
| J2-4 | T4 | NTC 4 — ambient | |
| J2-5 | CAN-H | CAN 2.0B high — VCU / cluster / charger | |
| J2-6 | CAN-L | CAN 2.0B low | |
| J2-7 | 12V / WAKE | Aux supply & ignition wake (fused) | |
| J2-8 | GND | Signal ground (chassis) | |
| J2-9 | LOAD-EN | Discharge enable / key input | |
| J2-10 | CHG-DET | Charger detect |
- Single module; with balance channels continuing B16–B16 (module m uses B((m−1)·16)–B(m·16)). Adjacent modules share the boundary node through the inter-module link.
- Cylindrical: series strips alternate between the faces — top: G1–G2, G3–G4 …; bottom: G2–G3, G4–G5 … (M− on the bottom of G1); each strip joins the 8 parallel cells of two adjacent groups. Balance taps B1, B3 … are on the top strips, B0, B2 … on the bottom strips. Spot / laser weld every cell; fuse-link strips recommended for p > 1.
- Balance wires: one per series node (17 total), 0.5 mm², fused or PTC-protected at the busbar end, routed in a separate harness away from power busbars; crimp ring / welded tab at the busbar.
- NTC: 4 sensors (2 per module on cell surface / busbar, plus power stage and ambient where the BMS provides channels).
- Before connecting, check the BMS user guide (connector pin-out, connection sequence, unused-channel handling). Connection order: fit B0 (most negative) first, then B1…B16 in sequence, check each cell voltage at the connector, then plug into the BMS; connect B− power last.
4. Executive Summary
Design status: ACCEPTED FOR PROTOTYPE — all design checks passed; certification tests to follow.
Design checks: 14 pass, 0 warn, 0 fail. Standards checklist: 4 pass, 9 to verify, 0 fail. Simulation stages completed: 8 of 8.
Design checks: 14 pass, 0 warn, 0 fail. Standards checklist: 4 pass, 9 to verify, 0 fail. Simulation stages completed: 8 of 8.
Configuration
16S8P
Nominal energy
1.52 kWh
Nominal voltage
51.2 V
Continuous current
115 A
Consumption
18.3 Wh/km
Est. range (usable)
75 km
Max cell temp. (CHT)
28.2 °C
SOH after 10 y
88.4 %
| Area | Status | Result |
|---|---|---|
| Pack sizing vs targets | PASS | 14 pass / 0 warn / 0 fail |
| Cell ↔ BMS compatibility | PASS | 5 checks |
| Drive cycle | PASS | MIDC Part-1 (urban, 4 x ECE-15): 4.07 km, min 48.4 V, peak 53 A, BMS BALANCING |
| Thermal (CHT, 25 °C coolant) | PASS | max 28.2 °C vs cell limit 60 °C |
| Life (physics-based ageing) | INFO | EOL not reached in 10 years (SOH 88.4 %) |
| HV / LV protection | PASS | fuse 175 A (derated margin 6 A), busbar ≥ 38.3 mm² |
| Mechanical fit (tolerance stack-up) | PASS | margin 1.5 mm |
| Safety & Compliance gates | PASS | 9 of 9 tests passed; release decision PASS, Quality Index 100.0 |
| Standards | VERIFY | 4 pass, 9 require test evidence |
5. Cell Specification & Model
| Cell | K2 Energy LFP26650UE | Manufacturer / model | K2 Energy Solutions K226650UE01 (LFP26650UE-1) |
|---|---|---|---|
| Chemistry (family) | LiFePO4 (LFP) | Nominal capacity / voltage | 3.70 Ah / 3.20 V |
| Voltage window | 2.50 – 3.65 V | OCV at 50 % SOC | 3.295 V |
| DCIR / ACIR (1 kHz) | 28.50 / 19.00 mΩ | Mass / volume | 85 g / 36 cm³ |
| Energy / specific / density | 11.8 Wh / 139.3 Wh/kg / 329.2 Wh/L | Max continuous discharge / charge | 15 / 4 A |
| Temperature limits | charge -20…60 °C, discharge -20…60 °C | Cycle life rating | cycles (Not stated (preliminary datasheet)) |
Estimated (not on the datasheet): dcImpedance_mOhm (not on datasheet; AC value used).
5.1 Equivalent-circuit model (2-RC)
| R0 (ohmic) | 28.500 mΩ |
|---|---|
| V∞ (relaxed) | 3.2942 V |
| RC branch 1 | 13.998 mΩ, 140 F (τ = 1.96 s) |
| RC branch 2 | 5.730 mΩ, 4,842 F (τ = 27.75 s) |
Fitted from the HPPC pulse (SYNTHETIC pulse generated from the cell model — replace with measured HPPC data).
