Mission-Critical LiFePO4 Battery Systems for Heavy-Duty Mobility & Industrial APU.
Drop-in replacement and custom-engineered non-standard battery packs. Tier-1 automotive and industrial Grade-A LiFePO4 only cells — strict zero-recycled, zero-B-grade compliance — integrated smart BMS with CAN 2.0B / SAE J1939 / RS485, IP67 potted enclosures, and temperature-gated charge control specified for 50 °C ambient operation.
Documented posture — no unverified certification claims
That is the whole story at cell level. What happens after the cover is the enclosure's job, and it is fixed per installation — which is why Fig. 01 stops at the module.
02 — Core product matrices
Four platforms. One engineering baseline.
Every platform shares the same cell qualification, mechanical restraint and BMS architecture. What changes is the envelope, the voltage class and the interface — not the safety logic.
Matrix A — Heavy-Duty Industrial APU
Cab and sleeper power for long-haul fleets. Replaces Group 31 lead-acid banks without modifying the truck, the harness or the parking-cooler controller.
| Nominal voltage | 12 V (4S) / 24 V (8S, 25.6 V nominal) |
| 24 V banks | 150 Ah = 3.84 kWh · 200 Ah = 5.12 kWh · 300 Ah = 7.68 kWh |
| Continuous | 1C — compressor running draw 45 A at 24 V |
| Drop-in envelope | BCI Group 31 · European DIN A / B / C |
| Declared runtime | 5.5 – 6.0 h continuous cooling |
| DC-DC interface | Isolated DC-DC with smart current limiting |
| Ignition logic | D+ ignition interlock |
Engineering notes
- Runtime is dimensioned, not advertised. 7.68 kWh × 85% DOD × 90% inverter efficiency = 5.875 kWh AC; against an overnight average load near 1.0 kW that is ≈ 5.75 h of continuous cooling. The 1.911 kW figure is a selection peak for worst-case compressor start, not the overnight average.
- The isolated DC-DC and D+ interlock exist to keep the truck's 28 V alternator and its diode stack out of the current path — a failed alternator rectifier is the most common way a lead-acid APU takes the whole electrical system with it.
- Specified for 50 °C ambient: high-temperature electrolyte stability, salt-fog-treated terminals, high-vibration potting. Charge is inhibited above 55 °C and resumes below 45 °C, so a sun-soaked cab does not silently abort a charging window.
Matrix B — AGV / AMR & Autonomous Logistics
Duty-cycle batteries for vehicles that never stop. Sized around fleet availability and swap logistics rather than single-shift runtime.
| Voltage classes | 24 V / 48 V (quoted per platform) |
| Continuous | 1C standard across the range |
| Transient overload | 1.5C – 2.0C surge held for no more than 10 s, inverse-time limited; BMS shunt, contactors and busbar cross-sections sized to pack capacity |
| Protection curve | Inverse-time over-current, thresholds resident in the BMS |
| Cycle life | 4,000–6,000 cycles @0.5C / 80% DOD (cell-level manufacturer endurance test report) |
| Swap architecture | Modular independent low-voltage compartment, hot-swap logic |
| Telemetry | CAN 2.0B / SAE J1939 / RS485 |
Engineering notes
- Transient ratings are written as a BMS protection curve, never as a cell marketing figure. A 1.5C–2.0C surge held for no more than 10 s covers a stalled drive or a jammed lift; it is not a working duty point, and the BMS shunt, the DC contactors and the busbar cross-section are sized against that surge rather than against the continuous figure.
- Continuous rating is standardised at 1C with no footnote that quietly relaxes it. Sizing decisions are made on that number, so it is the number the fleet will actually see.
- Hot-swap is an electrical architecture, not a connector choice: a pre-charge circuit in every drop-in unit removes the kilo-ampere inrush that otherwise welds contacts and destroys controller bus capacitance.
- Balancing is specified against the duty cycle rather than applied by default. Ultra-low-quiescent passive balancing is the standard build; 1–2 A bidirectional active balancing is available where long series strings or unequal cell ageing justify the extra electronics inside the enclosure.
