Electric Motorcycle Battery Box
Executive Summary
Electric Motorcycle Battery Box, ReVOLT EV
Designed and 3D modeled a battery enclosure in SolidWorks to accommodate a 200 A continuous current under 60°C. Optimized manufacturability by selecting 5052 aluminum sheet metal and incorporating the 0.76mm maximum bend radius constraint into the enclosure design. Utilized FEA simulations to improve strength, thermal performance, and component accessibility.
Interactive Assembly Preview
Material Analysis & Formability
While 11 GA HRPO steel is traditional for industrial enclosures, weight constraints for the ReVOLT EV platform necessitated a transition to aluminum.
- 5052 Aluminum (0.032" / 0.81mm thickness): Selected for edge pieces and sheet metal formability, strictly adhering to the 0.76mm maximum bend radius constraint to prevent micro-fracturing during brake forming.
- 6061-T6 Aluminum (0.1285" / 3.26mm thickness): Utilized for primary structural load-bearing components and base plates.
Thermal Management & FEA Optimization
To maintain operating temperatures below the 60°C threshold under a 200 A continuous electrical load, the assembly integrates a 120x120x38mm axial fan for forced-air convection.
Finite Element Analysis (FEA) was leveraged iteratively across the digital prototype to:
- Validate structural integrity against vehicle shock, vibration, and dynamic load factors.
- Simulate internal thermal gradients to ensure uniform heat dissipation across the 12x11 cell pack configuration.
- Refine internal packaging for optimized component accessibility during maintenance.