6. Cell ↔ BMS Compatibility
| BMS | JBD UP16S 150A (LFP 16S) configured for K2 26650 16S8P | Series channels | 16 (min 8) |
|---|---|---|---|
| OVP / UVP | 3.65 V/cell trip, 3.38 V release, 2 s (UP family default, app-configurable) / 2.70 V/cell trip, 2.95 V release, 2 s (UP family default, app-configurable) | OCP discharge / peak / charge | 115 / 150 / 25 A |
| Balancing | Passive (precision resistor array), 40 mA | Communication | Bluetooth built in; UART / RS485 / CAN by variant |
| Status | Check |
|---|---|
| PASS | Chemistry: BMS supports LFP cells. |
| PASS | OVP 3.650 V/cell matches the cell max charge 3.650 V. |
| PASS | UVP 2.700 V/cell protects the cell cut-off 2.500 V (conservative). |
| PASS | Series count: 16S is within the BMS range (8-16S). |
| PASS | Over-temperature: BMS discharge OT trip 60 C is within the cell limit 60 C. |
7. Design Verification against Targets
| Status | Requirement / result |
|---|---|
| PASS | Nominal voltage 51.2 V vs target 51.2 V (+0.0 %). |
| PASS | Operating window 43.2-58.4 V vs required 43.2-58.4 V. |
| PASS | Energy 1.516 kWh nominal (1.364 kWh usable) vs target 1.536 kWh. |
| PASS | Continuous power 5.06 kW (limit 115 A set by the BMS) vs target 4.60 kW. |
| PASS | Peak power 5.10 kW needs up to 118 A at 43.2 V; available 150 A. |
| PASS | Charge power 0.58 kW needs 9.9 A; cells/BMS allow 25.0 A. |
| PASS | Estimated pack mass 16.7 kg vs budget 18.5 kg. |
| PASS | Max ambient 50 C + ~10 K pack rise vs cell discharge limit 60 C. |
| PASS | Range: 1.36 kWh usable / 18.3 Wh/km = 75 km vs target 53 km (on MIDC Part-1 (urban, 4 x ECE-15)). |
Pack resistance = cell DCIR x Ns / Np + 10 % for busbars, welds and contactors; pack mass = cell mass / 0.65 and volume = cell volume / 0.4 (typical cylindrical pack ratios); usable energy at 90 % DoD.
8. Simulation Results
8.1 Conjugate heat transfer (module, coolant 25.0 °C)
| Max cell temperature | 28.17 °C (cell 15) | Cells in flow path | 16 |
|---|---|---|---|
| Film coefficient | 327 W/m²K | Re / Nu | 1,000 / 4.36 |
| Pressure drop | 3.612 kPa | Solver | Integration completed successfully. |
8.2 Drive-cycle closed loop (vehicle + pack + BMS)
| Cycle | MIDC Part-1 (urban, 4 x ECE-15) | Standard | India CMVR / AIS-137 (MIDC part 1); UNECE R83 ECE-15 operations |
|---|---|---|---|
| Distance / energy | 4.07 km / 75 Wh | Consumption | 18.3 Wh/km |
| Peak current / min voltage | 53 A / 48.41 V | Final SOC / voltage | 85.0 % / 53.17 V |
| Current limits (dis / chg) | 115 / 25 A | Derating / BMS state | 0.0 % / BALANCING |
8.3 Calendar & cycle ageing (physics-based)
| Model | AGEING-PHYS v1: mixed reaction/diffusion SEI + SEI-on-cracks + stress LAM + partially reversible Li plating; capacity = min(Li inventory, anode capacity) | Calibration | Not stated (preliminary datasheet) |
|---|---|---|---|
| Usage | 1 cycle/day, 42 % DoD (35 km/day), 0.5C/0.5C | Climate | 20 ± 15 °C, +5 K in operation |
| End of life (80 %) | not reached in 10 years | After 10 years | SOH 88.4 %, R/R0 1.27 |
| Loss split (LLI / LAM) | 11.6 % / 3.3 % | Lithium plating | none predicted |
EOL sensitivity to ambient: 15 °C: > 25 y, 25 °C: 16.9 y, 35 °C: 11.4 y, 45 °C: 7.8 y.