Matrix C — Heavy Machinery & Electric Forklifts
Asset rebirth for lead-acid fleets: repower the truck, keep the chassis, remove the maintenance overhead that never made it into the capital budget.
| Voltage classes | 48 V class · 80 V class (25S) · higher architectures quoted per application |
| Replaces | Conventional lead-acid traction banks, zero maintenance required |
| Enclosure | IP67 potted, industrial steel chassis |
| Service life basis | 4,000–6,000 cycles @0.5C / 80% DOD (cell-level manufacturer endurance test report) |
| Regeneration | Regenerative braking surge tolerated — reverse current does not trip the controller |
| HV switching chain | Main DC contactors + hardware pre-charge resistor / relay + manual service disconnect (MSD) + automotive-class fast-acting EV fuse, cascaded |
| Pre-charge | Resistor / relay pre-charge on every drop-in unit — removes the kilo-ampere inrush into controller bus capacitance |
| Venting | Cell relief vent on the cell top cover into the enclosure headspace; integrated IP67 explosion-proof venting valve combining a bidirectional breather element (pressure equalisation) with a one-way high-flow relief path |
Engineering notes
- The chain is deliberately four separate devices. The main DC contactors carry normal make / break, the pre-charge resistor and relay bring the controller bus capacitance up before the contactors close, the MSD is a human-operated physical break for service work, and the EV fuse carries fault disconnection. Collapsing any of them into one device is how service technicians get hurt or how a controller bus ends up welded closed.
- Each prismatic cell relieves through a vent on its top cover, so a fault pressurises the enclosure headspace before anything leaves the pack. From there the gas has to be routed out without discharging into the occupant space and without the outlet sitting against the mounting face: a blocked outlet simply pressurises the enclosure, and then the lid becomes the vent. The enclosure's own discharge route is fixed per installation, so it is not drawn.
- Cell discharge cutoff is a BMS protection setpoint, configurable across 2.50 – 2.85 V, with a factory default of 2.85 V that retains a 10–15% physical floor under the pack. The window exists so an integrator can trade a little usable capacity for a harder under-voltage margin on one specific duty cycle. The default sits at the conservative end because the LFP discharge curve is flat near 3.2 V across most of its usable range and then falls away sharply — on this chemistry a cutoff voltage is a protection threshold, not a state-of-charge reading.
Matrix D — LSV / Golf / Off-Road Utility
51.2 V 16S class for low-speed vehicles, golf fleets and side-by-side utility platforms in high-ambient markets.
| Configuration | 51.2 V 105 Ah = 5.376 kWh · 51.2 V 160 Ah = 8.192 kWh (16S LiFePO4) |
| Continuous | 105 A / 160 A respectively — 1C |
| Transient overload | 1.5C – 2.0C surge for no more than 10 s, inverse-time curve |
| Drop-in interface | Integrated hardware pre-charge circuit; regenerative braking surge tolerated |
| Mechanical | Aluminium end plates + tie rods, 3–5 kN constant face pressure |
| Off-road variant | 25 G mechanical shock, three-axis vibration fatigue, MSD + EV fuse cascade |
| Ambient posture | High-temperature electrolyte stability, >55 °C charge inhibit, <45 °C resume, salt-fog-treated terminals |
Engineering notes
- 51.2 V is not a separate voltage engineering problem — it is 16S LiFePO4. Treating it as a nominal "48 V" pack with a nominal "48 V" BMS is the single most common integration error we see in aftermarket requests.
- Constant face pressure from end plates and tie rods exists to absorb cycle-level cell swelling. Without it, stacked cells loosen, bus bar contact degrades, and contact resistance climbs into a thermal problem that never shows up in a data sheet.
- Fasteners, bus bars and terminal geometry are sized for coastal and high-humidity exposure, not for a climate-controlled warehouse.
03 — Engineering & supply chain architecture
Where the specifications actually come from
Cell sourcing
- Format: two qualified tracks — prismatic LFP for high-capacity traction, and 60-series large-format cylindrical arrays for high-vibration duty and non-rectangular envelopes.
