Energies 14 01939 v2
Energies 14 01939 v2
Energies 14 01939 v2
Article
Adopting a Conversion Design Approach to Maximize the
Energy Density of Battery Packs in Electric Vehicles
Erika Pierri 1, *,† , Valentina Cirillo 2 , Thomas Vietor 1 and Marco Sorrentino 2
Abstract: Innovative vehicle concepts have been developed in the past years in the automotive
sector, including alternative drive systems such as hybrid and battery electric vehicles, so as to
meet the environmental targets and cope with the increasingly stringent emissions regulations.
The preferred hybridizing technology is lithium-ion battery, thanks to its high energy density. The
optimal integration of battery packs in the vehicle is a challenging task when designing e-mobility
concepts. Therefore, this work proposes a conceptual design procedure aimed at optimizing the
sizing of hybrid and battery electric vehicles. Particularly, the influence of the cell type, physical
disposition and arrangement of the electrical devices is accounted for within a conversion design
framework. The optimization is focused on the trade-off between the battery pack capacity and
weight. After introducing the main features of electric traction systems and their challenges compared
to conventional ones, the relevant design properties of electric vehicles are analyzed. A detailed
Citation: Pierri, E.; Cirillo, V.;
Vietor, T.; Sorrentino, M. Adopting a
strategy, encompassing the selection of battery format and technology, battery pack design and
Conversion Design Approach to final assessment of the proposed set-up, is presented and implemented in an exemplary application,
Maximize the Energy Density of assuming an existing commercial vehicle as the reference starting layout. Prismatic, cylindrical
Battery Packs in Electric Vehicles. and pouch cells are configured aiming at achieving installed battery energy as close as possible
Energies 2021, 14, 1939. https:// to the reference one, while meeting the original installation space constraint. The best resulting
doi.org/10.3390/en14071939 configuration, which also guarantees similar peak power performance of the reference battery-pack,
allows reducing the mass of the storage system down to 70% of its starting value.
Academic Editor: Branislav Hredzak
Keywords: electric mobility; battery electric vehicles; lithium-ion batteries; engineering conceptual
Received: 22 February 2021
design; conversion design
Accepted: 29 March 2021
Published: 31 March 2021
vehicles (BEV), have already been successfully introduced to the market or are currently
receiving increasing attention, as is fuel cell vehicle technology [2]. In light of the increasing
worldwide acceptance of electricity-powered vehicles, car manufacturers are intending to
embark on the market for electric vehicles [3].
However, electric vehicles currently present higher prices than conventional vehicles
and are not considered a mature technology yet. The most common trend is to underesti-
mate EV performances and ranges [4] and overestimate the overall recharging cost, which
could indeed benefit from adequate planning measures [5]. To overcome this widespread
lack of knowledge, society’s perception shall be changed and EV performances and prices
must become competitive compared to existing options. Hence, it is fundamental to pro-
mote these new technologies by providing more incentives to the best alternatives for
electric transport [6].
Governments are boosting investments in research and development, particularly in
the domain of traction batteries. Improvements in battery technology are indeed needed,
concerning, for instance, their durability and efficiency in terms of energy density, safety
issues, appropriate recycling and disposal practices, as well as design strategies for an
effective vehicle integration. The technological development of storage systems in the
electronics sector is necessary, so as to introduce vehicles in the automotive market that
allow wider ranges, able to cover the individual daily average distance, provide better
performance than traditional vehicles and, in parallel, considerably reduce the pollutant
emissions [7,8]. The improvement of those crucial technical parameters, together with the
promotion of renewable energy sources, could yield in the near future the long-awaited
green revolution of the automotive sector [9].
Research work in the field of batteries for EV applications has mostly focused on the
cell electrode materials, battery modelling methods to assess the battery state, health and
safety and on integration of the charging infrastructure for EVs [10]. In BEVs and HEVs
the integration of the battery pack is crucial in terms of vehicle dynamics and stability, as
the battery pack is one of the heaviest components. The battery cell type and geometry
as well as the disposition of the cells within the battery module can determine the total
number of cells, their capacity and hence the overall range of the vehicle [11]. An optimal
disposition of the battery cells according to the given restrictions is crucial to increase the
energy density of the battery pack.
