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Lite Plus needs you to design two new casings for their Lithium-ion 12V car battery!
Cars have changed dramaticaly in the last 50 years, but their batteries have remained the same. With new technology that makes our battery five times lighter than the typical lead acid unit and YOUR new design, we can change that.
Join us in rethinking the battery. Make the casing look great! It should be so well-designed that you would want to put it on display, not hide it in an engine compartment.
Casing A and B need to have common design lines!
EACH ENTRY MUST HAVE DESIGN FOR CASING A AND B. ENTRIES FOR ONE CASING ONLY ARE NOT ACCEPTED.
* Image by autoblog.com
Please use the following color in the design:
HEX: #D3FD04 - PMS 389 C
Please note that the Lite Plus battery will be a direct replacement product and needs to have standard measurements as per the CAD files in the specification.
The task is to design two whole battery cases:
- Casing A consists 1 battery element.
- Casing B consists 2 battery elements.
- The orientation of the elements is free (horizontal, vertical diagonal etc). The element is given in separate file „LitePlus battery element“.
Size and shape restrictions:
- The shape of the lower attachment must remain unmodified but it does not have to be a separate piece, just integrate it to your designed part. (CADbody „Lower standard attachment“ in attached file „LitePlus battery base“).
- The shape up from lower attachment doesn't have to follow the given walls but should remain inside of the walls. (CADbody „Standard walls“ in attached file „LitePlus battery base“). See picture 1.
- Casing A height is free.
- Casing B height should be 185mm so that it can be attached with original hoop type attachment.
Terminal location:
- The 2 terminals should be at the same height.
- Terminals lateral and longitudinal location measurement should remain the same as on attached file „LitePlus battery base“. See picture 2.
- Casing A terminals height is free, but not higher than 185mm.
- Casing B terminals height is 185mm measured from the top of terminal to the bottom of battery. See picture 3.
- To be able to attach the car’s wire terminals, there should be at least 30mm free room around the battery terminal, measured from terminal centre.
Things to consider:
- The method for manufacturing the cases is plastic injection.
- Solution to attach battery terminals to plastic case.
- Solution to attach different case parts.
- Solution to fix battery elements inside of the case.
- Stay away from conventional battery design
Casing A and B need to have common design lines!
Each contestant MUST submit design for casing A and B as one project.
The competition is open to everyone.
Models can be done in any CAD software as long as STEP or IGES files and renderings are also uploaded.
Team entries are welcome. In case of team win, prize money will be transferred to team leader who is solely responsible for splitting it among team members.
By entering this competition, you
1. Warrant that the work is your original work.
2. To the best of your knowledge, it is not, and has not been in production or otherwise previously published or exhibited.
3. Neither the work nor its use infringes the intellectual property rights (whether a patent, utility model, functional design right, aesthetic design right, trade mark, copyright or any other intellectual property right) of any other person.
Applicants are not entitled to any compensation or reimbursement for any costs. The applicant’s participation shall not constitute employment, assignment or offer of employment or assignment.
Only models uploaded to GrabCAD library through this Challenge page will participate in the competition.
Winning designs will be chosen based on the rules and requirements.
This Challenge starts on April 15, 2013 and ends on May 6, 2013, at 11:59pm UTC.
Winners will be announced latest June 6, 2013.
All cash prizes awarded through Paypal (http://grabcad.com/faq#money). Void where prohibited.
The sum of the Awards is the total gross amount of the reward. The awarded participant is solely liable for the payment of all taxes, duties and other similar measures if imposed on the reward pursuant to the legislation of the country of his/her residence, domicile, citizenship, workplace, or any other criterion of similar nature.
Tag your model with “liteplus”. Only entries with valid tag will participate!
Cash prizes for TOP 3 entries
$ 500 cash + GrabCAD shirt and mug
$ 300 cash + GrabCAD shirt and mug
$ 100 cash + GrabCAD shirt and mug
GrabCAD shirt and mug
GrabCAD shirt and mug
GrabCAD shirt and mug
The jury has both Lite Plus and GrabCAD experts.