- Supply: Tier-1 automotive and industrial Grade-A LiFePO4 only — strict zero-recycled, zero-B-grade compliance; no other cathode chemistry is qualified or offered. Prismatic cells are 100–160 Ah capacity class.
- Cell impedance gate: cell DCIR ≤ 0.8 mΩ @ 25 °C, verified per lot before assembly.
- Lot-gated sorting: cell capacity variance ≤ 1.0 % and ACIR impedance variance ≤ 5 % across all production modules.
- Protocol: strict refusal of B-grade, downgraded or recycled material — a single downgraded cell invalidates the pack's matching.
Embedded BMS architecture
- Protocols: CAN 2.0B, SAE J1939 and RS485 industrial telemetry; register map released for integration.
- Matching: factory capacity + DCR dual matching, plus lot-gated sorting before assembly.
- Balancing: ultra-low-quiescent passive balancing as the standard build; 1–2 A bidirectional active balancing available as a specified option where the duty cycle justifies it.
- Quiescent drain: sleep current ≤ 50 µA on the passive baseline, so a pack parked for a season does not arrive flat.
- Protection: inverse-time over-current curve, over/under-temperature charge gating, short-circuit protection, and a cell low-voltage cutoff set in the BMS, configurable across 2.50 – 2.85 V with a factory default of 2.85 V.
Mechanical restraint
- Stack: aluminium end plates with tie-rod pre-load, 3–5 kN constant face pressure.
- Conductors: thickened tin-plated copper composite bus bar, ≥ 1.5 mm thick, ≥ 40 mm² cross-section.
- Thermal target: contact-loop temperature rise ≤ 15 K under accelerated and transient ramp current.
- Relief: each cell relieves through a vent on its top cover into the enclosure headspace; the enclosure carries an integrated IP67 explosion-proof venting valve with a bidirectional breather element for pressure equalisation and a one-way high-flow relief path. The discharge route is fixed per installation — never into the occupant space, never blocked by the mounting face.
Two form-factor tracks
One qualification baseline, two cell architectures
The track is selected from the duty cycle and the envelope, not from preference. Both are held to the same incoming-inspection, matching and pack-level safety logic.
Track 01 — Prismatic LFP architecture
Square-format LFP cells, 100–160 Ah class, stacked under constant face pressure. The default where the envelope is rectangular and the duty cycle is energy-limited rather than power-limited.
- Built for Class 1–3 forklifts, high-voltage heavy machinery and heavy-duty APU duty.
- 4,000 – 6,000 cycles @ 0.5C / 80% DOD, cell-level manufacturer endurance test report.
- Highest usable volume utilisation inside a rectangular steel or drop-in envelope.
- Fewer welded joints and fewer sense taps per kWh, so fewer internal failure sites.
Track 02 — 60-series large cylindrical array
Large-format cylindrical cells in a fixtured array. Selected where the envelope is irregular, the mounting face sees continuous vibration, or the machine needs high charge and discharge rates.
- Built for AGV / AMR and industrial handling chassis, where the pack shape follows the machine rather than the machine following the pack.
- 2,500 – 3,500 cycles @ 1C / 80% DOD — the rate is higher, so the cycle figure is quoted at that rate rather than the prismatic number restated.
- Full-tab construction for low internal resistance and high-rate charge / discharge.
- Better cell-to-cell thermal uniformity across the array; cylindrical geometry resists three-axis vibration fatigue.
- Fixtured, weld-free automated assembly — no tooling investment for a new envelope, which is where the whole-life cost advantage comes from.
Track selection is an engineering recommendation, not a preference field. If your RFQ states a preference we will say plainly whether the duty cycle supports it.
