Custom-Voltage LiFePO4 Battery Pack
Engineered for OEM industrial equipment, our custom-voltage LiFePO4 battery packs deliver stable power, integrated BMS protection, and exact mechanical integration for your application. We design and manufacture cells, BMS, and structural housings in-house to meet specific electrical and spatial constraints.
Key Features
Chemistry & Stability: Utilizes grade-A lithium iron phosphate cells providing thermal stability up to 60°C and inherent resistance to thermal runaway.
Cycle Life: Delivers >= 4,000 cycles at 80% DoD (Depth of Discharge) under standard operational temperatures (25°C).
Integrated BMS: Real-time monitoring of cell voltage, pack temperature, and current. Built-in hardware protection against over-charge, over-discharge, short-circuit, and cell imbalance.
Communication Integration: Supports standard industrial protocols including CAN 2.0B, RS485, and SMBus for real-time telemetry integration with host systems.
High Discharge Capability: Continuous discharge rates up to 3C and peak rates up to 5C (application-dependent) with minimal voltage sag.
Technical Specifications
|
Parameter |
Specification Range |
|
Nominal Voltage Range |
12.8V to 614.4V (Fully configurable in series/parallel topologies) |
|
Capacity Range |
10Ah to 500Ah+ |
|
Energy Density |
140Wh/kg to 175Wh/kg (Cell level) |
|
Operating Temperature |
Charge: 0°C to 45°C; Discharge: -20°C to 60°C |
|
Casing Material |
Cold-rolled steel, anodized aluminum alloy, or flame-retardant ABS (UL94-V0) |
|
Ingress Protection |
IP54 to IP67 (Customizable for harsh environments) |
|
Certifications |
UN38.3, CE, IEC62133, UL1973 (as required per project) |
Compatibility & Applications
Built for industrial systems requiring precise voltage matching and strict spatial envelopes.
AGV & AMR Robotics: Low-profile 24V and 48V configurations with high continuous current output for continuous material handling shifts. (Proven track record: Custom 48V 100Ah pack deployed in 500+ industrial AGVs).
Industrial Energy Storage (ESS): High-voltage rack-mounted configurations (100V - 600V+) for microgrids and commercial backup power.
Medical Carts & Diagnostics: Lightweight, maintenance-free power supplies with medical-grade isolation and SMBus data reporting.
Marine & Special Vehicles: Vibration-resistant packs with IP65+ enclosures designed for harsh marine environments.
Customization Options
We adapt our manufacturing lines to match your exact electrical and physical requirements.
Electrical: Custom nominal voltage (non-standard steps supported), total capacity, and discharge current profiles.
Mechanical: Custom footprint, height restrictions, mounting bracket locations, and terminal placements (Anderson, Amphenol, heavy-duty studs).
BMS Firmware: Customized cut-off thresholds, sleep modes, pre-charge circuits, and communication baud rates.
Enclosure: Metal stamping, CNC machining, and laser welding executed in our facility to ensure precise tolerances.
Manufacturing & Quality Control
Our 15,000 m2 production facility houses automated cell sorting, laser welding, and pack assembly lines, ensuring consistent batch quality from prototype to volume production.
Cell Matching: Internal resistance matched within 1mΩ and voltage matched within 5mV prior to module assembly.
Welding Inspection: CCD optical inspection and resistance checks on all nickel-strip laser welds.
End-of-Line (EOL) Testing: 100% automated testing of pack communication, BMS protection functions, insulation resistance (>50MΩ at 500V DC), and dynamic load performance.
Traceability: Laser-etched barcodes on every pack record raw material lots, cell test data, and EOL test logs.
Packaging & Shipping
Lithium battery transport requires strict adherence to international dangerous goods regulations.
Packaging: UN-certified fiberboard boxes, custom high-density polyethylene (HDPE) foam inserts, and insulated terminals to prevent short circuits during transit.
Documentation: MSDS, UN38.3 test summary reports, and Dangerous Goods Declaration (DGD) provided for air (PI965/PI966) and sea freight (IMO Class 9).
FAQ
Q: What is the typical lead time for a custom-voltage sample?
A: Standard custom prototypes are assembled and tested within 3 to 4 weeks, including BMS parameter configuration and mechanical enclosure fabrication.
Q: Can the BMS communicate with our existing PLC or host controller?
A: Yes. Our BMS firmware supports custom CANopen or RS485 register maps to integrate directly with your system controller for state-of-charge (SoC) and fault monitoring.
Q: What is the minimum order quantity (MOQ) for custom dimensions?
A: Proto-runs start at 1 unit for engineering evaluation. Volume production MOQs depend on custom tooling requirements for sheet metal or plastic injection parts.
Q: How do you handle thermal management in high-discharge packs?
A: We integrate aluminum thermal pads, phase-change materials, or liquid-cooling plates depending on the continuous discharge rate and ambient operational limits.
Q: Are your batteries compliant with international export standards?
A: All packs are manufactured in an ISO9001-certified facility and pass UN38.3 safety testing, enabling legal global transit.
Q: What data is included in the pre-shipment test report?
A: Each report includes cell sorting data, internal resistance values, capacity test curves, insulation breakdown test results, and BMS functional verification logs.
Request a Quote
Provide your project parameters below to initiate an engineering review. Our engineering team responds within 24 hours with a preliminary electrical and mechanical feasibility assessment.
Application Type: (e.g., AGV, Medical Cart, ESS)
Target Operating Voltage: (V)
Capacity Requirement: (Ah or Wh)
Maximum Dimensions: (Length x Width x Height in mm)
Continuous / Peak Discharge Current: (A)
Communication Protocol Needed: (CAN / RS485 / None)
Estimated Annual Quantity: (Units)
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