Lite Plus is developing lightweight Lithium-Ion 12v starter battery for spirited driving experience.
Our batteries employ Lithium Iron Phosphate elements, integrated battery management circuits (BMS) and status display, providing longevity and performance. Lite Plus Batteries are a replacement for Lead Acid technology.
Kaspar Kiis
Jaak Ennuste
Kristjan Maruste
Risto KõivHave an awesome idea for this competition? Want to win cool prizes? Sign-up now to upload your entries.
If you don't receive the email within an hour (and you've checked your Spam folder), email us as confirmation@grabcad.com.
72 comments
Hevi about 11 years ago
We are making whole casing or maybe just top of it? Cap?
Dragan Beljan about 11 years ago
Interesting challenge
Miguel Rodríguez about 11 years ago
Which should be the dimensions?
What sides, zones and elements should be essentially respected?
Hevi about 11 years ago
"CAD FILE WILL BE ADDED SHORTLY!"
Jaak Ennuste about 11 years ago
Hevi: We need both parts, case + top. But use Your imagination. Old Lead-Acid batteries used certain construction, because there was acid inside. We can use construction there top is all the way down, connecter to bottom -- kind of upside down solution.
Jaak, Lite Plus Batteries
Stephen Nyberg about 11 years ago
Are they only for car batteries or can we do a motorcycle batterie? is there a range of sizes?
Daniel Von Wirgart about 11 years ago
In which Porsche will the battery be in?
Tõnu Samuel about 11 years ago
What if PayPal steals the money?
Jaak Ennuste about 11 years ago
Stephen, we are developing lightweight battery for cars. Straightforward direct-replacement products for car enthusiasts.
Jaak, Lite Plus CEO
Jaak Ennuste about 11 years ago
Daniel, standardized size and terminal locations allow to use it any Porsche. First prototype actually is in my lightweight Porsche 911/993 RS (total vehicle weight ca 1260 kg).
Jatin Sapra about 11 years ago
We are to model battery , is there any specification regarding acid volume , rods etc , upside down solution ??
Stephen Nyberg about 11 years ago
I don't have a Porsche, what is the standard size and shape of the battery used? does the new battery take up less space than the standard battery? Are there any drawings available for the current prototype that would be available?
Aimo about 11 years ago
@Stephen Nyberg
"Please check the CAD file for additional details and dimensions under Download Specification button."
Risira Erantha Kannanagara about 11 years ago
what are different features that have in this batterry other than light weight? are we have to design interor of the battery casing?
Bryan about 11 years ago
what kind of space does this battery have to fit into
Sara Sigel about 11 years ago
Looks like we have some early interest, great! Please download the specifications for information on the battery and dimensions.
@Tonu.Samuel PayPal is a trusted way to transfer money, no need to worry.
@Jatin.Sapra There is no acid and no need to model the battery it is included in the download specs button. Focus on the casing.
tim about 11 years ago
Are the protrusion around the bottom required? What are they for?
teigan about 11 years ago
lead acid is the best solution for a car starter battery. lithium ion chemistry does not store well, and begins degrading in performance immediately from date of manufacture. conventional lead acid batteries also recover better from a discharge. decreased weight does not justify the shortened product lifespan of lithium ion car batteries.
Aimo about 11 years ago
I think that this a premium battery for premium cars, for people who don't care about the lifespan. They want to safe those kilograms regardles how much it will cost.
Any:)way, intresting chall:)enge
Riccardo Gatti about 11 years ago
Do you have the dimension of the clamp? Would be useful to understand how much space keep clear around the electrode. Tnks.
EDISON PHOENIX about 11 years ago
Interesting challenge ..!!!
@Jaak Ennustv , What do you mean by "top" ?(when you answering Hevi's quetsion case+top)
What should we design "only casing" or "whole model of battery with modified dimensions including casing"?
Or otherwise would do you need an attractive battery skin design(Rendering)?
-Edison.
