battery-module-cooling-plate

// Battery Module Cooling Plates
// A battery module cooling plate is a thermal management component used in battery packs—particularly in electric vehicles (EVs), energy storage systems, and other high-power applications—to regulate the temperature of individual battery cells or entire modules.

// Define units
@settings(defaultLengthUnit = mm)

// Define number of coolings per side
numberOfCoolingsPerSide = 5

// Define at least 3 coolings per side
assert(
  numberOfCoolingsPerSide,
  isGreaterThanOrEqual = 3,
  isLessThan = 100,
  error = "Number of coolings should be between 3 and 100",
)

// thickness of the channels
thickness = 17
thickness2 = thickness * 2

// depth of the channels
csgCuttingDepthThicknessOfChannel = 5

// connector dimensions
connectorLength = thickness + 10

// widths for the cooling sketch channels
w1 = 30
w2 = w1 * 2
w5 = w1 * 5
totalWidth = w1 * 5
legLength = w2
overLap = w1 - thickness

// compute the width of the sketches side by side
widthOfCoolingSketches = (w5 + thickness + overLap) * numberOfCoolingsPerSide

offsetX = thickness2

// compute the offset to the edge of the base plate
heightOfCoolingSketch = w1 + overLap + thickness

// dimensions of the plate
plateWidth = widthOfCoolingSketches + w2 + thickness + overLap + offsetX + connectorLength
plateHeight = 200
plateThickness = 10

// initial sketch positions
startX = plateWidth / 2 - offsetX - connectorLength
startY = (thickness + w1) / 2

// compute the offset to the edge of the base plate
edgeOfBasePlate = -(plateWidth / 2)
startHeadOfCoolingY = -startX - heightOfCoolingSketch + widthOfCoolingSketches - overLap + heightOfCoolingSketch

sketchXy = startSketchOn(XY)

fn getOverlap(@id) {
  return overLap
}

// index the margins for the lengths of the cooling sketches
overlapMargins = map([0 .. numberOfCoolingsPerSide - 2], f = getOverlap)
margins = push(overlapMargins, item = -thickness)

// Dimensions for the mounting holes
mountingRadius = 6
mountingBuffer = 5 + mountingRadius

// Create the base plate to be cut
basePlateExtruded = startProfile(sketchXy, at = [-plateWidth / 2, plateHeight / 2])
  |> angledLine(angle = 0, length = plateWidth, tag = $rectangleSegmentA001)
  |> angledLine(angle = segAng(rectangleSegmentA001) - 90, length = plateHeight)
  |> angledLine(angle = segAng(rectangleSegmentA001), length = -segLen(rectangleSegmentA001))
  |> line(endAbsolute = [profileStartX(), profileStartY()])
  |> close()
  |> extrude(length = plateThickness)

// Get extruded END face of the base plate to sketch on
basePlateEndFace = startSketchOn(basePlateExtruded, face = END)

fn coolingSketch(plane, startPoint, legLength, margin) {
  coolingSketch = startProfile(plane, at = startPoint)
    |> xLine(length = -legLength)
    |> yLine(length = w1 - thickness)
    |> xLine(length = w2)
    |> yLine(length = w1 + thickness)
    |> xLine(length = -w5 - thickness)
    |> yLine(length = -w1 - thickness)
    |> xLine(length = w2)
    |> yLine(length = -w1 + thickness)
    |> xLine(length = -legLength - margin)
    |> yLine(length = -thickness)
    |> xLine(length = legLength + margin + thickness)
    |> yLine(length = w1 + thickness)
    |> xLine(length = -w2)
    |> yLine(length = w1 - thickness)
    |> xLine(length = w5 - thickness)
    |> yLine(length = -(w1 - thickness))
    |> xLine(length = -w2)
    |> yLine(length = -w1 - thickness)
    |> xLine(length = legLength + thickness)
    |> close()
  return coolingSketch
}

