Mechanical Design Essentials for EV Battery Safety and Performance
The course Electric Vehicle Battery Pack – Mechanical Design is a comprehensive exploration of the structural and mechanical engineering principles essential to designing robust, safe, and efficient battery packs for electric vehicles (EVs). It begins with an overview of EV battery fundamentals, outlining what a battery pack needs to function effectively in real-world automotive conditions. Learners are guided through the full battery pack development process, with specific emphasis on the often-underappreciated role of mechanical design in concert with electrical and thermal considerations. The course breaks down the stages of battery pack design, covering core components such as the base plate, end plate, cell connections, and support structures. Students gain insight into the importance of stress-strain theory, vibration analysis, and mechanical forces acting on the pack during vehicle operation.
What you’ll learn
- Understand the fundamentals of EV battery systems and their structural design needs..
- Learn the complete battery pack development process, from concept to mechanical integration..
- Identify and analyze the essential components of a battery pack (cells, base plates, end plates, connectors)..
- Gain insight into the interaction between electrical, thermal, and mechanical design requirements..
- Apply stress-strain theory to evaluate mechanical loads and deformation in battery structures..
- Calculate base plate and end plate dimensions and support structures using engineering formulas..
- Select appropriate materials using the Ashby methodology based on performance and cost factors..
- Perform vibration analysis including free, forced, and modal analysis for MDOF systems..
- Analyze structural response under dynamic loads and excited frequency conditions..
- Apply mechanical design theory in a real-world case study involving a 60V battery pack..
Course Content
- Introduction –> 7 lectures • 30min.
- Mechanical Design –> 19 lectures • 53min.
Requirements
The course Electric Vehicle Battery Pack – Mechanical Design is a comprehensive exploration of the structural and mechanical engineering principles essential to designing robust, safe, and efficient battery packs for electric vehicles (EVs). It begins with an overview of EV battery fundamentals, outlining what a battery pack needs to function effectively in real-world automotive conditions. Learners are guided through the full battery pack development process, with specific emphasis on the often-underappreciated role of mechanical design in concert with electrical and thermal considerations. The course breaks down the stages of battery pack design, covering core components such as the base plate, end plate, cell connections, and support structures. Students gain insight into the importance of stress-strain theory, vibration analysis, and mechanical forces acting on the pack during vehicle operation.
Through practical lectures like “Material Selection Criteria using Ashby Methodology” and “Base Plate Dimension and Support Calculations,” learners develop the analytical and modeling skills needed to ensure structural stability under static and dynamic loads. The course offers in-depth treatment of vibration behavior, including free and forced vibrations, modal analysis for multi-degree of freedom systems, and the deformation patterns of battery structures under excited frequencies. Real-world applications are reinforced through a detailed case study of a 60V battery pack, where learners apply theoretical knowledge to analyze mode frequencies and structural deformation. The course equips engineers and designers with the skills to evaluate, model, and build safe and durable battery enclosures, focusing on reliability, manufacturability, and compliance with automotive standards. Whether you’re a mechanical engineer, EV system designer, or battery integration specialist, this course offers a specialized path to mastering the mechanical design challenges of modern electric vehicle battery packs.