Electric vehicle (EV) technologies have received great attention due to the potential contributions to relieving the energy dependence on petroleum and reducing carbon dioxide emissions. The advancement of EV technologies greatly relies on the development of battery technologies. Lithium-ion (Li-ion) batteries have recently become the main choice as the power source for major EV manufacturers. Previous research on EV Li-ion batteries is mainly focused on materials and chemical properties of single cells, while the effects of manufacturing processes on the performance of entire battery packs have almost been neglected. In practice, EV batteries are used in packs containing multiple cells, which may not be ideally manufactured. This research proposes a novel modeling method for analyzing the effects of manufacturing processes on the dynamics of EV Li-ion battery packs. The method will help engineers gain a deeper understanding of the roles of manufacturing processes in improving EV Li-ion battery performance.

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