Low-Speed Electric Vehicle LiFePO4 Battery Pack
Engineered for low-speed electric vehicles, commercial utility carts, and industrial transport equipment, this LiFePO4 battery pack serves as a direct, drop-in replacement for legacy lead-acid systems. Built around automotive-grade lithium iron phosphate cells and an industrial-grade Battery Management System (BMS), the assembly delivers stable voltage curves under high-load acceleration, reduced vehicle weight, and zero routine maintenance. Manufactured in our ISO9001-certified facility via automated laser welding and rigorous cell grading, each power pack is mechanically and electrically configured to match custom vehicle chassis enclosures and motor controller specifications.
Key Features
High-Current Power Delivery: Sustains continuous discharge currents up to 150A with transient peak capabilities designed for steep grade climbing and heavy vehicle startup.
Extended Operational Life: Exceeds 4,000 charge-discharge cycles at 80% Depth of Discharge (DoD) at 25°C, reducing total lifecycle replacement costs for commercial fleets.
Integrated Hardware & Software BMS: Real-time monitoring of cell voltages, internal pack temperatures, and current draw. Incorporates active balancing, short-circuit isolation, thermal cutoffs, and over/under-voltage protection.
Standardized CAN Bus / RS485 Telemetry: Interfaces directly with industry-standard motor controllers (e.g., Curtis, Sevcon) for real-time dashboard data transmission and diagnostics.
Rugged Mechanical Construction: Internal frame utilizes welded steel structural bracing and vibration-dampening insulation, validated to IEC 60068-2-6 standards for severe off-road and industrial environments.
Technical Specifications
|
Specification |
48V Standard Configuration |
72V Standard Configuration |
|
Nominal Voltage |
51.2V |
71.8V |
|
Rated Capacity |
100Ah / 150Ah / 200Ah |
100Ah / 150Ah |
|
Total Energy |
5.12 kWh - 10.24 kWh |
7.18 kWh - 10.77 kWh |
|
Cell Chemistry |
LiFePO4 (Lithium Iron Phosphate) |
LiFePO4 (Lithium Iron Phosphate) |
|
Max. Continuous Discharge |
100A - 150A |
100A - 150A |
|
Peak Discharge Current |
300A (30 seconds) |
300A (30 seconds) |
|
Recommended Charge Voltage |
58.4V |
82.1V |
|
Communication Protocol |
CAN 2.0 / RS485 |
CAN 2.0 / RS485 |
|
Operating Temperature |
Charge: 0°C to 45°C / Discharge: -20°C to 60°C |
Charge: 0°C to 45°C / Discharge: -20°C to 60°C |
|
Ingress Protection (IP) |
IP67 Sealed Enclosure |
IP67 Sealed Enclosure |
|
Enclosure Dimensions |
Customized to specific vehicle tray blueprints |
Customized to specific vehicle tray blueprints |
|
Total Weight |
Approx. 45 kg - 85 kg |
Approx. 65 kg - 110 kg |
Compatibility & Applications
Designed for factory integration or aftermarket fleet conversion across multiple low-speed mobility sectors:
Neighborhood Electric Vehicles (NEVs) & Low-Speed Vehicles (LSVs)
Commercial Golf Carts, Resort Shuttles, and Campus Patrol Cars
Airport Ground Support Equipment (GSE) & Cargo Tugs
Industrial Floor Scrubbers, Sweepers, and Automated Guided Vehicles (AGVs)
Integration Checklist: Requires verification of physical compartment dimensions, terminal lug configurations (M8 standard), and protocol synchronization with existing motor controllers via CAN bus mapping.
Customization Options
We execute custom engineering modifications to match exact vehicle chassis designs:
Electrical Architecture: Voltage scaling from 24V up to 96V; capacity scaling up to 400Ah.
Enclosure Engineering: Custom cold-rolled steel, stainless steel, or aluminum alloy housings engineered to non-standard compartment dimensions and specific mounting hole patterns.
