Key Points of PACK Design for New Energy

This document outlines critical design considerations for battery PACKs in the new energy industry. It covers key points such as module preload, foam selection and compression, cell thickness tolerance checks, and test verification. Detailed calculations for preload force (500N-3000N) and foam stress-strain relationships are provided. The guide also addresses battery core weld strength, end plate and steel strip strength under expansion forces, and cabinet strength. Assembly considerations include fitting clearances between cells, modules, boxes, and lids, as well as bolt and steel strip stress analysis. Design for manufacturing principles are emphasized, including reducing parts count, avoiding over-design, modular product design, and choosing reasonable manufacturing processes. Error-proof design (poka-yoke) is highlighted to prevent assembly mistakes, with recommendations for guiding features, avoiding sharp edges, and ensuring proper assembly direction. The document also covers reducing fastener types, using buckles and folds, and designing for automated assembly. Overall, it provides a comprehensive framework for efficient, reliable, and cost-effective PACK design.