In the current research work, BEV and HEV configurations are examined and the
optimal integration of energy storage systems is evaluated through a design methodology.
This research work thus aims at the development of a conversion design procedure to
optimize the integration of battery packs in commercial vehicles. The main purpose is to
maximize the energy and power density of the selected battery, taking into account technical
and geometrical constraints, by means of advanced conceptual design methodologies.
The latter were indeed already proven effective both for electric vehicle light-weighting
purposes [12], as well as to enhance the spreading of electrified aviation services [13].
Battery electric vehicles run fully electric and the combustion engine is replaced by
a battery system with rechargeable batteries [17]. The energy storage system, i.e., the
battery pack, is the most expensive and also the most crucial component, as the battery
capacity determines the range of the vehicle. The main drawback of BEVs is currently the
relatively limited range compared to conventional vehicles, due to technical and design
constraints [11].
Hybrid electric vehicles combine the benefits of fuel-based engines and electric motors
and can be configured in different ways [16,18]. In all hybrid electric vehicles, the internal
combustion engine provides most of the required power, while the electric motor is pow-
ered by a storage system and is used as secondary source of power. HEV configurations
are more complex than those of BEVs, as they include more components. HEVs are usually
classified into series and parallel configurations.
Table 1. Battery requirements matrix for electric vehicle chassis integration [9,29–37].
Another important parameter of a battery is the energy density, mostly used to com-
pare battery systems. It can be related either to the weight of the battery (gravimetric energy
density or specific energy), or to the volume (volumetric energy density in Wh/dm3 —or
Wh/litre). The higher the density, the lower the weight, when comparing batteries with
similar capacities [39,40].
The power density of a battery is defined as the maximum available power per unit
volume, in W/dm3 or W/liter while, if compared to the unit mass, it is called specific
power and is expressed in W/kg. The power density and specific power are a characteristic
of the battery type and packaging and are crucial in the dimensioning process. However,
a high energy density does not necessarily mean a high power density. A high power
density involves as an output of the system large amounts of energy based on its volume,
thus ensuring high driving performance. On the other hand, if a system has a high energy
density, it is able to store more energy in a small amount of volume and increases the
storage capacity in the system with the same mass.
Another relevant battery parameter is the so-called C-rate, the discharge rate of the
battery, influenced by charging and discharging current.
Batteries are also characterized by the state of charge (SOC), the amount of stored
residual energy, normalized with its total capacity.
The depth of discharge (DOD), is the amount of the battery capacity that has been
discharged. Specifically, it is the amount of capacity in the battery that is usable by the
system for powering the vehicle.
For automotive applications, batteries are connected into modules and packs. In those
conditions, charge–discharge cycles may cause degradation of the battery module or pack,
due to charge imbalances and different thermal characteristics. In order to reduce the
impact of those external factors on the battery life-time, battery equalizers (e.g., cell-to-cell
equalizers) can be integrated [41].
The battery efficiency (also called columbic efficiency) is the ratio of the number
of charges that enter the battery during charging, compared to the number that can be
extracted from the battery during discharging. In general, it can be defined as the ratio of
the total storage system input to the total storage system output. The losses that reduce
columbic efficiency are primarily due to the loss in charge due to secondary reactions such
as the electrolysis of water or other redox reactions in the battery.
Battery weight influences the travel range, which is, in turn, directly affected by the
capacity of batteries [47]. Higher battery capacities do not result in a proportional increase
in the range, because higher capacities result in higher inertial masses, which affect the
acceleration [48].
Figure 1. Installation and integration of battery pack into the vehicle: Overview of possible locations.
The options (A–D) are based on a benchmarking of available concepts; options (E–H) are possible
solutions to be explored, not yet used in the automotive market.
In the tunnel mounting, a T-shaped battery unit is mounted under the rear seats,
keeping the center of gravity low. The T-shape centers the battery system in the car and
the battery pack is in a more protected area in case of intrusion and collision. However,
the interior floor area is reduced, affecting the coefficient of drag and the aerodynamic
performance [50]. Commercially available car models are currently using this architecture,
such as the Chevrolet Volt and the EV1.
