Custom-Made Design

Lithium Power’s Custom-made Battery Pack Solutions

Lithium Battery Pack

For over a decade, Lithium Power, Inc. has custom-designed and manufactured lithium battery packs for many applications. Our battery packs operate robotic vacuums, outdoor security cameras, outdoor LED lights, medical devices, e-bikes, Unmanned Aerial Vehicle (UAV) / drones, Automatic Guided Vehicles (AGV) / AGV forklifts / pallet runners, 96V motor controllers.

We also design and build energy storage systems with outdoor weather-proof enclosures that provide an uninterruptible power supply for solar applications, PBX, computer servers, data centers, as well as telecom towers.

Our lithium battery packs are professional turnkey solutions that combine lithium battery cells, a battery management system, mechanicals, communications, testers, chargers and safety certifications (e.g. UL and IEC).

Our Applications

Hoverboard
UL Certified and Anti-explosion Design
Robotic Vacuum
Unmanned Aerial Vehicle (UAV) Drones
LED Light Tower
e-Bike
Automatic Guided Vehicles Forklifts
AGV Pallet Runners
LED Work Light
Energy Storage Systems for UPS
Solar Power
96V Motor Controller
Medical Devices

Lithium Battery Cell Selection

There are many different types of lithium batteries in the market. No one type works for all applications. For example, robotics need a high discharging output; power tools need high discharge C rate; energy storage systems need high power density; starter batteries need to be operable in freezing temperatures; and batteries with daily charging/discharging usage that need a long cycle life. We have been in the lithium battery application industry for numerous years. We are familiar with the battery supplier chain and emphasize on quality. We will offer you the most suitable lithium battery cells based on performance, price and reliability.

Smart Battery Management System (BMS)

Our unique battery management system separates us from other competitors. Most of our competitors have to rely on 3rd parties to complete their battery management system design.

We make our own battery management circuit boards. In the circuit boards, we have our own micro-controller chip that integrates a precise battery gauge, cell balancing and protection circuitry and system control firmware. There is nothing in our battery management system that requires help from 3rd parties.

This is the core competency of our turnkey custom-made lithium battery packs.

Conventional BMSs that most suppliers sell on the market are equipped only with simple over-charge/discharge protection. This kind of lithium battery pack requires a special balancing charger to recharge it. This is the same conventional, lowcost design used in Ni-MH/Ni-Cd battery packs, which offered very limited protection.

Using lithium batteries safely and smartly has become a top concern today. Our Smart BMS offers safety features like temperature protections that will not allow unexpected battery abuse by charging in high temperatures or discharging in low temperatures. These extreme conditions are the main cause of hoverboard battery fires in late 2015.

Our Smart BMS also provides communication protocols like SMBus 2.0, CANBus, and Bluetooth to communicate with the controller of the device to provide safer and smarter application features.

Smart BMS Features

Smart BMS Block Diagram

BMS Block Diagram

Examples of how Smart BMS works.

For drone applications, our Smart BMS will tell the controller of the drone how much power it has left, up to the second. Also, once the power level is lower than the alert power level, as defined by the controller’s calculation software, the drone will be forced to return back to the charging station, avoiding the chance for it to lose power in-flight and fall and hurt people or property. This is a typical example that shows how our Smart BMS enhances safety in using lithium energy smartly.

Another great safe and smart feature is that our Smart BMS provides a datalog function that will help device developers collect necessary information about battery power use and status in the product development stage and to retrieve insightful usage data from units received back from customers (which is real marketplace usage data). For example, for robotic applications, we and robot developers can find different peak current and operating time-period requirements based on the datalog information and fine tune or change the battery power design to fit their robots perfectly.

Mechanicals

Lithium battery cells and the battery management hardware/software system need to be designed as a unified battery pack to fit your specific application system. Some applications require special housing designs. Citing just two examples, medical grade energy storage systems need UL2054 certification to meet medical grade 60601 or FDA certifications for its pack; and outdoor batteries need an IP65 anti-dust/water resistance mechanical design for harsh environments and a metal housing to meet UL2271 anti-explosion mechanical design standards. This is critical for hoverboard applications, for example.

