Development of 96V Battery Pack for Split Plug-In HEV

This study presents the design and development of a high-power, efficient battery pack optimized for plug-in hybrid vehicles (PHEVs). The proposed 96 V battery pack integrates advanced technologies to enhance in-vehicle electrical performance, support extended electric-only operation, and meet stringent energy efficiency requirements. Key design considerations include thermal management to prevent overheating, fast-charging capabilities for user convenience, and seamless integration with the vehicle propulsion system, with a strong emphasis on safety and long-term reliability across diverse operating conditions. The methodology encompasses the integration of critical hardware components, including a 24 S 96 V battery management system (BMS) motor, a 100.8 V battery charger, twelve 2S2P Hyundai battery modules from the first-generation lineup, 12 V and 5 V DC cooling fans, and an acrylic casing. These elements are meticulously engineered to ensure optimal thermal regulation, fast-charging compatibility, and uninterrupted battery performance across various environments. This research introduces an innovative plug-in hybrid technology concept aimed at promoting low-carbon mobility and global sustainability. The outcome is a robust, efficient, and industry-compliant 96 V battery pack designed to meet the stringent standards of the automotive industry, contributing to the advancement of greener transportation solutions.