Author Archives: marketing@bemovedmedia.com

  1. Design Proposal Case Study: Compact Li-Ion Battery Design for Outdoor Surveillance Equipment

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    SUMMARY

    Excell Battery solved three critical challenges for a surveillance equipment manufacturer requiring a custom 15Ah Li-Ion battery pack for outdoor cameras: enabling safe charging in sub-freezing temperatures (with a self-heating system), delivering prototypes in an accelerated 8 week timeline (by prioritizing standard components over custom development), and supporting global manufacturing operations (leveraging Ultralife Corporation’s international production network for localized battery supply).

    The resulting 3S3P 21700 cell configuration with integrated 12W polyimide heater extends Li-Ion charging capability from the standard 5°C minimum down to -20°C ambient conditions, while the accelerated development approach and global manufacturing support provide competitive advantages for the OEM’s international operations.

    Li-Ion outdoor surveillance camera battery design
    Li-Ion outdoor surveillance camera battery design rendering.

    Table of Contents

    1. PROJECT OVERVIEW

    The Challenge (Real Problem)

    A surveillance equipment manufacturer required a battery solution for their next-generation camera system. The project presented three critical challenges that demanded innovative engineering solutions and strategic manufacturing approaches.

    Primary Engineering Challenges & Solutions:

    1. Cold Weather Charging Capability

    • Core Problem: Li-Ion batteries cannot be safely charged below freezing temperatures, however, battery needs to be able to charge in freezing conditions while maintaining safety standards.
    • Operational Requirements: Discharge operation from -20°C to 60°C, but charging limited to 5°C to 45°C without intervention
    • Solution: Integrated 12W polyimide heater powered by the battery’s own stored energy to warm cells above 5°C charging threshold, enabling safe charging in -20°C ambient conditions. See DESIGN SPECIFICATIONS section for more.

    2. Accelerated Development Timeline

    • Core Problem: Prototype delivery needed in 8 weeks vs. typical 6-month development timeline
    • Operational Requirements: Fast time-to-market prioritized to meet competitive positioning
    • Solution: Prioritized proven, off-the-shelf components (standard fuel gauge/protector IC with I2C interface) over custom firmware development to reduce design risk and validation time. See SYSTEM INTEGRATION, MANUFACTURING, AND REGULATORY STRATEGIES section for more.

    3. Global Manufacturing Requirements

    • Core Problem: OEM manufacturing operations across multiple international locations
    • Operational Requirements: Battery production needed to be localized near final device assembly sites
    • Technical Constraint: Solution must support distributed manufacturing while maintaining consistency
    • Solution: Leveraged Ultralife Corporation’s international manufacturing network to enable localized battery production with reduced shipping costs, lead times, and supply chain complexity. See SYSTEM INTEGRATION, MANUFACTURING, AND REGULATORY STRATEGIES section for more.

    Additional Technical Constraints:

    • Space Limitation: Maximum envelope of 3.5″ × 2.5″ × 5.1″
    • Power Demands: 15Ah capacity, 3A nominal/6A peak discharge current
    • Regulatory Compliance: UN38.3 transport and IEC62133-2 safety standards

    Solution Approach

    System Architecture: 3S3P Li-Ion configuration using 21700 cells

    Key Components:

    • 9× 5.0Ah 21700 cells (3.6V nominal)
    • fuel gauge/protector IC
    • 12W polyimide thin film heater with PTC thermostat at 55°C
    • Custom molded support frames in trapezoidal layout

    Target Specifications:

    • Capacity: 15Ah at 10.8V nominal voltage
    • Compact Design: Estimated dimensions approximately 3″ × 2″ × 4.75″
    • Operating Range: -20°C to 60°C discharge with integrated heating
    • Communication: I2C interface for system integration

    2. DESIGN SPECIFICATIONS

    Cell Selection and Configuration

    Component Specifications:

    • Cell Type: 21700 format
    • Individual Capacity: 5.0Ah @ 3.6V nominal @ 0.2C discharge rate
    • Configuration: 3S3P (3 series, 3 parallel)
    • Voltage Range: 7.5V minimum to 12.6V maximum

    Design Rationale: The 21700 format was selected to meet the capacity requirements within the space constraints. The 3S3P configuration provides the required 10.8V nominal voltage while achieving 15Ah capacity through parallel cell arrangement.

    Innovative Mechanical Layout

    Trapezoidal Cell Arrangement: The design employs a trapezoidal layout rather than conventional rectangular arrangement to optimize space utilization within the dimensional constraints.