Electrical envelope — single baseline, all platforms
| Parameter | Baseline |
|---|---|
| Continuous discharge | 1C, standardised with no relaxation footnote |
| Transient overload | 1.5C – 2.0C surge held for no more than 10 s, inverse-time limited; BMS shunt, DC contactors and busbar cross-sections sized to pack capacity |
| Protection curve | Inverse-time, thresholds resident in the BMS (not a cell-level claim) |
| HV switching chain | Main DC contactors + hardware pre-charge resistor / relay + manual service disconnect + fast-acting EV fuse, cascaded |
| Low-voltage cutoff | BMS protection setpoint, configurable 2.50 – 2.85 V per cell; factory default 2.85 V, retaining a 10–15% physical floor |
| Balancing | Ultra-low-quiescent passive as standard; 1–2 A bidirectional active balancing available as a specified option |
| Sleep current | ≤ 50 µA |
| Pre-charge | Hardware pre-charge circuit integrated in every drop-in replacement unit |
| Regeneration | Reverse-current surge tolerated under loaded downhill braking |
Commercial terms & logistics
| Item | Position |
|---|---|
| MOQ | Flexible — single-digit prototype or pilot sets, scaling to series volume |
| Incoterms | Turnkey DDP and CIF delivery; EXW and FOB available on request |
| Clearance & hazmat | Turnkey DDP / CIF delivery through certified dangerous-goods forwarding channels — Class 9 UN 3480 compliance, customs clearance and terminal drayage handled end-to-end |
| Engineering & assembly | Songshan Lake tech hub, Dongguan, China |
| Global logistics | Shenzhen / Hong Kong, China hub |
| Documentation pack | Dispatched per project: register map, mechanical drawings, endurance report, SDS |
| Custom engineering | Non-standard voltage, envelope and interface redesign quoted from your application data |
04 — Quality & compliance
What we claim, and how it is evidenced
Pack-level architecture fully engineered against UL 2271 / SAE J2929 requirements; cells are UL 1642 / UL 1973 certified. Internal test schematics and safety logs open for technical review.
We deliberately do not publish a badge row of mark logos we have not earned. Structural homologation is not transferable between pack designs, so a marks-only page is misleading at exactly the moment an integrator needs it to be accurate. What we publish instead is a document list, and we ship the documents.
Materials released to your qualification file
| Document | Status |
|---|---|
| Cell safety certificates | UL 1642 / UL 1973, Tier-1 cell maker — released per lot |
| Cell lot qualification | Capacity variance ≤ 1.0 %, ACIR impedance variance ≤ 5 % across all production modules — released per lot |
| Pack architecture statement | Engineered against UL 2271 / SAE J2929 — issued with quotation |
| Cycle-life endurance report | Prismatic track 4,000–6,000 cycles @0.5C / 80% DOD · cylindrical track 2,500–3,500 cycles @1C / 80% DOD — cell-level manufacturer test reports |
| SDS / MSDS | Issued per shipment, in the language of the destination market |
| Transport documentation | Class 9 UN 3480 dangerous-goods classification, test summaries and packing instruction — released with the commercial pack |
| BMS register map | CAN 2.0B / SAE J1939 / RS485 — released on NDA-free request for integration |
| Internal safety test logs | Abuse, thermal and mechanical logs open to customer engineering review |
| Mechanical drawings / CAD | Envelope and mounting interface, on request through the RFQ portal |
Third-party certification marks are added to our documentation package only when a specific pack design has actually been submitted and passed. We will tell you plainly which marks do not yet apply.
05 — RFQ portal
Send the application data.
We return a sized pack.
We quote from your duty cycle, not from a catalogue line. Voltage class, continuous and peak current, cell form factor, required bus telemetry, physical envelope and target quantity are enough for a first sizing pass.
Typical turnaround
- Within 1 business day — acknowledgement and any missing inputs
- 2 – 3 business days — sizing proposal, envelope drawing, DDP indication
- On request — prototype / pilot set at low MOQ before series commitment
Enquiry channel
Every enquiry arrives through the RFQ form on this page — one intake, one owner. There is no address to copy and nothing to open: complete the form and the brief reaches the sizing desk directly, drawings included.
- Read and answered by a person, not a queue
- Specification files travel with the enquiry
- Acknowledged within 1 business day
Engineering & assembly: Songshan Lake tech hub, Dongguan. Global logistics: Shenzhen / Hong Kong, China hub.