TY - THES

T1 - Concept development of a body-integrated battery housing

AU - Riahi Samani, Arash

N1 - embargoed until 14-02-2027

PY - 2024

Y1 - 2024

N2 - To seamlessly integrate the battery housing onto the Body in White (BIW), it is imperative to consider a concept that allows for the repair and replacement of battery housing components without the need to open the BIW again. This concept should be designed to be installed on the BIW without an upper cover, ensuring it is both waterproof and cost-effective. In the initial stages, a concept for the battery housing was formulated, with the aid of common CAD (Computer-Aided Design) software, taking into account the specific requirements set forth by the Magna company. To accommodate this battery housing concept, certain modifications were made to the existing platform. These adjustments included altering the height of the surface around the car's floor to create a level surface suitable for the battery housing installation. The frame of the battery housing and the components housed within it were designed to be both fixed and removable, with careful consideration given to their design and how they interconnect. Subsequently, the approach for assembly and the watertight sealing of the battery housing to the BIW were assessed. A comprehensive list detailing the weight of individual components and the production costs were compiled, facilitating a comparison between the conventional concept and the integrated concept. This comparative analysis enables a clear understanding of the advantages and disadvantages of the integrated concept. Compared to the old battery housing that were installed as a module and had a higher weight and manufacturer-specific sealing, the integrated model not only offers weight reduction but also allows for easier sealing during maintenance and convenient access for battery replacement due to its integration.

AB - To seamlessly integrate the battery housing onto the Body in White (BIW), it is imperative to consider a concept that allows for the repair and replacement of battery housing components without the need to open the BIW again. This concept should be designed to be installed on the BIW without an upper cover, ensuring it is both waterproof and cost-effective. In the initial stages, a concept for the battery housing was formulated, with the aid of common CAD (Computer-Aided Design) software, taking into account the specific requirements set forth by the Magna company. To accommodate this battery housing concept, certain modifications were made to the existing platform. These adjustments included altering the height of the surface around the car's floor to create a level surface suitable for the battery housing installation. The frame of the battery housing and the components housed within it were designed to be both fixed and removable, with careful consideration given to their design and how they interconnect. Subsequently, the approach for assembly and the watertight sealing of the battery housing to the BIW were assessed. A comprehensive list detailing the weight of individual components and the production costs were compiled, facilitating a comparison between the conventional concept and the integrated concept. This comparative analysis enables a clear understanding of the advantages and disadvantages of the integrated concept. Compared to the old battery housing that were installed as a module and had a higher weight and manufacturer-specific sealing, the integrated model not only offers weight reduction but also allows for easier sealing during maintenance and convenient access for battery replacement due to its integration.

KW - Battery housing of electric vehicle

KW - Battery housing integration

KW - Body in White

KW - Battery fire protection

KW - Batteriegehäuse für Elektrofahrzeuge

KW - Integration des Batteriegehäuses

KW - Body in White

KW - Brandschutz für Batterien

M3 - Master's Thesis

ER -