    Implementation Details:

    • Support Structure: Molded plastic support frames ensure proper cell spacing
    • Interconnect Strategy: PCB placement on one side of the cell assembly with direct tab connections
    • Housing: Molded cell frames with PVC shrink covering
    • PCB Integration: Side-mounted PCB retained by support frames

    Integration Considerations: The trapezoidal layout enables the heater element to contact the sides of all cells for thermal management.

    Battery Management System Design

    Core IC Selection:

    • Interface: I2C/SMBus compliant communication
    • Functions: Fuel gauging and protection
    • Development Advantage: Standard interface reduces development time compared to custom MCU firmware

    Serial Number Handling: The customer’s serial number format exceeds the standard 2-byte SN register capacity. Solution approach includes storing the serial number in Manufacturer Info registers (32 bytes available) or separate EEPROM on the same I2C bus.

    Self-Heating Thermal Management Strategy:

    • Core Challenge: Li-Ion batteries cannot be safely charged below 0°C, limiting outdoor operation
    • Innovative Solution: 12W polyimide heater powered by battery’s own stored energy brings cells above 5°C charging threshold
    • Operating Temperature: Discharge -20°C to 60°C, charging 5°C to 45°C (extended to sub-freezing operation via self-heating)
    • Protection Strategy: Hardware-based PTC thermostat provides primary thermal protection independent of software control

    3. SYSTEM INTEGRATION, MANUFACTURING, AND REGULATORY STRATEGIES

    System Integration

    Communication Protocol: I2C interface provides battery monitoring data to the host system. The component selected offers standard SMBus protocol implementation with comprehensive documentation.

    Development and Manufacturing Approach

    Prototype Strategy:

    • EVT Phase: 3D printed plastic frames for rapid prototyping (50 samples estimated)
    • DVT Phase: First injection molded parts to validate tooling (300 samples estimated)
    • Component Risk Mitigation: Early component ordering ahead of design completion to address lead time challenges

    Accelerated Development Timeline:

    • Mitigation Strategy: Prioritized standard, proven components over custom development to reduce design and validation time
    • Risk Management: Early component procurement with customer approval for design changes
    • Component Strategy: Selected established ICs with comprehensive documentation rather than custom firmware solutions

    Global Manufacturing Strategy:

    • Solution: Ultralife Corporation’s global manufacturing network enables battery production near final assembly sites
    • Advantages: Reduced shipping costs, shorter lead times, and simplified supply chain management for international operations
    • Scalability: Consistent battery specifications maintained across all manufacturing locations

    Regulatory and Safety Considerations

    Safety Standards Compliance and Testing:

    • Testing Strategy: UN samples built with first molded plastics to avoid schedule conflicts
    • UN38.3: Transport safety requirements. 16 samples required for transport certification.
    • IEC62133-2: Battery safety standard. 30 samples required for safety certification.
    • Additional: Customer responsible for FCC, NDAA, RoHS, TAA compliance

    Design for Safety:

    • Enclosure Requirements: Battery enclosed within end device, not end-user accessible
    • IP Rating: Applied to product as whole; battery itself does not require IP rating
    • Cell Qualification: 21700 cells specified for 800 cycles to 80% capacity at 0.5C charge, 1C discharge at 25°C

    4. KEY CONSIDERATIONS

    Design Decision Framework

    Cell Format Selection Criteria:

    • Capacity Density: 21700 format selected for optimal energy density within space constraints
    • Availability: Current manufacturing parts with confirmed stock availability
    • Qualification: No NRND (Not Recommended for New Design) or EOL (End of Life) parts used

    BMS Architecture Decisions:

    • Standard vs. Custom: Standard IC chosen to prioritize time-to-market over custom firmware development
    • Communication Interface: I2C selected for balance of functionality and development speed
    • Component Selection: All parts specified as currently manufactured with available stock

    Common Design Challenges and Solutions

    Space Optimization:

    • Challenge: Fitting required capacity within strict dimensional limits
    • Approach: Non-rectangular cell arrangement and side-mounted PCB placement
    • Consideration: Outer frame dimensions can be modified from trapezoidal to rectangular for mounting requirements without changing internal cell layout

    Cold Weather Operation:

    • Challenge: Li-Ion performance degradation at low temperatures
    • Solution: Integrated heating element with contact to all cells
    • Safety: Hardware-based thermal protection independent of BMS

    Development Timeline Pressure:

    • Challenge: Component lead times vs. accelerated schedule
    • Mitigation Strategy: Early component procurement with customer approval for design changes
    • Risk Management: Components ordered ahead of final design validation

    Key Technical Considerations

    Thermal Design:

    • Heater Sizing: 12W power level specified for application requirements
    • Distribution: Polyimide film heater enables uniform contact with cell surfaces
    • Control: PTC thermostat provides fail-safe protection at 55°C

    Manufacturing Transition:

    • Prototype to Production: 3D printed frames for EVT, injection molded for DVT/PVT
    • Tooling Risk: Mechanical confirmation required early in EVT phase to enable tooling order
    • Volume Scaling: Design accommodates estimated production volumes (1000+ PVT, 45,000+ annual forecast)

    Development Investment Structure

    Payment Schedule:

    1. Project Initiation
    2. Final Design Completion
    3. EVT Prototype Delivery
    4. DVT Approval

    Considering similar battery design challenges? Contact Excell Battery’s engineering team for technical consultation on space-constrained, environmentally demanding applications.

  2. Ensuring Safe Transit: Understanding UN 38.3 Battery Testing

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    For OEM manufacturers, battery transportation safety regulations are critical  considerations in the product development process. For those incorporating lithium battery solutions into industrial, medical device, or remote monitoring/remote sensing applications , understanding UN 38.3 testing requirements is essential. This guide will help you navigate these requirements and illustrate how Excell Battery can streamline your compliance process.

    What is UN 38.3 Testing?

    UN 38.3 is a series of safety tests established by the United Nations Recommendations on the Transport of Dangerous Goods. These tests specifically address the safe transportation of lithium batteries, whether individual cells or complete battery packs. For any device containing lithium or lithium-ion cells, UN 38.3 testing is mandatory before legal shipment can occur.

    This testing standard isn’t merely a bureaucratic hurdle—it’s a critical safety protocol designed to ensure that lithium batteries can withstand the varied conditions encountered during transport without creating hazardous situations.

    Why Engineers Should Prioritize UN 38.3 Compliance

    When designing equipment powered by lithium battery packs, transportation logistics must be considered early in the development process. Compliance with UN 38.3 is a fundamental requirement for the legal transport of lithium batteries by air, sea, and land in most countries worldwide.

    Non-compliance can lead to:

    • Significant project delays
    • Regulatory penalties
    • Transportation restrictions
    • Potential safety incidents
    • Product launch setbacks

    Understanding these requirements in advance allows for more accurate project timelines and reduces the risk of unexpected compliance issues derailing your development schedule.

    The Eight Critical Tests of UN 38.3

    UN 38.3 testing comprises eight rigorous tests designed to simulate various stresses that batteries might encounter during transportation:

    • T1 – Altitude Simulation: Tests battery performance under low-pressure conditions equivalent to air transport at 15,000 meters.
    • T2 – Thermal Test: Evaluates stability during extreme temperature variations (from -40°C to +75°C).
    • T3 – Vibration: Assesses resilience to transport-related vibrations across three perpendicular mounting positions.
    • T4 – Shock: Tests the battery’s ability to withstand impact and sudden acceleration changes.
    • T5 – External Short Circuit: Evaluates safety mechanisms when subjected to external short circuiting.
    • T6 – Impact/Crush: Assesses mechanical stress tolerance under impact (cells) or crushing force (batteries).
    • T7 – Overcharge: Examines built-in protection against dangerous overcharging conditions.
    • T8 – Forced Discharge: Tests safety under conditions where cells are forcibly discharged.

    Only after successfully completing all applicable tests can a battery be certified for transportation.

    Planning for UN 38.3 Testing: Timeline and Resource Requirements

    For realistic project planning, it’s crucial to understand the resources and time required for UN 38.3 testing:

    • Testing Cost: Approximately $2,500 USD
    • Sample Requirements: Around 16 battery packs must be provided for testing
    • Timeline: Typically 6-8 weeks for complete testing and certification

    These factors must be incorporated into your development schedule and budget to avoid unexpected delays in your product launch timeline.

    Simplifying Compliance with Excell Battery Solutions

    At Excell Battery, we understand the technical and regulatory challenges engineers face when incorporating lithium battery technology into their designs. Our experience with UN 38.3 compliance can significantly reduce your development complexity in several ways:

    1. Our technical team can guide you through transportation compliance requirements early in the design phase
    2. We provide detailed documentation on our batteries’ UN 38.3 status
    3. Our engineering support includes consideration of transportation requirements alongside performance specifications
    4. We can assist with testing preparation and coordination for custom battery solutions

    Engineering Considerations for Transportation-Ready Designs

    When developing products with lithium batteries, several design considerations can facilitate smoother UN 38.3 compliance:

    • Incorporate robust protection circuits that address short-circuit and overcharge scenarios
    • Design mechanical housings that provide appropriate crush resistance
    • Consider temperature management systems that maintain stability in extreme conditions
    • Document battery specifications thoroughly to streamline testing procedures

    By addressing these factors early, you can significantly reduce development iterations and accelerate time-to-market.