Carlos Pérez about 11 years ago
Como se interpreta la referencia de color HEX: # D3FD04 - PMS 389 C
Flaviano Crespi about 11 years ago
@ Carlos Perez, http://www.oakgraphics.be/pdf/download-pantone.pdf
Donald Wilson about 11 years ago
I know the base must be square so that it can be installed in a car, but does the rest of it have to have the traditional box shape of a battery? If not, what are the inside dimensions you require to have enough space for your components?
teigan about 11 years ago
in a 1400kg automobile, the weight of a 20kg lead acid battery is insignificant. the heaviest batteries are about 2% of the vehicle weight and the lightest are about 1% of the vehicle weight.
Paul Tripon about 11 years ago
Thank you for the link Flaviano. Other possible links for colors tools
http://colorschemedesigner.com/
http://www.colorschemer.com/online.html
http://colllor.com
Flaviano Crespi about 11 years ago
Useful, thanks Paul!
Bryan Morris about 11 years ago
@teigan Every bit counts my friend
teigan about 11 years ago
those bits count if you're especially gullible, or lack the ability to think for oneself.
anand singh about 11 years ago
need to know where battery will be mounted, as requirement shows on display. but what kind of display? please give details....
Tommy v/d Laan about 11 years ago
What are the dimentions of the sidebars on the battery?
Carlos Pérez about 11 years ago
Gracias flaviano por la aclaración de la referencia de color, muy amable.
Harrell Holloway about 11 years ago
Does the color specified have to be the primary color or just a percentage? If it is the major color and made of plastic I forsee it attracting a lot of dirt and oil.
Antonis Asimakopoulos about 11 years ago
For the color
http://www.colorhexa.com/d3fd04
Paul about 11 years ago
Is the clear top fused to the gray base or is it some type of snap system so it can be taken apart? Also what is the minimum radius from the center of the terminals required for clearence (so cables can be attached)?
John Dee about 11 years ago
This is something Boeing should have done.
Surajmal about 11 years ago
What should be the wall thickness of case ?
teigan about 11 years ago
perhaps if the boeing 787 batteries had been adorned in a puke green colour case, they would not have caught fire.
Nichollya about 11 years ago
The "status display" mentioned above in About Lite +, is this a display attached to the battery case? Any additional information would be helpful. Also in the picture I see some labels/ barcodes etc, are these supposed to be in a specific location?
Eric Chen about 11 years ago
Must be cubic? Can I change shape? does it need to add water? I mean can it up side down? when it moving
Thierry about 11 years ago
Hello,
Can we have the authorized working area as well as the thickness material of the cover?
The addition of paint and authorized?
Thank you in advance for your answer.
Zoltan about 11 years ago
Hi everyone,
Many people ask the size of the case thickness.
I do not think this is a really important issue.
The essence of the material from which they want to make the case.
Car battery is the most common material polypropylene.
because we know the weight of the battery, and the presumed maximum operating temperature 42Celsius.
Thus, it is predictable that the interface and functions, taking into account.
Lite plus Technical specifications:
Weight: 2.5 Kg
Dimensions WxLxH: 175mm x 210mm x 75mm
Battery design: LiFePO4 (Lithium Iron Phosphate), electronically controlled
Type: starting
Cold crancing amps: 600 A
Reserve capacity: 20, 40 or 60 Ah
Polarity: positive right
Warranty: 12 months
Terminal position: top
Typical estimated life: 5 years or 1500 charge cycles
polypropylene (PP-homo) properties:
Physical properties:
Density of 0.90 g/cm3
70% crystallinity
Tellítettségi% water absorption -
Mechanical properties:
Tensile strength is 30 MPa
Elongation at break% 150
Tensile Modulus of elasticity 1.6 GPa
Flexural strength MPa 37
Flexural modulus of 1.4 GPa
Impact strength at 23 °, unnotched kJ/m3> 40
Notched impact strength at 23 ° 10 KJ/m2
Thermal properties:
Melting temperature of 165 ° C.
Glass transition temperature ° C 0
HDT heat resistance (1.8 MPa), 55 ° C
Long-term heat load 90 ° C
Linear thermal expansion below Tg 10-4 K-1 1.4
over Tg 10-4 K-1 1.8
Zoltan about 11 years ago
If someone does not feel like it to count.