Energies 2021, 14, 1939 8 of 24
The floor integration consists of integrating the battery pack under the occupants as a
removable component, using all available space under the seats. This configuration pro-
vides an optimal weight distribution and a low center of gravity. Nevertheless, the battery
could be exposed to impact conditions, leading to leakage or short-circuiting [51,52]. The
models Mercedes B-Class Electric drive, Smart ED, Nissan Leaf and Toyota RAV4 EV follow
this configuration. This configuration is used as benchmark in the proposed use-case.
The rear mounting is another possible arrangement, consisting of locating the battery
pack in the rear part of the vehicle, under the back seat area. This location does not reduce
the vehicle space available for occupants but it makes the battery pack vulnerable in a rear
impact. The Toyota Prius PHEV was designed in this configuration.
The vehicle front area is usually occupied by most of the vehicle components, limiting
the available space for additional components. Hence, the front mounting is not commonly
used in conversion design strategies. In addition, this solution would lead to a bad weight
distribution along the vehicle and a significant shift of the center of gravity. On the other
hand, in the case of crash and fire, this location would be easier to access to extinguish
a fire.
The platform configuration can be used in purpose design strategies, such as the Tesla
S Model. In contrast to the floor-integrated packaging, the battery pack is not removable
and does not require an additional protective structure. This battery system configuration
allows an optimal weight distribution around the vehicle body. Nevertheless, if batteries
are placed out of the vehicle perimeter, side impacts could be dangerous.
Roof integration has not been employed so far by any EV manufacturer; however,
a critical analysis is worthy. Some bus models are in fact equipped with roof-integrated
battery packs [53]. Of course, the design requirements of a car differ from those of a bus
and the integration on a car’s roof would change the overall car geometry, shift the center
of gravity to the upper part of the vehicle and consequently result in poor aerodynamic
and drivability performance. Besides, the battery pack would require an additional casing
to protect the system from the external weather conditions.
The door integration would embed battery cells in the body panels, thus exploiting
an additional space otherwise unused and distributing in an optimal way the ESS weight
between both sides of the vehicle. On the other hand, this configuration obviously adds
complexity to the vehicle structure and manufacture. The weight penalty could be offset
by the use of lighter materials, such as carbon fiber, and by installing very thin pouch cells,
although aging may be a concern. Safety might also be an issue because even a minor
parking mishap where a door gets dented could result in a lower operating mode of the
battery pack or in serious damages. Moreover, battery access for testing, cleaning and the
possible replacement of cells would not be so easy.
Finally, there could be the possibility of adding an external battery pack towed from
the vehicle. This way, the design complexity would be reduced from a structural point
of view because the battery pack would not be located inside the architecture and among
the existing components; nevertheless, other problematic issues would appear. In fact,
since the battery pack would be an external element, not included in the vehicle chassis, it
would be subjected to mechanical shocks and vibrations from outside and thermal stress
because of the different weather conditions. Hence, a protection casing and an appropriate
heating/cooling system would be needed, considering that the wiring system would
be more complex and more expensive. Additionally, the installation of a further heavy
component in the rear area of the car would affect the vehicle stability both because it
influences the center of gravity of the vehicle and makes the driving harder, even in the
case of an easy and simple parking maneuver.
After this analysis, it is easy to understand how much wider the range of options is that
the automotive designers have when the final battery pack installation and/or integration
shall be chosen (see Figure 1). Different areas within the vehicle may be theoretically used,
but the geometry is not the unique factor that drives to the best choice. Vehicle stability
and passenger safety shall be adequately investigated, so as to ensure the vehicles the best
Energies 2021, 14, 1939 9 of 24
performances and, at the same time, to guarantee to the passengers the expected protection
in the event of car accidents and heavy shocks during each drive. Hence, the outcome of
choosing the best battery pack location, between the ones described above, results in a
vehicle with a proper center of gravity and a high crash safety performance. In this way,
EVs can achieve dynamic stability and safety.
3. Methodological Approach
A well-designed battery pack system is essential to ensure high-performing operation
of electric vehicles. Indeed, the vehicle performance parameters are affected by various
factors deriving from the pack design, including the size of modules and cells, together
with the arrangement of the cells in the delimited space and their technical specifications,
such as rated capacity, nominal voltage, weight, etc.
Design methodologies are developed to identify optimal battery pack designs, taking
into account a range of requirements, including velocity, acceleration, capacity, weight
and safety.