    Conclusion

    Understanding and planning for UN 38.3 testing is essential for any engineering team working with lithium battery technology. By partnering with Excell Battery, you gain access to expertise that can simplify this complex aspect of product development and ensure your power solutions are both high-performing and transportation-compliant.

    Contact our battery specialists today to discuss how our solutions can help you navigate battery safety requirements while meeting your technical specifications and development timelines.

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  3. Reducing Battery Waste in Downhole Drilling: A Case Study

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    Summary

    The oil & gas downhole drilling industry discards lithium/thionyl chloride batteries prematurely, wasting substantial unused capacity and increasing operational costs. Excell Battery’s Criterion family of smart battery monitoring systems addresses this challenge by providing accurate, real-time battery usage data. This case study, based on assessments conducted for a key customer, quantifies the waste problem and demonstrates the tangible benefits of implementing Criterion technology. With over 40 years of experience and global reach through Ultralife Corporation, Excell Battery delivers innovative solutions for critical applications.

    The Challenge: Invisible Battery Capacity

    Lithium/thionyl chloride batteries are ideal for downhole drilling due to their stable voltage output throughout operational life. However, this consistency creates a significant drawback: determining the remaining capacity without electronic monitoring is impossible. Consequently, operators discard batteries prematurely to avoid operational failures.

    A 2019 assessment of a key customer’s battery disposal practices revealed that approximately $3.3 million was spent annually on MWD batteries alone, highlighting the substantial potential for cost reduction.

    Assessment Methodology & Findings

    Excell Battery conducted residual capacity studies in 2015 and 2019 to quantify waste. Used  MWD batteries returned for disposal were tested after appropriate depassivation. Discharge testing used an electronic load configured at a constant current of 0.5A, with capacity recorded in Amp-Hours (Ahr).

    The studies revealed alarming levels of waste:

    • 58% of total capacity remained unused in MWD batteries tested in 2019 (blended average)
    • 150C MWD batteries showed 56% residual capacity in 2019, improving slightly from 62% in 2015
    • 165C MWD batteries exhibited even higher waste at 73% residual capacity in 2019
    • Approximately 9% of batteries (639 units) were disposed of with minimal or no usage, representing $297,000 in essentially wasted expenditure
    • The total value of unused capacity was estimated at $1.9 million annually

    Criterion: Smart Battery Monitoring Solution

    To address this significant waste, Excell Battery offers two Criterion monitoring systems:

    Criterion 4 (CR4)

    • Advanced battery monitoring with comprehensive data collection
    • Tracks battery capacity used, voltage, current discharge (average/peak), temperature
    • Records 3-axis shock and vibration data (up to 140g vibration, 200g shock)
    • Measures stick-slip and RPM
    • Features Power Line Modulation for communication
    • Includes sophisticated yet user-friendly analysis software

    Criterion Lite (CRLite)

    • Simplified system focused on basic battery capacity monitoring
    • Includes depassivation feature accessible through included Interface Unit
    • Designed for users primarily needing capacity information

    Both systems provide a permanent, non-erasable record of battery usage throughout its lifecycle, eliminating guesswork and human error. The monitoring systems maintain the original physical dimensions and connectors of the batteries. Excell Battery has deployed over 50,000 batteries with earlier Criterion 3 systems, demonstrating proven field reliability.

    Financial Impact Analysis

    Break-even analysis demonstrates immediate cost-saving potential:

    • CR4: Reducing residual capacity from 58% to 39.5% achieves break-even
    • CRLite: Reducing residual capacity from 58% to 49.5% achieves break-even

    Based on data from existing Criterion users, achieving 70-75% capacity efficiency (25-30% residual capacity) is realistic. For a customer spending $3.3 million annually on MWD batteries, potential savings include:

    • CR4 with 30% residual capacity: $314,700 annual savings
    • CR4 with 20% residual capacity: $644,700 annual savings
    • CRLite with 30% residual capacity: $640,800 annual savings
    • CRLite with 20% residual capacity: $970,800 annual savings

    Operational Benefits Beyond Cost Savings

    Implementing Criterion systems delivers valuable operational advantages:

    1. Permanent Usage History: Each battery retains its complete usage data, providing an auditable history for analysis.
    2. Downhole Environmental Data (CR4): Critical measurements of temperature, shock, vibration, stick-slip, and RPM offer insights into drilling conditions and tool performance, enabling optimization and troubleshooting.
    3. Elimination of Subjective Assessment: Objective capacity data removes the guesswork that contributes to premature disposal.
    4. Standardized Protocols: Enables consistent, data-driven methods for battery usage and replacement across operations.
    5. Versatility: Criterion is effective for multi-cell designs and is rated for temperatures up to 165°C.