For me 2.46 mm to 3, 27 mm come out size the depending on the task
abhivardhan about 11 years ago
i would like to know the specifications of battery
abhivardhan about 11 years ago
i would like to know the specifications and is it rechargable
Marcel Bakker about 11 years ago
I have some questions: Is a sticker space with certain dimensions required on the top cover? If yes, what are the sticker dimensions? What about the dimensional restrictions in height: how much higher can design features be above the flat Cover surface in the CAD file? Is it specifically for Porche, or also for other brands? Which detail is needed in the design? Also draft angles, wall thicknesses, radii etc, so that the file is ready for injection moulding? Or just design concept...v
Kristjan Maruste about 11 years ago
Dear GrabCaders,
Thank you for all of your intriguing questions, we apologise for a vague description of the challenge.
We have compiled all of your questions and have made a new updated challenge description.
This will be uploaded shortly.
This file includes 1pdf with all the necessary requirements + 2CAD files to help you get going.
One thing I have noticed is that you are asking about the battery displayed in the top of the description (the one with Porsche logo). Do not take this too seriously this picture is just to illustrate the challenge. We do not want to make our battery case derived from this.
You mainly have to consider the bottom mounts, space for the inner components and position of terminals. All of this will be explained in detail.
If you have any problems after reviewing the updated specification please let us know here in Comments.
All the best,
Kristjan from LitePlus
Marcel Bakker about 11 years ago
I still have my questions of yesterday + some new ones: 1. Do the cases have to be water tight? 2. How will the internal battery elements be connected to the 2 terminals. 3. Are there safety requirements like clearance and creepage distances from internal battery element connections to touchable outside surfaces, in case it doesn't have to be water tight?
Timo about 11 years ago
I don't get it. Is this a styling challenge or engineering?? Make a good looking casing. Ok, But I have to find a solution how to attach the battery terminals to the case. OK. But Solution to fix the battery elements inside of the case. I have no clue how this kind of accumulator is working. i.e which parts are inside?? And is it now one casing seperated in lower (freezed) and uper part. Or two seperate casings??
abhivardhan about 11 years ago
Dear Sir, how many battery elements or cells will be their inside the casing
abhivardhan about 11 years ago
dear sir, i got the elements thanks
Girish.K.S about 11 years ago
Hi,
Please reply to the queries given below.
What are Battery elements? pls explain - "Casing A consists 1 battery element.
- Casing B consists 2 battery elements." ...
Any spec on Inner volume?..Its mentioned that the Outer profile of design proposals should not exceed the standard models given as attachments like wise is there any constraints on the Inner profile of design proposals.
Terminal Location and Heights are given ; is there any contraint on the casing upper cover height
Please provide the Information for existing designs or production parts for following
- Solution to attach battery terminals to plastic case.
- Solution to attach different case parts.
- Solution to fix battery elements inside of the case.
Thanks
Risto Kõiv about 11 years ago
Thank you all for showing so much interest on this challenge and asking the questions. Below are some answers.
To Marcel Bakker
Yes, the case needs to be water tight
The elements connect to the terminal through cable or sheetmetal stripes depending on the design
No extra clearance required between given battery element and case
To Timo
It is more design and styling contest, less engineering challenge, but after the contest we have to be able to apply the design to actual product and if the elements don't fit inside or there impossible to produce it, we cannot use it. Therefore we have specified some engineering points under paragraph 4 „Things to consider“. These are the first considerations our engineers have when they look at some design. You don't have to finalize all the engineering considerations, but if we cannot find any solution for those considerations, then we connot use this design.
There should be two casings - one for battery A and the other one for battery B, but both of them have to have the same design style.
To Girish.K.S
There are no other inner volume restrictions other than Battery A should consist one element and battery B should consist 2 elements. The elements are in the stp file.
Casing upper cover height is defined in paragraph 2.3 and 2.4
There is not one and only right solution for paragraph 4 considerations and we don’t expect full solution from you. Just some solution needs to be applicable.
Good luck!
Risto
LitePlusvv
Paul about 11 years ago
Just a couple of questions.