Communications

One of the major reasons why companies choose Lithium Power, Inc. as their technical partner is because we can provide them with communication protocols to control, command, remotely monitor/manage their custom-made battery packs. The ability to offer communication capabilities makes our battery packs far more intelligent and desirable. Our OEM/ODM customers also value how our lithium technology as an energy source combined with communication capabilities meet the needs of future trends for their cloud applications.

Our design of lithium battery pack

Cloud Connected Battery

Battery Pack Testers Equipment

We provide tester equipment for OEM/ODM customers to test the battery packs we design and produce. To ensure quality, customers can use our provided testers to test battery packs in incoming and outgoing inspection stages. Our OEM/ODM customers will have right fit tools to test their battery packs before final assembly of their end products. This add-on value brings us to another level of service from design to manufacturing.

Safety Regulations

For mission critical applications, safety certifications for Lithium battery packs are a must. With a customers’ financial commitment, we provide safety certifications once we complete the custom-made designs.

  • UN 38.3
  • UL 1642
  • UL 2054
  • UL 2271 for light vehicle with UL 2272
  • UL 3030 for commercial drone uses
  • IEC 62133

For example – The Hoverboard/Self-Balancing Scooter safety concern:

The CPSC (United States Consumer Product Safety Commission) has reported 52 cases of hoverboard fires between December 1, 2015 and February 17, 2016. The factors that cause hoverboard batteries to catch fire are:

  • A lack of a BMS protection board
  • Low-cost design that offers little or no protection to the circuitry
  • Poor quality materials and cheap assembly processes
  • Inadequate mechanical and safety design
  • A lack of UL and other certification testing

Lithium Power provides turnkey solutions for hoverboard batteries that solve these quality gaps and provide a safer, consumer-friendly power solution:

  • UL Certified battery pack (See above list)
  • Meets or exceeds U.S. CPSC’s safety standards
  • Built-in SMART and proprietary BMS technology that offers multi-level protections while charging and discharging
  • Proprietary mechanical design - aluminum housing that meets anti-explosive requirements and protects from shocks and vibrations
  • Extensive testing, inspection and quality control of each battery pack

ISO and UL Production Lines

Lithium Battery Charger

We provide custom-made lithium battery chargers to secure and enhance the performance and reliability of our battery packs. This is important especially when customers have unique charging requirements. For example, charging the lithium batteries quickly, providing charging status as a percentage, giving a “charge successful” indication, and the like.

To charge a lithium battery in full, the charger has to conduct CC to CV mode. Lithium Power’s charger will indicate that the battery is charged in full when tapper current drops down to 250mA or lower in CV mode. The lithium battery voltage will drop immediately once the charging current terminated. The reason is that the electromotive force is no more present to push up the battery charge. Chemical equilibrium forces the reaction to reserve a bit, with the voltage down. So, we design battery and charger so that both devices can have -handshake functions. They can communicate and deliver precise messages to users using LED lighting.

Our expertise in lithium batteries and their applications offer our customers professional turnkey solutions. We eliminate concerns about where to find the battery sources, how to integrate the battery management system, or how to coordinate the technical issues and shipments.

Our value is compounded when technical problems arise. While other vendors may point fingers, we accept blame and focus on fixing the problem. We hold full responsibility to take care of you and your business.

Please call us at (408) 837-0206 or Email us info@lithiumpowerinc.com for additional information.

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At Lithium Power, Inc., we bring lithium technology to life through innovative ideas. Our engineers are constantly developing next generation solutions. We need people just like you to provide inventive and resourceful ideas.

As we head towards the future, we know our success depends on the groundbreaking ideas of today. In order to continue the creative cycle and provide you with a better quality of life, we encourage you to submit your ideas to help us create products that are inspired by you and to be used by you – our customers and partners.

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