    Implementation Approach

    Integrating Criterion systems requires:

    • Strategic Integration: Define implementation scope based on operational needs
    • Personnel Training: Comprehensive training on hardware and software use
    • Data Management: Establish procedures for analyzing and interpreting battery data
    • ROI Validation: Track post-implementation usage and disposal rates to quantify savings

    Conclusion

    This assessment demonstrates significant cost-reduction opportunities through intelligent battery monitoring. Excell Battery’s Criterion solutions provide accurate usage data, enabling operators to drastically reduce wasted capacity. Financial analysis indicates rapid ROI with substantial annual savings. Additionally, the operational data collected enhances drilling efficiency and equipment performance.

    By adopting Criterion technology, drilling services companies can implement smarter, more sustainable, and cost-effective battery management practices.

     

  4. Cell and Cell Provider Considerations for OEMs

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    Device OEMs are tasked with a design process that incorporates numerous components and systems including power and battery storage. There often isn’t time to dive deep, assessing all of the options available.

    In this article, Excell Battery shares its learnings from 40+ years of custom battery pack manufacturing and therefore cell and cell provider selection. 

    What OEMs Need to Know About Choosing Battery Cell Providers

    There are three important questions that OEMs need to ask when choosing a cell provider:

    1. Can the provider consistently and reliably supply the necessary cells?
    2. What are the technical specifications required for the application (e.g. discharge rate and capacity requirements)?
    3. Can the provider produce cells that meet the required specifications?

    When selecting battery cells and a cell provider, it’s important to be aware of some common pitfalls and misconceptions that OEMs might face. One significant challenge is limited market awareness. While conducting market research and identifying a cell provider offering a suitable product is a good start, it is important to recognize that the battery market is vast and diverse. Many ideal options for a specific application may not even appear in a Google search, requiring a more comprehensive approach.

    Often, past experiences and time constraints may also limit the decision-making process. Without a dedicated battery expert, these factors can restrict an OEMs choice to a handful of preferred brands, none of which carry a cell that fits the ideal profile for the application.  

    An experienced custom battery pack manufacturer such as Excell can help OEMs overcome these obstacles, bringing the depth of knowledge and time needed to explore the cell and cell providers in the market.

    Considerations for Choosing a Cell

    It can often be challenging to recognize the specifications that are most important. An OEM engineer might prioritize capacity, while overlooking the factors that are critical to performance in their application. For example, selecting a high-capacity cell without considering its discharge rate can lead to reduced performance under high-load conditions.

    Lithium-Ion Cell Considerations

    Packs composed of lithium-ion batteries require a protection circuit. They also can’t be charged or discharged below zero degrees unless they are expensive, specialized cells. While some online vendors offer low-cost lithium-ion batteries, these may not meet the required specifications, or may not be capable of combining multiple specifications. OEMs should be aware that some of these cheap lithium-ion batteries are even known to simply have a tiny cell at the top of the can while the remainder is filled with sand. Any cells purchased from Excell will be sourced from a reputable supplier that stands behind their product and will be able to meet all the required specifications.

    Cell Considerations for Hazardous and Extreme Environments

    Cells that will be used in extreme environments or hazardous locations also necessitate specialized battery solutions. Devices used in these environments may require certification to identify safety hazards and reduce the risk of accidents. For example, they must pass a short circuit test without exceeding a set temperature. Although it might seem counterintuitive, cells with lower discharge rates often work best for applications in these environments. Higher-rate cells, capable of delivering high currents can rapidly heat up, potentially reaching these limits. On the other hand, older lower-rate cells release the same amount of energy over a longer period, resulting in lower peak temperatures.

    There are various strategies that can be employed to achieve certification compliance, depending on the device and the certification requirements. One approach involves adding redundancies to increase internal resistance. Cells may also be encapsulated in thermally conductive potting compounds to help dissipate heat more effectively, reducing peak temperatures. However, these solutions come with trade-offs, such as reduced energy density or increased weight.

    How Excell Battery Can Help

    By partnering with Excell Battery, OEMs gain a reliable and knowledgeable partner in battery solutions. Our cell-agnostic approach and our deep understanding of battery technology enable us to deliver customized solutions that optimize performance, reduce costs, and meet the most stringent safety and environmental standards.