8.4 Busbar magnetostatic analysis
| Current | 115 A | Busbar section / spacing | 5 × 4 mm @ 25 mm |
|---|---|---|---|
| Max |B| | 7.92 mT | Force per length | 0.017 N/m |
8.5 HV / LV circuit, protection sizing and DFM
| Configuration | 1 x (16S8P) = 16S8P | Design current | 115 A (cell 120, BMS 115 A) |
|---|---|---|---|
| Main fuse | 175 A (derated capacity 121 A, margin 6 A) | Busbar section | ≥ 38.3 mm² (74.1 µΩ per 150 mm) |
| Pre-charge | 3.41 Ω, τ 6.8 ms, full 34.1 ms | Isolation (min) | 25,600 Ω |
| Module envelope | 316 × 344.0 × 82.2 mm, packing 51.6 % | Tolerance stack-up | fits, margin 1.5 mm |
| Joint | Method | Rationale |
|---|---|---|
| cell tab | Resistance (spot) welding | Low per-tab current typical of a single cylindrical-cell nickel-strip interconnect; resistance welding is the standard, low-cost, high-throughput method for this joint. |
| busbar to busbar | Laser welding | Busbar-to-busbar splice at moderate current; laser welding gives a strong, low-resistance, automatable joint for solid copper/aluminum busbar stock in this range. |
| hv terminal | Bolted (mechanical) connection | Main HV terminal connections are conventionally bolted (not welded) so the pack, contactor box, and external cabling remain serviceable and individually replaceable. |
8.6 Thermal-imaging cooling-controller simulation (reference 8-module network)
| Final max / mean / min | 29.9 / 28.7 / 28.6 °C | Final cooling stage | OFF |
|---|---|---|---|
| Stage transitions | 21 | Hot-spot module | MOD_3 |
9. Standards & Compliance Checklist
| Standard | Requirement | Status | Evidence / source |
|---|---|---|---|
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Cells tested to IS 16893 Part 2 and Part 3 at an NABL-accredited lab (Phase 2) | VERIFY | Cell test reports for K2 Energy LFP26650UE |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | REESS tests: vibration, thermal shock & cycling, mechanical shock, mechanical integrity, fire resistance, external short circuit, overcharge, over-discharge, over-temperature, over-current | VERIFY | Use Safety & Compliance screen to record results |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Water immersion: REESS at 100 % SOC to IPX7 (IEC 60529) | PASS | IP target in Define Application: IP67 |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Thermal propagation: single-cell thermal runaway must not cause fire or explosion; audio-visual warning to the rider (Phase 2) | VERIFY | Propagation test + STAR-CCM+ (d) screening |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Microprocessor-based BMS with OV, UV, over-current, short-circuit and over-temperature protection | PASS | Selected BMS: JBD UP16S 150A (LFP 16S) configured for K2 26650 16S8P |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | At least 4 temperature sensors in the pack (Phase 2) | PASS | BMS NTC channels: 4 |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | BMS EMC tested to AIS-004 (Phase 2) | VERIFY | EMC test report |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Pack fuse plus additional safety fuse; protection against overcharge from regenerative braking | VERIFY | Other Parts: main fuse / BMS charge OCP |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Cell-to-cell spacing and pressure-relief / vent on the pack | VERIFY | HV/LV DFM cell gap; GORE vent in Other Parts |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Traceability: pack ID and cell manufacturing date | VERIFY | Label / MES records |
| ARAI AIS-156 (Amd. 3/4) - L category REESS | Charger with earth-leakage detection and charge cut-off logic (Phase 2) | VERIFY | Charger datasheet |
| UN R100 / R136 electrical safety | Voltage class: A (<= 60 V DC) | INFO | Max pack voltage 58.4 V |
| UN R100 / R136 electrical safety | Class A (<= 60 V DC): isolation monitoring, HVIL and MSD not mandatory | PASS | Below 60 V DC |
| UN 38.3 | Transport tests T1-T8 (cell and pack) before shipping | VERIFY | UN 38.3 test summary |
Checklist aid only, not a certification. Requirements summarised from ARAI / MoRTH AIS-156 (with Amendments), AIS-038 Rev 2, IS 16893, UN R100/R136, UN 38.3 and IEC 62619; confirm against the current official texts and a testing agency (ARAI, ICAT, GARC).
Compliance targets selected in Define Application: 0.
