The electric vehicle market has rapidly expanded due to technological advancements for the last decade and a key enabler is the development of high-performance batteries with greater energy density, faster charging, and longer lifespan. The construction equipment sector faces unique challenges in electrification, including high power demands, extended operating hours, and the need for minimal downtime. To address these challenges Volvo Construction Equipment is investigating a battery swap system solution that allows for quick battery swaps, reducing downtime and a decoupled lifetime from the machines. The aim for this study is to design a battery pack used for the battery swap system while answering the following research questions: RQ1: What configuration of battery modules, rack and auxiliary systems achieve the highest energy density when designing a battery pack for construction equipment? RQ2: What factors should be considered when designing the battery modules, rack, and auxiliary systems to achieve the highest energy density of a battery pack for construction equipment? This project followed a limited version of Ulrich et al.'s (2019) product development process, focusing on concept development and system-level design for a battery swapping system. An inductive research approach was taken, gathering qualitative and quantitative data from interviews, literature, documents, and meetings to create a holistic understanding of the project challenges. A structured literature review was conducted using relevant keywords across multiple databases, employing techniques like forward and backward snowballing. Data analysis methods, including conversation analysis, were employed to structure and analyze collected data, ensuring validity and reliability through triangulation, and cross-referencing with experts at Volvo. Empirical studies were conducted through benchmarking and a case study, providing quantitative data on specifications and qualitative insights from internal documentation and communication with product developers. The findings formed an iterative concept generation process, emphasizing the importance of exploring diverse possibilities in the early stages. The design process involved evaluating previous battery pack solutions, working within predefined constraints like using a specific shell, internally developed battery modules, auxiliary components while satisfying a set of stakeholder needs. Some auxiliary components and a rack that supports the battery modules were also developed as there is a new internal layout of the battery pack. This resulted in a conceptual battery pack that theoretically have a 30% higher energy density than the previous battery pack solutions. The proposed solution enables Volvo Construction Equipment to offer machines with longer runtimes and increased productivity by maximizing the energy storage capacity within the given constraints.
| Identifer | oai:union.ndltd.org:UPSALLA1/oai:DiVA.org:mdh-67130 |
| Date | January 2024 |
| Creators | Blom, Carl, Sjögren, Elias |
| Publisher | Mälardalens universitet, Akademin för innovation, design och teknik |
| Source Sets | DiVA Archive at Upsalla University |
| Language | English |
| Detected Language | English |
| Type | Student thesis, info:eu-repo/semantics/bachelorThesis, text |
| Format | application/pdf |
| Rights | info:eu-repo/semantics/openAccess |
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