    Let us help you navigate the complexities of battery technology and select the ideal solution for your specific needs. Contact us today to discuss your project requirements.

  5. New EU Rules Revamp Battery Safety, Recycling, and More (EU Regulation 2023/1542)

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    The rise of lithium-ion batteries has changed how we power our world. From electric vehicles (EVs) and e-bikes to household devices and even powering the electrical grid, they are prevalent in more applications than ever. According to the European Commission, the global demand for batteries may increase up to 14-fold by 2030. However, as their popularity surges, so has the push for stronger safety and environmental regulations.

     

    Why Lithium-Ion Battery Safety Needs Attention

    The potential safety risks associated with mishandled lithium-ion batteries are causing concern. Incidents during transport or storage within residential or commercial buildings can lead to devastating property losses and significant increases in insurance premiums. Some residential buildings, hospitals, and transit systems are preemptively banning e-bikes and other products powered by these batteries within their facilities. Stakeholders in the battery industry must address these concerns to ensure the continued adoption of lithium-ion technology.

     

    Another issue arising as lithium-ion batteries become more popular is consumer awareness of proper disposal methods. Disposal of lithium-ion batteries in regular waste bins can be dangerous. Crushing during trash collection and handling can cause them to ignite and potentially cause fires. These batteries not only power electric vehicles, e-bikes, e-scooters, and small personal devices like phones and laptops, but also unexpected items like singing greeting cards. Some argue that their use in unexpected products is irresponsible by manufacturers, as consumers may unknowingly dispose of them improperly. 

     

    EU New Battery Regulation 2023/1542

    To combat these issues the European Union (EU) published the EU New Battery Regulation (EU) 2023/1542 on July 28, 2023, in the Official Journal of the European Union. Just weeks later on August 17, 2023, the Regulation was officially put into effect. It covers all batteries available on the EU market and aims to improve sustainability, safety labeling, and waste management. The Regulation supports the shift to a circular economy and increases the security of supply for raw materials. 

     

    Scope of applications and battery sizes

    The EU New Battery Regulation includes both rechargeable and non-rechargeable batteries. It is relevant for manufacturers of cells, modules, battery packs, energy storage systems, EV battery systems, and end products utilizing batteries. The regulation itself casts a broad net, encompassing battery categories such as waste portable batteries, electric vehicle batteries, industrial batteries, starting, lightning, and ignition batteries, and batteries for light means of transportation such as e-bikes, mopeds, and e-scooters. While specific rules within the regulation place stricter requirements on larger batteries exceeding 2 kWh, batteries of all sizes are affected.

     

    However, small to medium-sized enterprises with less than 250 employees and an annual turnover of up to 50 million Euros or a balance sheet total of no more than 43 million Euros are exempt from many of these requirements unless they produce batteries over 2 kWh capacity. This includes Excell Batteries as their largest rechargeable battery in 540Wh, and the largest primary stick packs are approximately 2kWh. 

     

    Key requirement: replaceable batteries for portable devices

     

    As part of the Regulation, the EU will require all portable devices sold within the bloc to have replaceable batteries by 2027. This applies to all smartphones, laptops, and tablets, including those produced by Apple, Samsung, and Google. This is just one example of how the Regulation will likely significantly impact the rest of the world, despite being an EU directive. It is unlikely that manufacturers will produce two different versions of their products – one for the EU and one for the rest of the world.

     

    Key requirement: battery passport

     

    To ensure compliance with the EU New Battery Regulation, EV and industrial batteries over 2 kWh will be required to have a unique digital battery passport accessible via a QR code integrated into their label. The battery passport will include relevant data from the entire battery lifecycle including battery chemistry, capacity, performance, safety, cycle life, carbon footprint, and calendar data.

     

    Key requirement: label markings

     

    The EU New Battery Regulation also imposes new requirements for CE markings. An abbreviation of “Conformité Européenne,” or European conformity—the CE mark has been around since 1993, and serves as a way for manufacturers to declare that their product complies with all the applicable legal requirements within the European Economic Area. 

     

    All portable batteries sold within the EU market will need to carry the CE marking by August 2024. Compliance is self-declared and obligations depend on the type of battery. 

     

    The current best practices for battery label compliance are:

    • CE Mark,
    • Makers mark,
    • Assembly site
    • Serial number,
    • Model number,
    • Warning/safety information,
    • Battery chemistry
    • Ah, 
    • Wh (best practice, but also mandatory for Li-Ion batteries), 
    • Voltage (best practice, but also mandatory for Li-Ion batteries),
    • Crossed-out waste bin symbol
    • Lithium battery recycling symbol
    • IEC series/chemistry/parallel coding

     

    For lithium primary (non-rechargeable) batteries, the amount of lithium in grams is also required.