The design methodology presented in this paper aims at simultaneously optimizing
two vehicle parameters: the battery pack weight and capacity. Some of the most critical
control factors to be considered in the pack design approach are the battery cell type,
geometry, size, number of cells, location and space between cells and modules.
As depicted in Figure 2, the proposed methodology consists of three main phases.
Figure 2. Proposed conversion design methodology to optimize battery pack weight and capacity,
based on the available pack size within the chosen vehicle configuration.
Energies 2021, 14, 1939 10 of 24
In the first phase, the initial vehicle configuration is selected, in order to define the
dimensions of the existing electrical components, i.e., cells, modules and the overall battery
pack. This stage is crucial for the conversion design approach, as it allows to define the
reference architecture, based on the chosen commercial vehicle, and the related restrictions.
The obtained reference is qualitative, compared to the chosen vehicle, because various
assumptions have to be made in this stage. Battery management system and cooling are,
for instance, neglected in the methodology. The main technical parameters are calculated
as follows:
Ncell = n ·m (1)
Cap pack = Ncell ·C [Ah]·V [V] = [Wh] (2)
Weight pack = Ncell · M [kg] = [kg] (3)
where n is the number of cells per module and m is the number of modules in the pack. C
is the rated capacity and V is the nominal voltage of the single cell, whereas M is its mass.
In this way, the overall utilizable space is quantified, as well as the initial pack capacity
and weight, and new design solutions can be developed.
In the second phase, various geometry and topology considerations are considered
for assembling the overall battery pack in the available space, aiming at an optimization of
the capacity and weight of the selected reference vehicle, as calculated in the previous step.
Three specific cell formats are used in the analysis (i.e., prismatic, cylindrical, pouch) and
various battery pack configurations are investigated for each cell typology. A screening of
commercially available cells is made, based on their technical specifications.
Specific optimization strategies for each cell format are developed, taking into account
both cells arrangement in modules and the module disposition in the battery pack. A
rectangular case is assumed as the geometry of the module. The overall battery pack
weight and capacity are calculated for each proposed configuration. A discussion about
the different proposed design configurations investigated in each strategy is made so as to
identify the format solution and relative configuration that provide better results in terms
of the capacity and weight in comparison to the original vehicle scheme.
In the third phase, the best configurations, identified for each cell format in the
previous step, are compared and the final optimal configuration of the cell dispositions
within the module and the battery pack is determined. A CAD model of the optimal
configuration is developed, providing a detailed graphical view of the optimized design,
e.g., the configuration that provides an optimal minimization of mass and maximization of
the energy capacity.
4. Results
4.1. Reference Vehicle and Battery Cells
A conversion design approach is followed; i.e., a commercial electric vehicle con-
cept (BMWi3 (https://www.press.bmwgroup.com/global/article/detail/T0259598EN/
technical-specifications-for-the-bmw-i3-94ah-valid-from-07/2016?language=en, accessed
on 31 March 2021) is used as a reference and modified with the final aim of optimizing
its battery pack configuration. The BMWi3 model has been used as a reference in other
studies, e.g., for powertrain modelling [54].
The BMWi3 was designed with floor battery integration architecture, equipped
with 96 prismatic cells, manufactured by Samsung SDI (https://www.samsungsdi.com/
automotive-battery/products/prismatic-lithium-ion-battery-cell.html, accessed on
31 March 2021). The high-voltage battery system (HVBS) consists of eight rectangular
modules, arranged in four rows of two elements along the drive axle, each containing
12 cells connected in series.
Table 2 provides an overview of the technical specifications for the reference bat-
tery cells.
Energies 2021, 14, 1939 11 of 24
Table 2. Technical specifications of the battery pack for the commercial vehicle BMWi3 (94 Ah)
Reproduced from [55], BMW 2016.
Figure 3 shows the original scheme of the BMWi3 battery pack, reporting the top and
side view, detailing cells and modules disposal and all the geometrical measurements.
Figure 3. BMWi3 battery pack schematic (reference) in floor integration installation (configuration B).
