Heavy-duty lithium battery pack engineered for industrial utility vehicles, material handling equipment, and commercial electric fleets. Built as a direct, maintenance-free drop-in lead-acid replacement lithium battery, this system delivers stable voltage output under high-drain loads, vibration, and extreme temperature shifts. Designed for OEM integration and heavy retrofits, it combines high energy density with robust thermal management.
Compatibility & Applications
Engineered for seamless integration into existing battery compartments and electrical architectures.
Target Vehicle Types:
Airport Baggage Tractors & Ground Support Equipment (GSE)
Warehouse Utility Carts & Burden Carriers
Automated Guided Vehicles (AGVs) & Autonomous Mobile Robots (AMRs)
Industrial Floor Scrubbers & Sweepers
Mechanical Fit: Standardized drop-in form factors or custom-extruded aluminum/steel chassis designed to match OEM battery tray dimensions.
Electrical Integration: Programmable CAN bus communication interfaces ensure direct handshake compatibility with standard motor controllers (Curtis, Sevcon, Zapi).
Key Features
High Cycle Life: Delivers over 4,000 cycles at 80% Depth of Discharge (DoD) at 25°C, lowering total cost of ownership over the vehicle's operational lifecycle.
Smart BMS Integration: Real-time monitoring of cell voltage, pack temperature, and current. Features hardware-level short-circuit, over-charge, over-discharge, and thermal runaway protection.
High Discharge Capability: Supports high continuous and peak discharge currents to maintain vehicle torque during steep inclines and heavy load transport.
Fast & Opportunity Charging: Accepts high current charging rates, enabling full or partial rapid charges during shift breaks without memory effect.
Rugged Mechanical Design: Welded steel enclosure with internal shock-absorbing dampening to withstand continuous vehicle vibration on uneven industrial surfaces.
Technical Specifications
|
Parameter |
Specification |
|
Nominal Voltage |
48V / 72V / 80V (Customizable) |
|
Rated Capacity |
100Ah to 400Ah |
|
Energy Density |
5.12kWh to 32.0kWh |
|
Chemistry |
Lithium Iron Phosphate (LiFePO₄) |
|
Continuous Discharge Current |
150A – 300A (Model Dependent) |
|
Peak Discharge Current |
400A (30s) |
|
Communication Protocol |
CAN 2.0B, CANopen, RS485 |
|
Ingress Protection |
IP67 (Enclosure & Connectors) |
|
Operating Temperature |
Charge: 0°C to 45°C; Discharge: -20°C to 60°C |
|
Certifications |
UN38.3, CE, IEC 62133, UL 2580 (Cell level) |
Customization Options
We support custom engineering for specialized vehicle architectures and operational environments:
Electrical Dimensions: Voltage scaling from 24V to 96V; capacity configuration via parallel/series cell grouping.
Mechanical Enclosure: Custom sheet metal dimensions, mounting bracket placement, and terminal/connector positioning (Anderson, REMA, DIN).
Communication & Monitoring: Tailored CAN bus protocol mapping, custom dashboard display integration, and optional telemetry/GPS module integration.
Thermal Management: Integration of low-temperature self-heating films for operation in cold-storage warehouses or winter environments down to -30°C.
Manufacturing & Quality Control
Manufactured in our ISO 9001 and IATF 16949 certified facility utilizing automated laser welding and strict cell sorting protocols.
Cell Sorting & Matching: Incoming prismatic cells are sorted by internal resistance (≤ 0.5mΩ) and capacity (± 1%) to prevent internal imbalances.
Production Line Testing:
Automated optical inspection (AOI) for busbar connections.
100% Weld pull-force testing.
High-pot (dielectric) testing at 2500VDC.
Aging & End-of-Line (EOL) Testing: Every finished pack undergoes full-cycle charge-discharge testing, BMS functional validation, and simulated load testing prior to packaging.
Documentation: Each shipment includes individual test reports, capacity matching data, and MSDS.
Packaging & Shipping
Packaging: Heavy-duty wooden crates compliant with ISPM 15 standards, utilizing custom anti-static foam bracing to prevent shock during transit.
Dangerous Goods Logistics: Transported in accordance with UN 3480 Class 9 hazardous materials regulations.
Documentation Support: Provision of UN38.3 test summaries, Dangerous Goods Declaration (DGD), and sea/air freight booking support.
Lead Time: Standard production and delivery: 2 to 3 weeks. Custom configurations: 4 to 6 weeks.
FAQ
Q: Can this battery directly replace lead-acid batteries in older utility vehicles?
A: Yes. Physical dimensions match standard industrial battery trays, and the discharge voltage profile is compatible with existing motor controllers. Verify compartment dimensions and continuous current draw prior to selection.
Q: How does the BMS communicate with the vehicle dashboard?
A: The integrated BMS outputs real-time telemetry (State of Charge, temperature, fault codes) via standard CAN 2.0B or CANopen protocols, connecting directly to the vehicle's instrument cluster or VCU.
Q: What charging equipment is required?
A: A dedicated LiFePO₄ profile charger with matching voltage and communication handshaking (if required) must be used. We supply compatible high-frequency industrial chargers upon request.
Q: What is the lead time for standard versus custom models?
A: Standard stock models ship within 7 to 14 days. Custom mechanical enclosures or specialized CAN protocols typically require 4 to 6 weeks for prototyping and validation.
Q: How is thermal safety handled during high-drain operation?
A: The internal BMS continuously monitors cell temperatures across multiple sensors. If thresholds exceed safe operating limits (60°C discharge), the BMS cuts power output to prevent thermal runaway.
Q: What warranty terms apply to volume purchases?
A: Standard industrial warranty covers 5 years or 4,000 cycles (whichever occurs first) under normal operating parameters. Extended warranty agreements are available for OEM contracts.
Request a Quote
To receive a technical proposal and volume pricing, please provide the following details to our engineering team:
1.Vehicle make and model (or application type)
2.Target system voltage (V) and capacity (Ah or kWh)
3.Maximum continuous and peak operating current (A)
4.Battery compartment spatial limitations (Length × Width × Height in mm)
5.Required communication protocol (CANopen, J1939, or none)
6.Annual volume and target delivery schedule
[Submit Technical Inquiry / Request Specification Sheet]
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