Terminal & Interface Layout: Anderson power connectors, Amphenol heavy-duty plugs, or bolted busbar terminals routed to match existing vehicle wiring harnesses.
Advanced BMS Features: Tailored hardware protection thresholds, custom CAN bus ID mapping, and optional low-temperature heating film integration for sub-zero operating conditions.
Quality Control & Manufacturing Standards
Production is executed entirely in-house on automated assembly lines to eliminate manual variance:
Cell Matching & Sorting: Internal DC resistance and capacity are sorted within a strict 1% tolerance window prior to module grouping.
Automated Laser Welding: Cell busbars are joined via automated laser welding to ensure minimal contact resistance and high mechanical shear strength under vehicle vibration.
End-of-Line (EOL) Testing: Every single battery pack undergoes 100% automated test cycling, internal resistance profiling, high-potential (Hi-Pot) dielectric strength testing (2500VDC), and BMS firmware verification.
Traceability System: Laser-etched data matrices on every cell and master pack record raw material batches, production operator IDs, and complete EOL test logs.
Regulatory Compliance: Manufactured in an ISO9001-certified facility; UN38.3, CE, and RoHS test summaries available upon engineering request.
Packaging & International Shipping
Dangerous Goods Packaging: Packed strictly inside UN-certified wooden crates (compliant with IATA P965/P966 regulations) with high-density EVA structural foam cushioning to absorb transit impact.
State of Charge (SoC): Transported at an optimized 30% SoC in compliance with international maritime and air cargo safety mandates.
Export Documentation Package: Complete documentation provided for customs clearance, including UN38.3 Test Summaries, Material Safety Data Sheets (MSDS), and Dangerous Goods Declarations (DGD).
FAQ
Q: Can this LiFePO4 battery pack drop directly into existing lead-acid vehicle compartments?
A: Yes. Mechanical dimensions can be custom-engineered to drop into existing lead-acid tray footprints, and the voltage operating range aligns with standard motor controllers. Note that a dedicated LiFePO4 profile charger (CC/CV charging algorithm) must be utilized.
Q: What is the typical lead time for prototype samples versus mass production orders?
A: Standard-spec evaluation samples are completed within 15 days. Custom enclosure designs and specialized BMS parameter samples require 25 to 30 days. Volume production orders typically ship within 35 to 45 days depending on raw material scheduling.
Q: How does the BMS integrate with our vehicle's onboard computer or display?
A: The integrated BMS features a standard CAN 2.0 data port. We supply the complete CAN protocol DBC file, allowing your engineering team to map state-of-charge (SoC), pack voltage, thermal metrics, and diagnostic fault codes directly to your digital dashboard.
Q: What third-party safety certifications back this battery assembly?
A: Individual cells and assembled packs undergo rigorous testing according to UN38.3 (transportation safety), IEC 62190 (safety requirements), and UL 2273 standards. Complete test reports can be shared under a mutual Non-Disclosure Agreement (NDA).
Q: What is the engineering workflow if a custom metal enclosure is required?
A: Submit your 3D CAD files (STEP format) or physical tray dimensions, electrical voltage targets, and discharge current profiles to our technical team. We return a comprehensive mechanical drawing and electrical proposal within 48 hours.
Q: What warranty coverage applies to commercial fleet deployments?
A: We provide a 5-year or 4,000-cycle commercial warranty (whichever occurs first), backed by life-cycle data logging securely stored within the BMS flash memory.
Request a Project Quotation
To receive a technical specification proposal and commercial quotation for your application, please provide the following parameters to our engineering team:
1.Vehicle Type & Operating Environment: (e.g., Golf Cart, Utility Vehicle, AGV)
2.Target Nominal Voltage & Capacity: (e.g., 48V 150Ah)
3.Continuous & Peak Discharge Current: (Amps)
4.Available Installation Enclosure Space (L x W x H mm):
5.Estimated Annual Volume / Trial Batch Quantity:
6.Destination Port / Country:
[Submit Project Specification / Contact Engineering Team]
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