As mentioned above, some assumptions are made to reproduce the ESS structure of
the chosen reference vehicle:
• Modules dimensions are calculated on the basis of the geometrical size of the cell
typology used in the reference vehicle. Samsung SDI 94 Ah cells are arranged, side
by side, in two rows of six elements per each module, thus obtaining 12 cells per
module. Particularly, the length and width of modules are multiple of both sides of
the prismatic cell installed;
• A width of 5 mm is assumed for the module casings;
Energies 2021, 14, 1939 12 of 24
• The distance between modules, without casing, and from modules to the pack bound-
ary is assumed to be equal to 30 mm. However, the design procedure will be con-
ducted assuring and maintaining at least 1.5 cm between module casings because all
the electrical connections between modules always need to be guaranteed;
• No mechanical structure to hold and manage the cells arranged inside the modules
are considered in the design methodology. All the electrical components are simply
disposed next to each other;
• The reference battery pack is manufactured with rectangular models. This shape is
retained also for the design methodology and, therefore, only rectangular cases are
considered in the analysis;
• In the developed design analysis, neither the battery management system (BMS) nor
the cooling systems are considered;
• Only the weight of the cells is considered in the calculation phases; e.g., the external
cases of modules do not affect the overall weight evaluation.
The presence of the frame structure necessary for the installation of the batteries as well
as the cooling and thermal systems would further reduce the available installation space.
The optimization procedure is therefore not based on the real dimensions of BMWi3 battery
pack but rather on a qualitative configuration. Furthermore, since this electric vehicle
model is assumed as a basis for the implementation of the proposed design procedure, the
methodology refers exclusively to the integration of batteries mounted in the lower part
of the vehicle, i.e., floor integration (configuration B). During this study, the geometry of
installation space within the body of the reference vehicle under examination was kept as
fixed and was used to develop new and optimized battery pack configurations.
Considering the technical specifications of the Samsung SDI 94 Ah cells, it is possible
to calculate the number of cells, the capacity and the weight of the BMWi3 battery pack:
Table 3. Strategies for cell and module disposition in the specific battery pack configurations with
prismatic, cylindrical and pouch-cell formats.
Configuration 1 involves the same cells installed in the reference vehicle but oriented
differently, i.e., rotated 90◦ . The cell is arranged vertically, with the longer side parallel
to the y-axis of the reference system, as shown in Figure 4. Based on the geometrical
assumptions and the minimum distances to be respected, a disposition of 90 cells stacked
in nine modules is obtained. Considering the new cell arrangement, six of the 96 cells
originally installed in the reference BMWi3 pack are not included in the new configuration
and, as a consequence, a slight weight reduction is expected.
Figure 4. Pack schematic of configuration 1 with prismatic cells in the floor integration installation of
reference vehicle.
Energies 2021, 14, 1939 14 of 24
Figure 6. Toshiba SCiB cell disposition in one module, developed for configuration 2 (left side) and
3 (right side).
In configuration 4, the dimensions of the modules are not fixed and equal to those
of the initial BMWi3 pack. The available space is filled by arranging the cells within
the modules and the modules within the pack in the preferred way. The same cell as in
configuration 2 and 3 (SCiB 23 Ah) is used. This configuration is obtained by arranging
51 cells in three rows of 17 in each module along the x-direction, and on the y-direction, six
cells are considered (see Figure 7).
Figure 7. Pack schematic of configuration 4 with prismatic cells in the floor integration installation of
reference vehicle.
y-direction. The angle obtained between the centers of the circular surfaces of adjacent
cylinders in the same row or between two consecutive rows is zero. As a result of the
straight cells arrangement, 252 cells per module are obtained and, in total, 2016 cells are
inserted in the pack. Figure 8 shows that the module available space is not completely filled.
Figure 8. Reference module schematic with cylindrical cells arranged according to straight packing
(left) and offset packing (right).
Configuration 6 is obtained by arranging the cells in the module according to the offset
packaging (see Figure 8, right). Once, the diameter of the cells and the dimensions of the
module are defined. As Figure 8 clearly shows, with this new arrangement, it is possible
to insert in the same available space a greater number of cells, equal to 294 per module.
Therefore, it can be deduced that the offset packaging is more efficient from a geometrical
perspective.
In configuration 7, the Panasonic 21700 cell, instead of Panasonic 18650, is considered.
