What’s different about designing and building large format batteries?

Nov 1, 2022 in Resource

“Companies that make products from golf carts and ebikes, to lawnmowers and robots – and everything in between are going Lithium” says Trent Keeney, Business Development Manager for Excell Battery.  Just like in the EV market, there are benefits for companies that require longer run time, quicker charge time, lighter weight, smaller footprint, better temperature performance, or any combination thereof.  “Our engineering team has years of experience in designing some unique large format batteries, which is where any company must start when looking to develop their own large format custom battery pack,” says Keeney.

A large format battery normally is just what it says.  Large.  It is normally more than 24V and can be well in excess of 1 KWh.  Designing and manufacturing these types of large battery packs is not for everyone.  The engineering and manufacturing expertise required are very different from a normal, standard size battery pack.

Manufacturing can also be totally different than smaller more hand held type assembly operations.  Automated welders or bonders popularized by the EV market can have significant automation and quality benefits as well.  However, when moving a 1,000 lb battery, unique and custom equipment is required.  “These batteries likely can’t be moved by hand, which adds another element of complexity to the manufacturing process”, says Keeney.

At Excell we have to look at each of these opportunities uniquely because they are very different.  Building a 2 cell battery pack is entirely different than building a 1 KWh battery pack. The differences really have to be well thought out in the engineering phase in order to design and manufacture a quality product.

Please contact us to learn more about our large format battery expertise and discuss how Excell can help you achieve your battery project goals.