     

    Those best practices are highlighted on the portable battery example label below:

    Figure 1: Current Battery Labeling Best Practices (Portable Batteries)

     

    Key requirement: responsible sourcing

     

    The EU New Battery Regulation echoes existing initiatives like RoHS and REACH by including language that discourages battery manufacturers from using certain materials. Additionally, the regulation mandates responsible sourcing of base materials, prohibiting the use of conflict minerals obtained through practices like slave labor, environmentally damaging mining, or practices that violate health and safety standards.

     

    Timeline

    The EU New Battery Regulation encompasses a significant number of mandates that will gradually roll out over the next few years with the goal of reaching climate neutrality by 2050. Stakeholders in the battery industry should be aware of the following timeline for the Regulation. It is of note that most of the upcoming requirements of 2023/1542 only apply to batteries greater than 2 kWh at this point. As we approach the following dates, it is important to check the criteria for any regulatory implementations:

     

    February 18, 2024: Mandatory enforcement of the Battery Regulations

    August 18, 2024: Mandatory enforcement of safety requirements for stationary battery energy storage systems, performance and durability requirements for rechargeable industrial batteries with a capacity greater than 2 kWh, LMT batteries and electric vehicle batteries, conformity assessment procedures, and economic operator obligations

    February 18, 2025: Mandatory enforcement of carbon footprint requirements for electric vehicle batteries

    August 18, 2025: Mandatory enforcement of supply chain due diligence / Mandatory enforcement of waste battery management

    February 18, 2026: Mandatory enforcement of carbon footprint requirements for rechargeable industrial batteries

    February 18, 2027: Mandatory enforcement of battery passports for rechargeable industrial batteries larger than 2Kwh and electric vehicle batteries / Removability and replaceability of portable batteries and LMT batteries

    August 18, 2028: Mandatory enforcement of requirements for recycled materials in rechargeable industrial batteries with a capacity greater than 2 kWh, except those with exclusively external storage, electric vehicle batteries, and SLI batteries, conformity assessment procedures, and economic operator obligations.

     

    What EU New Battery Regulation (EU) 2023/1542 Means for OEMs

    OEMs that may be impacted by the EU New Battery Regulation (EU) 2023/1542 should involve their battery suppliers early in the product design process to ensure timely compliance. All companies doing business within the European market must undergo IEC 62133 testing to verify their batteries meet safety requirements. Additionally, they need to meet labeling requirements and best practices, including affixing the CE mark. The complete directive can be found here.

     

    The EU New Battery Regulation isn’t the only set of rules that manufacturers and users need to be aware of. A few examples include the previous EU Battery Directive, which has been in effect since 2006. It focuses on the chemical content of batteries, and recycling practices, and establishes requirements for battery capacity, and rating. 

     

    Another important directive is the Electromagnetic Compatibility (EMC) Directive (2014/30/EU). It ensures that electric and electronic equipment, including those powered by batteries, don’t interfere with the functionality of other devices through electromagnetic emissions.

     

    Applicable both inside and outside of the EU, the International Air Transport Association (IATA) and the International Civil Aviation Organization (ICAO) are introducing new regulations specifically for the transport of lithium-ion batteries. These regulations, effective on January 1, 2025 , limit the state of charge for all lithium-ion batteries transported by air, land, or sea to 30%. It applies regardless of whether the batteries are shipped loose or packed as part of an end product. 

     

    Excell Battery Company: Your Partner in Compliance

    With over 30 years of experience, Excell Battery Company has established itself as a trusted partner for OEMs navigating the complexities of battery regulations. Through a commitment to continuous learning, Excel maintains a strong understanding of the ever-evolving regulatory landscape. This includes changes in regulations, training requirements, label requirements, and packaging requirements. Excell works closely with their customers to ensure compliance and create a better battery industry for everyone.

    The EU’s New Battery Regulation 2023/1542 marks a significant step toward a more sustainable and responsible future for lithium-ion batteries. By addressing safety concerns, promoting responsible sourcing, and ensuring steps toward circularity, the Regulation will ensure the continued growth of lithium-ion technology. While the regulation targets the EU market, its impact will likely be felt globally as manufacturers strive for consistency across their product lines.

  6. Downhole Battery Data Analysis with Criterion 4

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    How do you use a CR4-equipped battery to find out what’s happening downhole? How do you diagnose tool and/or battery failures? How can you learn more about the conditions of a downhole run? Play the following webinar recording about Downhole Battery Data Analysis with Criterion 4 to find out.