A comparison between the application of these two cylindrical cells is carried out and two
cases are analysed; the first is the configuration with 18650 cell, the latter considers the
installation of 21700. The BMWi3 pack weight parameter is fixed, and the capacity is then
calculated for both cells.
M pack,BMWi3 198kg
∗
Ncell18650 = = = 4082.4 ∼
= 4083 cells (7)
Mcell,18650 0.0485kg
Figure 9. Pack schematic of configuration 7 with Panasonic 21700 cylindrical cells in the floor
integration installation of reference vehicle.
Both configurations 8 and 9 investigate the insertion of pouch cells within rectangular
cases. Car manufacturers that adopt this cells format usually order them vertically and side
by side. This makes pouch cells the technology with the most efficient use of space, thus
achieving a considerably high packaging efficiency. However, the dimensions of most of the
pouch cells found in the market do not fulfill the geometrical boundaries of the reference
module. Pouch cells may also be placed in a flat disposition, parallel to the ground, by
considering the cell’s largest surface as the base surface, and overlapping more cells to form
the modules. Nevertheless, the amount of pouch cells would be greatly reduced and the
existing potential of this cells typology would not be fully exploited. In order to overcome
the issue of commercial cells, pouch cells with smaller dimensions manufactured by the
Battery LabFactory Braunschweig (BLB) for research purposes were used in the analysis.
Configuration 8 consists of 10 modules, in which the cells are arranged in two different
positions: two long modules are placed on the right and left side of the available space with
the pouch cells aligned not vertically but laterally (see Figure 10). To overcome the spatial
boundary, each cell is rotated 90◦ with respect to the usual disposition and is oriented
in such a way that the cell height is parallel to the ground. Hence, the terminals of both
modules are not located in the upper part of modules but they are turned toward the
inner space. In this way, two long modules are generated along the y-axis. Another four
modules equal to two external ones could be positioned between them, but the electrical
connections would be rather difficult. Therefore, a different orientation for the cells was
chosen in the remaining volume: two rows of four modules are located in the inner part,
each of them containing 40 cells piled on top of one another. In these eight modules,
the cells are arranged in a flat position, with the terminals turned toward the center of
the battery pack. The cells in the flat position are located in the inner part of the pack
volume for guaranteeing safety from eventual external impacts and for improving the
vehicle dynamics.
Energies 2021, 14, 1939 18 of 24
Figure 10. Pack schematic of configuration 8 with BLB2 pouch cells in the floor integration installation
of reference vehicle.
Figure 11. Pack schematic of configuration 9 with BLB2 pouch cells in the floor integration installation
of reference vehicle.
formulas (1–3) are applied. The results are summarized in Table 4 and a comparison
with the reference battery pack is proposed. A new parameter is defined to carry out the
comparison and identify the optimal solution: the ratio between the battery pack capacity
and weight (ρpack ). The cell and pack ratio do not differ as the calculations are based on cell
values and the number of cells per pack configuration. As pointed out above, the analysis
does not consider various factors that would increase the weight of the pack (i.e., battery
pack casing, wiring harnesses, cooling system, etc.), thus affecting the ratios. Based on
these assumptions, the ρcell and ρpack , namely, the ratio on cell and pack level, respectively,
have the same values.
Table 4. Summary table of all pack configurations with prismatic, cylindrical and pouch cell format.
Pack
ρcell Nr Nr Pack Weight ρpack
Group Configuration Cell Type Capacity
[kWh/kg] Modules Cells [kg] [kWh/kg]
[kWh]
Samsung
BMWi3 Reference 0.17 8 96 33 198 0.17
SDI 94 Ah
Samsung
1 0.17 9 90 31.2 185.4 0.17
SDI 94 Ah
Prismatic cell Toshiba
2 0.10 8 256 13.5 129.3 0.10
SCiB 23 Ah
Toshiba
3 0.10 8 272 14.4 137.4 0.10
SCiB 23 Ah
Toshiba
4 0.10 6 306 16.8 154.5 0.11
SCiB 23 Ah
Panasonic
5 0.24 8 2016 23.2 97.8 0.24
18650
Cylindrical cell
Panasonic
6 0.24 8 2352 27 114 0.24
18650
Panasonic
7 0.25 4 2000 34.6 136 0.25
21700
8 BLB2 0.11 4 740 23 214.6 0.11
Pouch cell
9 BLB2 0.11 4 840 26.1 243.6 0.11
The data collected for the four prismatic cells configuration do not show improved
results with respect to the original BMWi3 values. In fact, the pack capacities are lower and
the weight values are higher. The Toshiba SCiB cells lead to a battery pack configuration
with a strongly decreased weight, but, on the other hand, the capacity is reduced. This is
strongly dependent on the specific cell characteristics: SCiB cells have small dimensions
and reduced weight, but they have nominal capacity and voltage values quite lower than
the Samsung SDI cells. Configuration 1 is the only case in the prismatic group that provides
a high capacity and an acceptable pack weight, although the values are not optimized
compared to the original model, having an energy-to-weight ratio equal to 0.17 kWh/kg,
the same as the reference.
