Development of a 3D model of the casing for LiFePO4 battery cells

Excellent! Here is the updated request with clarification on tire options:

Project Title: Development of a 3D model of a casing for LiFePO4 battery cells with a flexible busbar system

Task Description:

A 3D model of a casing for a battery system based on LiFePO4 cells of two sizes needs to be created:

• 280Ah
• 314Ah

Work Requirements:

1. Main Task: Development of a complete 3D model of the casing considering the existing design (examples attached)
2. Technical Requirements:
   • Placement of cells in 2 layers (as in reference photos)
   • Spaces for installing BMS and display
   • Holes for cable exits
   • Mounting for power connectors (red/black)
   • Ventilation holes
   • Mounting holes for securing components
   • Space for the display with a frame
   • Wheels for mobility
3. Additional Elements:
   • Spaces for DC-MCCB (TOMZN 200A circuit breaker) need to be provided
   • Space for YRO 160A disconnect switch with base and fuse
   • Handles for transportation
4. IMPORTANT - Flexible Busbar System (TWO OPTIONS):Option 1 - Cells with 1 terminal (connector) per pole:
   • Develop a busbar design for connecting cells with a single bolt connection on + and -
   • Busbars with one mounting hole at each end
   • Option 2 - Cells with 2 terminals (connectors) per pole:
   • Develop a busbar design for cells with two bolt connections on + and -
   • Busbars with two mounting holes at each end
   • Ensure even current distribution between the two terminals
   • General requirements for both busbar options:
   • Series connection of cells in the battery module
   • Parallel connection of layers (if needed)
   • Reliable contact with cell terminals
   • Thickness and width of busbars for 200A current
   • Bolt mounting to cell terminals (M6 or M8)
   • Insulation of busbars (protective covers/heat shrink)
   • Ease of installation and maintenance
   • Balance cables for BMS to each cell
   • Distances between busbars for electrical safety
   • Possibility of easy disassembly of individual cells

What is needed as output:

• 3D model files in formats: STEP, STL, and working formats (SolidWorks/Fusion 360/other software)
• Drawings with dimensions for manufacturing the casing
• Drawings of flexible busbars with dimensions (for both options - 1 terminal and 2 terminals)
• Material specification (including busbar specification: length, width, thickness, material)
• Wiring diagram of cells with busbars (for both options)
• Recommendations for choosing the optimal option

Materials:

• Casing: sheet metal 2mm thick
• Busbars: flexible copper
• Busbar insulation: heat shrink or protective covers

References:Photos of the existing design that should be used as a basis are attached to the project

Additional Information:I would be happy to consider proposals for the optimal configuration of busbars and their mounting for maximum reliability and safety of the system. The ability to adapt to different types of cells is needed.