9.1 Safety & Compliance Verification
| Track | Test (AIS-156 / BIS) | Status |
|---|---|---|
| A | Capacity & Energy | PASS |
| A | Internal Resistance | PASS |
| A | HV Isolation Resistance | PASS |
| B/C | Overcharge Test | PASS |
| B/C | External Short-Circuit | PASS |
| B/C | Mechanical Drop Test | PASS |
| B/C | Mechanical Shock Test | PASS |
| B/C | Vibration Test | PASS |
| B/C | Protection Response Time | PASS |
| Release decision — Quality Index 100.00 | PASS |
From the Safety & Compliance screen, set up from this design. Test set-up values follow AIS-156 Part II (Annex 8); the measured values and observations entered there are the expected result until they are replaced with the accredited-laboratory test results.
10. Bill of Quantities (BOQ)
For one pack, 16S8P, 1.52 kWh. Quantities follow from the pack configuration and HV/LV sizing; "library" parts are suggestions from the component database by application category and must be checked against the rating column. Unit rates come from the database unitCost field; blank = request for quotation (RFQ).
| Item | Description | Specification | Make / part no. | Qty | UoM | Mass (kg) | Rate / amount |
|---|---|---|---|---|---|---|---|
| A. Cells & module structure | |||||||
| A1 | Li-ion cell | LiFePO4, 3.7 Ah, 3.20 V, Cylindrical, DCIR 28.50 mΩ | K2 Energy Solutions K226650UE01 (LFP26650UE-1) | 128 | EA | 10.88 | RFQ |
| A2 | Cell holder (top / bottom) | FR PC/ABS holder for 128 cells per module, 26.5 mm bore | Keystone Electronics Corp. 1042 (library, check size) | 2 | EA | — | RFQ |
| A3 | Cell insulation ring / fish-paper | Positive-terminal insulator ring | to be selected | 128 | EA | — | RFQ |
| A4 | Thermal-propagation barrier (2 mm aerogel pad) | Silica aerogel blanket 2 mm, k ≈ 0.02 W/m·K, compressible, encapsulated, between adjacent cells (sheets between rows) | to be selected | 15 | sheet | — | RFQ |
| A5 | Cell busbar (intra-module series link) | Cu (tin-plated) series link joining 8P groups, ≥ 38.3 mm² (3 A/mm² at 115 A), Resistance (spot) welding | ARB Accessories Pvt Ltd (Greater Noida) 8522 (universal-1.5mm) (library) | 15 | EA | — | RFQ |
| A6 | Module terminal busbar (+ / −) | Cu, ≥ 38.3 mm², bolted M8 with disc-spring washer | to be selected | 2 | EA | — | RFQ |
| A7 | Module cell-holder frame / module housing | Module 16S8P, envelope 316 × 344.0 × 82.2 mm | to be selected | 1 | EA | — | RFQ |
| B. HV power circuit | |||||||
| B1 | Main pack fuse | 175 A, ≥ 73 V DC, breaking capacity ≥ pack short-circuit current | Littelfuse 0298175.ZXEH-UL (library, verify rating) | 1 | EA | — | RFQ |
| B2 | Main power cable (+ / −) | 35 mm² Cu, ≥ 73 V DC, 2 runs × 0.6 m (estimate) | to be selected | 1.2 | m | — | RFQ |
| B3 | Pack power connector (output) | Rated ≥ 115 A continuous, ≥ 73 V DC, IP67 | TE Connectivity AMP+ HVA 280 (library) | 1 | pair | — | RFQ |
| C. BMS & electronics | |||||||
| C1 | Battery management system | LFP 16S, OVP 3.65 V / UVP 2.70 V, 115 A discharge / 25 A charge, Passive (precision resistor array) balancing | Shenzhen Jiabaida Electronics Technology (JBD) JBD UP16S-series 16S LFP, 150 A hardware variant - project parameter set ATH450X-16S8P (K2) | 1 | EA | — | RFQ |
| C2 | BMS / LV supply fuse | 5–10 A, automotive blade / inline | Littelfuse 0ATO005.V (library) | 1 | EA | — | RFQ |
| C3 | Communication harness (CAN, wake, 12 V) | Bluetooth built in; UART / RS485 / CAN by variant, twisted pair, sealed connector | TeleWire Technology Co., Ltd Micro-Fit 3.0 2x4 harness (library) | 1 | set | — | RFQ |
| D. Sensing harness | |||||||
| D1 | Cell voltage sense lead | 0.5 mm² (AWG 20), with inline fuse / PTC per lead, ring or welded terminal | to be selected | 17 | EA | — | RFQ |
| D2 | NTC temperature sensor | 10 kΩ B3435, cell-surface / busbar mounted (≥ 4 per AIS-156) | to be selected | 4 | EA | — | RFQ |
