Challenge
Create a removable battery pack for an electric vehicle pusher trailer.
Approach
We designed four daisy-chained packs whose weight can be distributed around an uneven chassis floor, each with anchor points for lifting and secure fastening. The packs are armored against piercing in a collision, hermetically sealed, and control-vented to retain noxious gases after an internal failure. An aftermarket battery management system monitors the certified pre-owned OEM EV modules, with a software-defined barostat in Node-RED regulating internal pressure. Bulkhead unions route coolant from an external Cooling Unit: dual pumps, dual radiators, coolant tanks, thermocouples, solenoid valves and pressure-control logic.
Highlights
- High-voltage disconnects sit at the top of each pack, with internal fuses against current overdraw.
- Access hatches reach disconnects, fuses and coolant bulkheads without removing the main doors.
- An auxiliary power distribution panel provides a 110 VAC supply and an energy consumption gauge.