By using cylindrical cells instead of the prismatic ones, the weight of the pack is halved.
However, the capacity is also greatly reduced. For instance, the battery pack manufactured
according to configuration 5 would weigh half but would result in a lower capacity. Similar
results arise from configuration 6: a higher pack capacity with a considerable reduction
in weight. Obviously, the offset packaging allows for inserting more cells in the available
space, thus increasing the overall pack capacity. The Panasonic 21700 cells are used in
configuration 7, instead, and the new layout results in a battery pack with a considerably
higher capacity and lower weight. The three configurations obtained with cylindrical
cells exhibit ρpack values that are significantly higher than both the reference model and
prismatic cell usage. This means that all the cylindrical study cases offer good energy to
weight ratios. The best solution is configuration 7: its ρpack is much higher than the others
Energies 2021, 14, 1939 20 of 24
and, at the same time, is able to provide more capacity with an inferior weight with respect
to the BMWi3 configuration.
Finally, the last two configurations with pouch cells show ρpack values that are ex-
tremely low if compared to the original BMWi3 energy to weight ratio. In both cases
under examination, the pack capacity is much lower than the reference one, whereas the
weight is excessive (i.e., over 200 kg). Hence, neither configuration with pouch cells can
be considered optimal, despite the pouch format being the technology with the highest
expectations. This demonstrates that the cell type and its format do not represent the only
factor that influences the performance of the battery pack. The arrangement of cells and
the overall disposition of cells and modules in the pack volume also has major relevance.
The reference vehicle BMWi3 is equipped with Samsung SDI 94 Ah prismatic cells.
The safe integration of Samsung SDI cells in the battery pack has been validated within the
patent published by Samsung and Bosch in 2014 [56].
The results of the proposed methodology show that the configuration that guarantees
an optimized battery pack design with respect to the original BMWi3 pack model, based on
lower weight and higher pack capacity, is configuration 7 with 21700 Panasonic cylindrical
cells, arranged in four modules with an offset packaging. Out of the analyses, these cells
turn out to be the best solution for a co-optimized converted design, thanks to their low
mass and their high packing efficiency. However, the effect of considering additional
parameters and components might significantly influence the outcomes of the analysis.
Components to be integrated in the assessment are, for instance, safety devices, battery
management system, and cooling devices. Those components have an influence on the
space constraints. Factors that could influence the vehicle performance are the safety and
vehicle dynamics.
A detailed CAD model of the battery system was thus developed for the chosen
configuration (see Figure 12). This solid modelling computer-aided software was used to
provide a visual example of how the selected battery pack configuration appears, so as
to better understand how the cell typology and the general layout influences the overall
design and differs with respect to the reference model depicted in Figure 3.
Figure 12. CAD model of the optimal configuration (Configuration 7 with 21700 Panasonic cylindrical
cells, arranged in four modules with an offset packaging).
Energies 2021, 14, 1939 21 of 24
Author Contributions: Conceptualization, E.P., T.V. and M.S.; methodology, E.P. and V.C.; investi-
gation, E.P. and V.C.; writing—original draft preparation, E.P., V.C. and M.S.; writing—review and
editing, E.P., T.V., M.S. and V.C.; visualization, V.C.; supervision, E.P., T.V. and M.S. All authors have
read and agreed to the published version of the manuscript.
Energies 2021, 14, 1939 22 of 24
Funding: The authors would like to acknowledge the financial support provided by the European
Union, within the framework of the Erasmus + Programme.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.
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