| D3 | Sense harness connector | Module-to-BMS, sealed, keyed | to be selected | 1 | EA | — | RFQ |
| E. Thermal management | |||||||
| E1 | Thermal pad (module to enclosure base) | 1–2 mm, ≥ 2 W/m·K, UL94 V-0 (passive cooling) | to be selected | 1 | EA | — | RFQ |
| F. Enclosure & mechanical | |||||||
| F1 | Battery enclosure / tray | Al or powder-coated steel, IP67, fits 1 module(s) + BMS / switchgear, est. internal volume 11.5 L | Old Skool Co. (Pune) Aluminium battery pack enclosure IP67 (50 Ah) (library, verify size) | 1 | EA | — | RFQ |
| F2 | Enclosure cover | Matching tray, with fire-resistant liner (mica / composite) | SABIC PPc H1030, STAMAX 30YH570, VALOX 420SE0, LEXAN 3412ECR, CYCOLOY C6600 (library) | 1 | EA | — | RFQ |
| F3 | Cover gasket | EPDM / silicone foam, sized to cover flange, IP67 | to be selected | 1 | EA | — | RFQ |
| F4 | Pressure-equalisation / burst vent | ePTFE membrane, IP67, thermal-event burst function | W. L. Gore & Associates AVS 200 (AMF300200) (library) | 1 | EA | — | RFQ |
| F5 | Insulation barrier sheet | Mica / PC, module-to-enclosure and HV-to-chassis | to be selected | 2 | EA | — | RFQ |
| F6 | Mounting bracket | Pack to vehicle / rack | to be selected | 4 | EA | — | RFQ |
| F7 | Fastener kit | Busbar bolts M6/M8 with disc-spring washers (34 joints), module and cover screws, torque-marked | to be selected | 1 | lot | — | RFQ |
| G. Labelling & packaging | |||||||
| G1 | Labels and nameplate | Rating plate (V, Ah, kWh, chemistry), HV warning, AIS-156 / AIS-038 marking, QR traceability, recycling mark | to be selected | 1 | set | — | RFQ |
| G2 | Transport packaging | UN3480 Class 9, UN 38.3 test summary, SoC ≤ 30 % for shipping | to be selected | 1 | set | — | RFQ |
| Total: 26 line items, 128 cells | 10.9 | RFQ | |||||
Mass column covers items with a known mass (1 of 26); estimated complete pack mass from the pack model: 16.7 kg. Pack is voltage class A (≤ 60 V DC): switching, pre-charge and current sensing are assumed inside the BMS (MOSFET switching); contactors, MSD and IMD are not required.
11. Assumptions, Limitations & Open Actions
| # | Item |
|---|---|
| 1 | Results are engineering design aids from reduced-order models (ECM, 1-D/lumped thermal, physics-based ageing, closed-loop drive cycle). They do not replace certification testing (AIS-156 / AIS-038, IS 16893, UN 38.3, IEC 62619 as applicable). |
| 2 | HPPC / EIS / identification inputs were SYNTHETIC (generated from the cell datasheet). Replace with measured cell data (HPPC at 3 temperatures, EIS) before design freeze. |
| 3 | Pack resistance includes +10 % for busbars, welds and contactors; usable energy uses the DoD stated in section 3. |
| 4 | Thermal-imaging stage uses the reference 8-module network for the cooling-controller logic; use Thermal Analysis (e) 3-D cooling for the actual module layout. |
| 5 | BOQ library suggestions are matched by application category only; confirm ratings (current, voltage, IP, temperature) with the supplier datasheet and obtain quotations. |
| 6 | Open actions: supplier cell drawing and test reports; BMS calibration file and CAN database; enclosure drawing with IP and mechanical tests; safety (propagation, short-circuit, overcharge) tests at an accredited laboratory. |
12. Review & Approval
| Role | Name | Signature | Date |
|---|---|---|---|
| Prepared by (Design Engineer) | |||
| Reviewed by | |||
| Approved by |
Revision history
| Rev. | Date | Description | Author |
|---|---|---|---|
| 00 | 23-Oct-2026 | Initial issue — generated by IST Li-ion Battery Simulator V-10.0.1 |
IST-BDR-IST-ATH450X-LFP-16S2P-R1-20261023 · Generated 23-Oct-2026 08:29 · IST Li-ion Battery Simulator V-10.0.1, Copyright © IST Sunpower System 2026 · Confidential: not for distribution without approval.
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