    The webinar will cover several topics, including:

    • Live demo of the CR4
    • Important data to look out for when analyzing downhole drilling and how to interpret
    • 4-5 case studies from real-life examples

  7. Remote Monitoring & Asset Tracking: Challenges & Solutions of Battery Design

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    Play the following video to watch our webinar on Remote Monitoring & Asset Tracking: Challenges & Solutions of Battery Design.

    In this webinar/panel discussion, Excell Battery and Ultralife will provide insider, specialist information for engineers and technical decision-makers based on insights and lessons from our years of experience in remote monitoring and asset tracking battery manufacturing.

    We will discuss:

    • Overall trends in the industry
    • Limitations and ideal applications for different battery chemistries
    • Designing for limited available space
    • Regulatory considerations
    • Sourcing/procurement/supplier considerations

  8. Downhole Battery Data Analysis With Criterion 4: Q&A with Bob Fay, Regional Manager, Houston, Excell Battery

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    In this Q&A, Excell Battery’s Houston Regional Manager Bob Fay discusses the basics of downhole battery analysis and how to use Criterion 4 to maximize your downhole battery and tool investments. For more on the subject, you can watch our latest webinar HERE.

    Q: Why is accurate and reliable data imperative to a downhole drilling operation?

    Bob: When something happens to a tool or battery downhole, accurate and reliable data can help you find the cause and troubleshoot. Battery data from a Criterion 4-equipped battery gives operators insights into potential issues.

    Q: Are there any common misconceptions amongst operators and/or manufacturers?

    Bob: Operators and manufacturers often underestimate the high-resolution data that Criterion 4 can provide. Many do not realize the quality of data that this tool offers, leading to misinterpretations or missed opportunities for a better understanding of downhole conditions.

    Q: Is there a problem in interpreting the data? Do operators struggle with understanding the amount of data provided?

    Bob: Interpreting the data collected by Criterion 4 can be challenging for some operators. It is important for them to be trained to use the data effectively to make informed decisions. Understanding what metrics to look for and how to interpret them can help operators gain valuable insights.

    Q: What are the top metrics that an operator should pay attention to?

    Bob: Operators should focus on checking the voltage versus current output. That seems to be the number one indicator of issues that have occurred downhole. Whether they’ve used up the battery, or the tool has a failure causing a short circuit, you’re able to look at the current curves to see what that tool is doing. Comparing that against the voltage curve allows you to check if the battery is reacting appropriately to different conditions. Additionally, the CR4 has a very sensitive shock and vibration monitor which can give you a pretty good idea of the downhole conditions.

    Q: How can an operator get the best usage out of a Criterion 4 battery?

    Bob: The biggest thing is making sure you have sufficient memory capacity to cover the entire run downhole. There are tools in the Criterion app to optimize the amount of data you collect over a period of time, and using them ensures you gain a comprehensive picture of downhole conditions.

    Q: What are the limitations of today’s technology?

    Bob: One limitation of today’s technology is that the CR4 gauge is a consumable item that cannot be reused. While it collects accurate data from downhole conditions, the cost of the gauge needs to be balanced to ensure it does not significantly increase the overall battery price. But considering what it does cost, it is a very powerful electronic board that collects very good data from downhole conditions.

    Q: Where is the technology headed?

    Bob: Well, we do have Criterion 5 in the works. We’ll keep specific details confidential for now, but the upcoming upgrades are expected to enhance data analysis capabilities and further improve operations in the industry.

    Q: With respect to downhole drilling data analysis, are there any current trends you see?

    Bob: I think the biggest thing I find when I look at the data are blown fuses. The battery’s fuse is blown, and so why did that happen? So what are the signs that cause the batteries to blow the fuse? The Criterion data can show that to you if you know how to look for it.

    For more information, watch our latest webinar on Downhole Battery Analysis With Criterion 4 HERE.

  9. 2024 Medical Battery Market Insights

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    Play the following video to watch our webinar on The Current State of Medical Device Battery Procurement.

    In this webinar, we will provide current and up-to-date information for procurement professionals in the medical device industry on the dynamic medical battery market. We will explore the latest trends and supply challenges, equipping you with the knowledge and risk mitigation strategies to overcome today’s and tomorrow’s obstacles. The following topics will be covered:

    • Understanding medical equipment battery applications, the importance of reliable power sources, and key factors to consider when evaluating supply options,
    • Regulatory considerations, including costs and expected timelines
    • Current trends in the medical battery industry/market from supply chain and technical standpoints, including those driven by EV development,
    • Q&A session, including perspective on the new EU Battery Regulation 2023/1542

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