Custom Power Solution

Cell Selection & Design

Cells are the main component of a battery pack, which provide the primary power source. The voltage of a battery pack is the voltage of single cell multiplied by the series cells’ number and its capacity is the capacity of the individual chain multiplied by the number of parallel chains. For applications which require higher voltage and more capacity than a single cell can deliver, some custom battery packs are assembled with both series cells and parallel cells so that both the voltage and amp hour capacity are increased.

As there are many types of cells on the market, no single cell chemistry and standard specifications can work for all applications. We use our wealth of experience to listen to our customers’ needs and help them to select the most suitable cell types based on performance, reliability, and price. We supply not only a wide range of standard models but also custom designed ones to best meet customer's special requirements.

cell selectrion & design

Electrical Design

Either NCM cells or LiFePO4 cells can not be used directly in electronic devices. They need special protection and management circuits to keep them within their predefined voltage, current and temperature operating limits. They have to be assembled with a PCM (protection circuit module) and other components of different devices. PCM works as safety devices and it protects cells against over charge, over discharge, over current, short circuit and over heat. Sometimes more complex designs may use integrated PCM and BMS (battery management system) which provide advanced functions such as fuel gauge calculations, protection, cell balancing, thermal sensing, statues indicating lights and serial communications buses. BMS is mainly used in high power lithium ion batteries.

In battery development, we fully manage the battery design elements of your project. We work with your engineers to reduce risk in the design process and throughout the production process, and create a fully customized management system that provides the functionalities required for your product. We are committed to manufacturing customized battery management systems that are safe, effective and have the absolute lowest failure rate.

battery electrical design

Mechanical Design

Mechanical design of a battery pack has to meet the requirements for physical and electrical interfaces with the appliance as well as maintain the assembly form and protect all the components. It involves the pack shaping, housing, insulation and external contacts. The simplest and low cost way is designing a shrink-wrap packaging and wire lead terminals with or without connectors. More complex is a typical injection molded plastic case and metal contacts for more precision packs. Either an external shrink-wrap or plastic enclosure, by applying 2D/3D systems and automation equipments, we are able to design cases and contacts with high precision and reliable connection.

battery mechanical design

Battery Pack Design & Assembly

A battery pack is a set of any number of identical batteries or individual cells. Its purpose is to provide an integrated power source for applications. They may be configured in a series, parallel or a mixture of both to deliver the desired voltage, capacity, or power density. Components of battery packs include individual cells, management circuits and the interconnects which provide electrical conductivity between them. For an inline package, cells are selected and stacked with solder in between them. Cells are pressed together and a current pulse generates heat to solder them together and to weld all connections internal to the cell.

With decades of combined experience our fully equipped electrical, mechanical and industrial engineers ensure battery packs are designed and assembled the right way from the start of the project to beyond. In our production facilities highly trained assembly and production staffs are employed and continuously trained to provide advanced assembly technology for all types of modern equipments.

battery pack design & assembly

Charging Design

Lithium batteries have charging voltage and current limits. They must use the "constant current/constant voltage (CC/CV)" charging method. The battery is first charged by a set constant current until it reaches a set voltage, then charged with this constant voltage until the current falls below a set value. If charging exceeds this limit, the battery will be permanently damaged and there is a risk of fire or explosion. The charging system also affects battery performance such as runtime and cycle life. Therefore, charging must be strictly controlled. Special consideration is required when designing a charging system to ensure the battery is both fully charged and not over charged.

We use the world high precise circuit components to monitor and control the current and voltage statues. The chargers are compact, portable, universal and safe. It can be customized with various outputs, to meet different demands. With CPU control and PWM technology they have the advantages as high efficiency, good stability, low-carbon and energy saving. Three section charging modes can control the charging current and voltage automatically and precisely and both ensure that battery is charged fully and not over charged.

battery charging design

System Integration

With the industry leading technical knowledge and extensive experience we can provide complete power system solutions, ranging from advanced cells, battery packs, managing system, charging to power supplies. We begin the design process by understanding customers’ performance targets for the final product. The first step in this process is to collect as much performance information as possible, including electrical characteristics, mechanical characteristics, environment conditions, testing and qualification etc. If you did not find one of our standard products that can meet all your requirements, simply contact us. Our well experienced team can work closely with you to customize them to perfectly suit your particular needs.

system integration

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