fn coolingSketchNoArms(plane, startPoint) {
  coolingSketch = startProfile(plane, at = startPoint)
    |> yLine(length = w1 - thickness)
    |> xLine(length = w2)
    |> yLine(length = w1 + thickness)
    |> xLine(length = -w5 - thickness)
    |> yLine(length = -w1 - thickness)
    |> xLine(length = w2)
    |> yLine(length = -w1 + thickness)
    |> yLine(length = -thickness)
    |> xLine(length = thickness)
    |> yLine(length = w1 + thickness)
    |> xLine(length = -w2)
    |> yLine(length = w1 - thickness)
    |> xLine(length = w5 - thickness)
    |> yLine(length = -(w1 - thickness))
    |> xLine(length = -w2)
    |> yLine(length = -w1 - thickness)
    |> xLine(length = thickness)
    |> close()
  return coolingSketch
}

fn drawCoolingSketch(@id) {
  return coolingSketch(
         plane = basePlateEndFace,
         startPoint = [
           startX - (totalWidth * id) - (w1 * id),
           startY
         ],
         legLength = legLength,
         margin = margins[id],
       )
    |> extrude(length = -csgCuttingDepthThicknessOfChannel)
}

fn drawCoolingSketchFlipped(@id) {
  return coolingSketch(
         plane = basePlateEndFace,
         startPoint = [
           startX - (totalWidth * id) - (w1 * id),
           startY
         ],
         legLength = legLength,
         margin = margins[id],
       )
    |> rotate(roll = 0, pitch = 0, yaw = 180)
    |> translate(x = 0, y = 0, z = 0)
    |> scale(x = -1, y = 1, z = 1)
    |> extrude(length = -csgCuttingDepthThicknessOfChannel)
}

// Create mounting holes
mount1 = circle(
       basePlateEndFace,
       center = [
         -plateWidth / 2 + mountingBuffer,
         plateHeight / 2 - mountingBuffer
       ],
       radius = mountingRadius,
     )
  |> extrude(length = -plateThickness)
mount2 = circle(
       basePlateEndFace,
       center = [
         -(-plateWidth / 2 + mountingBuffer),
         plateHeight / 2 - mountingBuffer
       ],
       radius = mountingRadius,
     )
  |> extrude(length = -plateThickness)
mount3 = circle(
       basePlateEndFace,
       center = [
         -(-plateWidth / 2 + mountingBuffer),
         -(plateHeight / 2 - mountingBuffer)
       ],
       radius = mountingRadius,
     )
  |> extrude(length = -plateThickness)
mount4 = circle(
       basePlateEndFace,
       center = [
         -plateWidth / 2 + mountingBuffer,
         -(plateHeight / 2 - mountingBuffer)
       ],
       radius = mountingRadius,
     )
  |> extrude(length = -plateThickness)

// Draw one half of the cooling sketchs
coolings = map([0 .. numberOfCoolingsPerSide - 1], f = drawCoolingSketch)
// Draw the other mirrored half of cooling sketchs
coolingsFlipped = map([0 .. numberOfCoolingsPerSide - 1], f = drawCoolingSketchFlipped)
// Draw the cooling sketch that connects both halves
headOfTableCooling = coolingSketchNoArms(plane = basePlateEndFace, startPoint = [0, 0])
  |> rotate(roll = 0, pitch = 0, yaw = 90)
  |> translate(x = startY, y = startHeadOfCoolingY, z = 0)
  |> extrude(length = -csgCuttingDepthThicknessOfChannel)

// Extend the ends of the cooling sketch
connector1 = startProfile(basePlateEndFace, at = [startX, startY])
  |> xLine(length = connectorLength)
  |> yLine(length = -thickness)
  |> xLine(length = -connectorLength)
  |> line(endAbsolute = [profileStartX(), profileStartY()])
  |> close()
  |> extrude(length = -csgCuttingDepthThicknessOfChannel)

connector2 = startProfile(basePlateEndFace, at = [startX, startY])
  |> xLine(length = connectorLength)
  |> yLine(length = -thickness)
  |> xLine(length = -connectorLength)
  |> line(endAbsolute = [profileStartX(), profileStartY()])
  |> close()
  |> rotate(roll = 0, pitch = 0, yaw = 180)
  |> translate(x = 0, y = 0, z = 0)
  |> scale(x = -1, y = 1, z = 1)
  |> extrude(length = -csgCuttingDepthThicknessOfChannel)