Prismatic EV Truck Battery Design
Budget: £18 – £36 GBP
I’m engineering a next-generation battery module for heavy-duty electric trucks and need a specialist to turn the concept into a validated, production-ready design.
Scope
The pack will use large-format lithium-ion prismatic cells assembled into a 400–800 V architecture. Integrated monitoring PCBs must sit directly on the cell tabs, while high-current copper or aluminium busbars (500 A continuous, >1 000 A peak) route power to the main contactors. Alongside the electrical layout, I require a full 3-D mechanical model, electro-thermal simulations, and design files ready for prototype manufacture.
Key performance targets
• High energy density without sacrificing serviceability
• Fast-charge operation up to 2 C with minimal temperature rise
• Calendar and cycle life optimised for long-haul duty cycles
Compliance
All work has to satisfy ISO standards, UL standards (notably UL 2580), and ECE R100. Evidence—calculations, simulation reports, and references to the clauses addressed—must accompany the final documentation.
Deliverables
1. Electrical schematics and PCB Gerbers for cell monitoring/balancing boards
2. Detailed busbar drawings with current-carrying and thermal analysis
3. Full 3-D CAD assembly (STEP + native format) including cooling plates, enclosure, service disconnect, and sealing strategy
4. Electro-thermal simulation report (CFD or equivalent) showing steady-state and fast-charge scenarios
5. Bill of materials and manufacturing notes suitable for RFQ
Acceptance criteria
• Maximum cell temperature rise <8 °C during 2 C fast charge, validated in simulation
• Voltage drop across the pack <1 % at 500 A continuous
• All referenced standards met with documented evidence
Typical tools I expect you to leverage include SolidWorks or OnShape (preferred) for CAD, ANSYS Icepak/Fluent or COMSOL for thermal-fluid modelling, and Altium Designer for the PCBs, but I’m open to equivalent platforms if they meet the objectives.
If this aligns with your expertise in large-format lithium packs, thermal management, and regulatory compliance, let’s discuss how we can bring this truck battery to life.
Scope
The pack will use large-format lithium-ion prismatic cells assembled into a 400–800 V architecture. Integrated monitoring PCBs must sit directly on the cell tabs, while high-current copper or aluminium busbars (500 A continuous, >1 000 A peak) route power to the main contactors. Alongside the electrical layout, I require a full 3-D mechanical model, electro-thermal simulations, and design files ready for prototype manufacture.
Key performance targets
• High energy density without sacrificing serviceability
• Fast-charge operation up to 2 C with minimal temperature rise
• Calendar and cycle life optimised for long-haul duty cycles
Compliance
All work has to satisfy ISO standards, UL standards (notably UL 2580), and ECE R100. Evidence—calculations, simulation reports, and references to the clauses addressed—must accompany the final documentation.
Deliverables
1. Electrical schematics and PCB Gerbers for cell monitoring/balancing boards
2. Detailed busbar drawings with current-carrying and thermal analysis
3. Full 3-D CAD assembly (STEP + native format) including cooling plates, enclosure, service disconnect, and sealing strategy
4. Electro-thermal simulation report (CFD or equivalent) showing steady-state and fast-charge scenarios
5. Bill of materials and manufacturing notes suitable for RFQ
Acceptance criteria
• Maximum cell temperature rise <8 °C during 2 C fast charge, validated in simulation
• Voltage drop across the pack <1 % at 500 A continuous
• All referenced standards met with documented evidence
Typical tools I expect you to leverage include SolidWorks or OnShape (preferred) for CAD, ANSYS Icepak/Fluent or COMSOL for thermal-fluid modelling, and Altium Designer for the PCBs, but I’m open to equivalent platforms if they meet the objectives.
If this aligns with your expertise in large-format lithium packs, thermal management, and regulatory compliance, let’s discuss how we can bring this truck battery to life.