Design, Prototyping, and Integration of Battery Modules for Electric Vehicles and Energy Storage Systems

The design of battery modules for Electric Vehicles (EVs) and stationary Energy Storage Systems (ESSs) plays a pivotal role in advancing sustainable energy technologies. This paper presents a comprehensive overview of the critical considerations in battery module design, including system requirements, cell selection, mechanical integration, thermal management, and safety components such as the Battery Disconnect Unit (BDU) and Battery Management System (BMS). We discuss the distinct demands of EV and ESS applications, highlighting trade-offs in cell chemistry, form factor, and architectural configurations to optimize performance, safety, and cost. Integrating advanced cooling strategies and robust electrical connections ensures thermal stability and operational reliability. Additionally, the paper describes a prototype battery module, a BDU, and the hardware and software architectures of a prototype BMS designed for a Hardware/Model-in-the-Loop framework for the real-time monitoring, protection, and control of battery packs. This work aims to provide a detailed framework and practical insights to support the development of high-performance, safe, and scalable battery systems essential for transportation electrification and grid energy storage.