1. Is the actual battery element a cube or does the file represent the envelope of the element
2. Can we assume that the battery element provided is the max envelope or nominal? If nominal what is the design tolerance?
3. What end of the element (long or short) are the terminals or wires on?
Thanks,
-Paul
Risto Kõiv about 11 years ago
Hi Paul,
The given battery element is max size, no other tolerance needed.
Terminal wires will connect to short side of element
Cheers
Risto
Paul about 11 years ago
I noticed that the terminal locations in the provided case model disagree with the locations given in picture 2 (the model seems to have been measured from the case side wall and picture 2 is measured from the attachment base). Which is the correct location?
Thanks,
-Paul
teigan about 11 years ago
if you ever need to drive in wintery climates, the anode gets permanently plated by metallic lithium, thus irreparably compromising performance and safety. i once made the mistake of taking lithium ion batteried equipment on a cold weather mountain climb. nothing extreme(0C to -10C). the almost new batteries soon failed, and never recovered even after they were brought home.
Risto Kõiv about 11 years ago
Paul,
I double checked. I cannot see any mismatch. Can you be more specific?
Risto
Paul about 11 years ago
Risto,
Thanks for your help. I was still using the first model provided. After getting the latest model the numbers match up. Sorry for the trouble.
thanks,
-Paul
Kristjan Maruste about 11 years ago
To Teigan:
We are situated in Estonia, this year we had 7months of below freezing temperatures. The prototype batteries have been in daily use with temperature below -20 deg C.
So I believe Your bad experience might come from either the wrong chemistry or improper electronic control.
I hope we can prove that our batteries work fine with all temperatures and You will wnjoy using our products in the future.
Thanks for sharing your experience.
teigan about 11 years ago
hi kristjan. these were lithium ion batteries originally developed for mobile phones and are currently in wide use for handheld devices. and the battery damage happens slowly during the charging cycle. we charged them with a manufacturer recommended charge controller and a 5 watt PV panel. charging issues occur when the anode gets electroplated during low temperature charging. i complained to the japanese manufacturer, and they confirmed that lithium ion batteries should never be charged at subzero temperatures, because the damage done to the anodes is cumulative and irreversible. they did not have a solution other than to manufacture special batteries designed for a colder operating range, with the side affect of them not working well in warm temperatures.
so what that means to you is that you had better add a task to your charge controller software to shut off charge current from the alternator until the battery warms up, and also stops when the ambient temperature gets too hot. you also should not be locating your battery in the same place that the lead acid formerly occupied. lithium ion batteries have a far narrower operating temperature designed in. so that is a very basic mistake you are making now, that you will surely regret later.
Helio Zuazua almost 11 years ago
Can we have a brief description of inside elements?
Also , can we design a complete new connection system?or must be round standard connectors.
Thanks
Risto Kõiv almost 11 years ago
To Helio Zuazua
Please download specifications, the element stp file is in there.
terminals must remain originals.
Julius Siador almost 11 years ago
@Sara, how come I can't upload updates anymore w/ any browser for 3 days in a row already? I've been trying, and it still failed, even w/ a lighter jpg file.
Chester Lee Coloma almost 11 years ago
@Julius I think it's because deadline has passed.
Martin Remiar almost 11 years ago
congratulations...perfect choice for No.1
Carlos Pérez almost 11 years ago
I respect the jury's decision but do not share
Janne almost 11 years ago
Congratulations to the winner and runner-ups! Nice work!
I don't want to be bad loser or anything like that, but I need to give some feedback to the jury. If you give regulations to the competition, I expect that at least jury respect those when selecting winning work. Now five of six selected work clearly violate given regulations. Those who followed regulations, were obviously suffered from this. Too bad.
But anyway, thank you Lite Plus and GrabCad for arranging this good competition!
Sara Sigel almost 11 years ago
For anyone that wants to read a little more on the winners: http://blog.grabcad.com/2013/05/challenge-results-lite-plus-gets-new-battery-designs/. Congrats!
Girish.K.S almost 11 years ago
It was mentioned in rules to retain the Bottom part which created design constraints...but wonder the winning model does'nt followed this or the colour
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