Custom-Size Industrial Lithium Battery Pack
Engineered for industrial OEMs whose equipment requires exact physical dimensions and specific electrical profiles. Unlike off-the-shelf modules, these packs are custom-configured in length, width, height, and terminal layout to fit constrained equipment compartments. Built using tier-one cylindrical or prismatic cells (LiFePO4 or NMC) paired with programmable Battery Management Systems (BMS), they serve as direct, drop-in replacements for legacy lead-acid batteries or custom power upgrades for new machinery designs.
Key Features
Precision Form Factor: Custom enclosure dimensions mapped directly to your equipment chassis, eliminating spatial waste.
High Discharge Capability: Supports continuous high-current draws with minimal voltage sag, matched to heavy motor startup requirements.
Advanced Cell Chemistry: Utilizes stable LiFePO4 chemistry for extended thermal stability, or NMC for high-energy-density compactness.
Smart BMS Protection: Real-time monitoring of cell voltage, pack temperature, and current. Includes hardware-level protection against overcharge, over-discharge, short circuits, and extreme temperatures.
Cycle Longevity: Delivers over 3,000 cycles at 80% Depth of Discharge (DoD) under nominal operating conditions (tested at 0.5C charge/discharge rate and 25°C ambient temperature).
Technical Specifications
|
Parameter |
Specification Range (Customizable) |
|
Nominal Voltage |
12.8V to 96V (custom configurations available) |
|
Capacity Range |
10Ah to 300Ah+ |
|
Energy Capacity |
128Wh to 15kWh+ |
|
Cell Chemistry |
LiFePO4 (Lithium Iron Phosphate) / NMC |
|
Max Continuous Discharge |
Up to 3C (application-dependent) |
|
Communication Protocols |
CAN2.0B, RS485, SMBus, UART |
|
Operating Temperature |
Charge: 0°C to 45°C; Discharge: -20°C to 60°C |
|
Ingress Protection |
IP54 to IP67 (sealed housing options) |
Compatibility & Applications
Designed for integration into electrically demanding industrial environments:
AGVs & AMRs: Low-profile dimensions engineered for under-chassis mounting with high-speed charging support.
Material Handling: Electric pallet jacks and tuggers requiring robust shock and vibration resistance.
Industrial Floor Cleaners: Strict sizing constraints for scrubber-dryer battery compartments.
Portable Medical & Diagnostic Carts: Stable low-noise power delivery with medical-grade isolation standards.
Robotics & Automation: Rapid transient response for multi-axis servo and actuator loads.
BMS Customization: Custom firmware parameters, sleep-mode current thresholds, custom discharge cut-offs, and specific CANBus register maps for PLC integration.
Figure 2: Production line execution featuring automated spot welding and automated test equipment (ATE) cell validation.
Quality Control & Testing
Internal manufacturing incorporates strict process controls and verification steps prior to dispatch:
Cell Sorting: Internal Resistance (IR) and voltage matching within 1mΩ and 5mV to prevent cell imbalance.
Spot Welding Inspection: Automated pneumatic resistance spot welding with pull-force shear testing.
BMS Functional Test: Automated Test Equipment (ATE) verification of protection thresholds, current limiters, and communication handshake protocols.
Aging & Load Testing: 100% full-charge/discharge cycle testing under simulated operational loads.
Environmental & Safety Tests: Vibration table testing (simulating transport and rough terrain), thermal chamber cycling, and short-circuit protection verification.
Compliance Documentation: UN38.3 test summaries, MSDS, CE, and IEC62133 documentation available for cargo and equipment export.
Packaging & Shipping
Dangerous Goods Packaging: Complies with PI965 / PI966 Section II UN3480/UN3481 regulations for lithium-ion battery transport.
Internal Protection: Custom high-density EPE foam cushioning and insulated terminal caps to prevent transit short-circuits.
Outer Carton: Heavy-duty double-wall corrugated export cartons or fumigation-free wooden crates for heavy packs.
Logistics Support: Complete documentation package provided (Shipper's Declaration for Dangerous Goods, UN38.3 test report, MSDS) for air, sea, or land freight.
FAQ
Q: What is the minimum order quantity (MOQ) for a custom-size battery pack?
A: Prototype and engineering sample orders start at 1 unit. Batch production MOQs depend on tooling and enclosure customization requirements, typically starting at 20–50 units per batch.
Q: How do we specify the exact physical dimensions for our equipment?
A: Provide a 2D/3D CAD file (STEP or IGES format) of your battery compartment, along with clearance limits, center of gravity requirements, and mounting bracket locations.
Q: Can these packs replace existing lead-acid batteries directly?
A: Yes. Output voltage curves, terminal types, and physical footprints can be engineered as drop-in replacements, though charger profiles must match lithium charging parameters (CC/CV).
Q: What communication protocols are supported by the BMS?
A: Standard firmware supports CAN2.0B and RS485. Custom register maps can be flashed to interface directly with your host controller or PLC.
Q: What safety certifications are provided with shipment?
A: Each batch is delivered with individual test reports covering cell matching, internal resistance, and BMS cutoff verification. UN38.3 test summaries are standard for transport compliance.
Q: What is the typical lead time for custom samples?
A: Standard sample fabrication, testing, and delivery take 2 to 3 weeks following mechanical drawing sign-off and electrical specification approval.
Request a Quote
To facilitate a prompt and accurate engineering proposal, please provide your project parameters below:
Application Type: AGV / AMR / Industrial Floor Scrubber / Material Handling / Medical Cart / Other
Target Voltage (V): Input field
Target Capacity (Ah): Input field
Maximum Enclosure Dimensions (L x W x H in mm): Input fields
Continuous / Peak Discharge Current (A): Input fields
Communication Protocol: CAN2.0B / RS485 / SMBus / UART / None
Upload 3D CAD Drawing (STEP/IGES preferred): Choose File Button
Estimated Annual Quantity & Delivery Timeline: Input fields
Submit Engineering RFQ
Hot Tags: custom-size industrial lithium battery pack, China custom-size industrial lithium battery pack manufacturers, suppliers, factory
