Lithium Battery Customization
Lithium battery customization is reinforcing battery performance to achieve the capacity required for a device or application. It requires a trusted battery manufacturer and professional sourcing team to find the best raw materials to meet the power output and charge/discharge cycles needed.
The first step is filling out the customization questionnaire and providing information about your device or application’s energy needs.
Customized Battery Design
Customizing a lithium battery design allows the creation of batteries with specific power consumption parameters. This includes the voltage operating range, temperature range, capacity size, charging and discharging modes, raw materials, important technical specifications and parameters, as well as the battery shape design (round, trapezoidal, prismatic, etc).
A custom lithium solution also allows for a more compact battery pack. This can improve the overall design of a product and make it more efficient. Additionally, a custom battery pack can provide more consistent and reliable performance than off-the-shelf alternatives.
When choosing a provider, it’s critical to work with a team that has experience designing lithium-ion batteries for a wide variety of applications. This will ensure that the battery meets all of the key requirements for your specific application. A skilled provider will also be able to determine which battery chemistry is best for your application.
Lithium batteries are often used to power specialized equipment, including medical devices, industrial equipment, and portable electronics. Their high energy density makes them a perfect choice for applications that require a long operating time and repeated charge and discharge cycles. In addition, these batteries can operate in extreme temperatures and are safe to use in harsh environments. A customized lithium battery will also be able to provide more power than off-the-shelf alternatives and help you achieve your project’s energy storage capacity targets.
Customized Cell Design
There are a few key factors that need to be taken into consideration when designing a lithium cell. Firstly, the voltage of the battery must be determined. The main advantage of using a lithium battery is its high energy density, but this can also lead to safety issues if not managed properly. To prevent this, the use of a battery management system (BMS) must be implemented to monitor and control the cell’s voltage and current.
It is also important to consider the capacity of a lithium battery. The higher the capacity, the longer the Lithium battery customization device will be able to run. However, it is vital that you keep the weight of the battery to a minimum, as this will increase efficiency and help to improve safety.
During design, the battery must be able to withstand various conditions such as different temperatures and loads. This requires a thorough design process and the use of accurate simulation tools. Recently, improvements in optimization algorithms, surrogate models, and multi-physics simulations have opened up new perspectives in battery design.
Lithium-ion chemistries are currently the most popular due to their high energy density and cycle life. They can be manufactured with a wide variety of anode and cathode materials, offering specific advantages for each application. For example, the anode material can be based on graphite, or a mixture of transition metal oxides such as LiFePO4, LMO, NCA, NMC, and LMFP.
Customized Battery Pack Design
Custom lithium batteries are designed for customers to meet their specific power requirements. This may include power consumption parameters, operating ambient temperature ranges, discharge current size and battery cycle requirements. The battery manufacturer will discuss these requirements with the customer and recommend lithium batteries for solar panels an appropriate design. They will also provide a cost estimate, raw materials list, important technical specifications and parameters.
Once the design is finalized, the battery assembly process begins. This involves physically placing the battery cells in the exact arrangement specified in the design. Advanced welding and fixing techniques ensure a quality, durable connection between the cells and other components. In addition, each battery pack must be tested to verify the integrity of its components and ensure that all specifications are met.
Battery assembly and testing are important parts of the process because they can affect battery performance and longevity. This includes ensuring that the battery packs are properly sized and have sufficient protection circuits to prevent thermal runaway. In addition, it is important to ensure that the battery packs are compliant with all relevant international safety standards. This is especially important for lithium-ion batteries, as they are prone to overheating and thermal runaway if not handled properly.
Customized BMS Design
BMSs control the charging and discharging levels and parameters of battery packs. They observe the state of charge and health (SOC and SOH) of individual cells in a pack, which can have varying conditions due to their age, capacity, and environment. They can also detect errors such as a cell’s excessive current draw, which could lead to damage and safety hazards.
A BMS uses a combination of protection circuit modules (PCMs) and single-board computers to determine the state of each cell. The PCMs communicate with each other using a communication bus such as CAN, SMBus, HDQ, or I2C. These messages are then sent to the single-board computer to make calculations, determine SOC and SOH, and manage the battery’s charging, discharging, and other processes and states.
The BMS also manages cell balancing by actively redistributing energy from high-SOC cells to lower-SOC ones during the charging cycle. This optimizes the performance of the pack and extends its lifespan.
A BMS must monitor temperature to prevent battery damage and inflammation. It can use thermistors or NTCs to measure the resistance changes caused by temperature variations, which it then compares with a set of protective limits. If a cell’s resistance exceeds a predetermined threshold, the BMS will stop or reduce the current to avoid thermal runaway. It can also trigger fuses to prevent overheating and fire.
