johu wrote: ↑Wed Nov 01, 2023 8:51 am
Can I read up on it somewhere?
I'm restricted height-wise to 250mm but the modules are only 110mm.
I will inspect the original cooling plates, maybe I can sort of reuse them
....
If you can use them yes!!! That would be really good. Even if you get to chop it in halfh and get it rewelded.
Let me discuss how i intend to solve this for my ID3 modules.
I will assemble modules in 4 packs 2modules on top and 2modules on bottom inverted. In between i will have a cooling plate which will double as a mounting jig, so assembly will be turnover proof.
Cooling plate i first intended to assemble from 2 plates one 8mm and the other 12mm and bolted together. 12mm plate would have cooling channels cut on milling machine as well as O ring seal channel.
But as i couldnt find a milling machine operator who would machine just one or two pieces for me i decided to make the plate in 3 pieces.
3 piece construction will include two 8mm side plates and middle 5mm plate. This plate i will be able to just cut by my hand jigsaw. There will be no Oring seal instead i will use sika silicon glue on both sides together with countersunk head screws.
I will still have to position 10mm tubes somewhere on the top plate and weld them to have inlet and outlet.
Also dont forget each module is 30kg and 4module pack is 120kg which is quickly too much for a single person and it might cause problems with two not so strong persons. Having more than 4 modules on a single plate will require additional supports to bolt to the chassis to enhance material stiffness.
Modules have 10mm bolt holse and those are quite sufficient to support 30kg individual weight of the module.
Grade 8.8 bolt should hold upwards of 640MPa force converted to G loading should be 1.9T for each bolt = 60G+.
Shear strength is a different animal. You have material capacity of 60% at shear forcess only. And if one bolt goes everything goes! Usually Aluminum box will fail before that bolt. You will now see the weak point really is mounting assembly to a car.
I am still assembling my rear box on Mazda. I will post photos of it here:
https://mazdamx3ev.wordpress.com/
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