In the dynamic landscape of energy storage, choosing the right battery pack is a critical decision that significantly impacts performance, efficiency, and overall product design. This webinar aims to unravel the complexities surrounding standard and custom battery packs (primarily lithium), providing you with a comprehensive understanding to make informed decisions. We'll embark on a journey to explore the fundamental distinctions between standard off-the-shelf battery packs and their bespoke counterparts tailored to specific applications. We will delve into the nuance of what is defined as a standard battery pack along with its benefits, limitations, and how it caters to broad market needs. Simultaneously, we will dissect the world of custom battery packs, diving into the advantages they offer in terms of precise energy requirements, form factors, and unique design considerations. Whether you are a product designer, engineer, or industry professional, this webinar is designed to equip you with the knowledge necessary to navigate the intricate terrain of battery pack selection. Join us for this webinar as we navigate through the intricacies of standard and custom battery packs, empowering you to make strategic decisions that align with your project goal. For more information on our battery pack solutions, visit https://www.epectec.com/batteries/.

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Standard vs. Custom Battery Packs
Decoding the Power Play
05.09.24

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Agenda
 Defining the difference between standard and custom battery packs –
at a 10,000-ft. level
 Some critical definitions – BMS, capacity, cycle life, etc. – to help
frame our discussion
 Standard packs – benefits and limitations
 Custom battery packs – there is so much more than meets the eye
 Development and certification timelines for each
 Summary

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Defining The Difference Between Standard and
Custom Battery Packs – At A 10,000-ft. Level

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Why Have This Discussion?
 We can make anything you would like, but …
– Do you really need it?
– Is it in your budget?
– Do you have time to wait?
 To better define:
– Standard but not off-the-shelf
– Custom – endless possibilities

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Why Choose Custom Over Standard?
 Unit Cost
 Operational Requirements
– Charging once every week versus once a day
 Application Specifics
– Hunting decoy vs. a wearable medical device
 Regulatory Specifications
– Nail propagation test vs. just UN 38.3 certification

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Some Critical Definitions

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Things To Understand - First
 Battery Management System (BMS) Defined
– Definition:
• A Battery Management System is an electronic system that manages and
monitors the charging, discharging, and overall health of a battery pack.
– Functions:
• Balancing cell voltages
• Monitoring temperature
• Controlling charging and discharging rates
• Implementing safety measures
– Importance:
• Ensures safe and efficient operation of battery packs.

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Battery Cycle Life
 Definition:
– Battery cycle life refers to the number of charge-discharge cycles a battery
can undergo before its capacity drops to a specified level.
 Factors Affecting Cycle Life:
– Depth of discharge (DOD)
– Charging and discharging rates
– Operating temperature
 Example:
– A battery rated for 500 cycles at 80% capacity retention can be charged
and discharged 500 times before its capacity diminishes to 80% of its
original capacity.

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Battery Capacity
 Optimizing Performance:
– Understanding battery capacity helps match the battery size to the energy
requirements of the application.
 Maximizing Runtime:
– Higher capacity batteries provide longer
operating times between charges.
 Selecting the Right Battery:
– Knowing battery capacity aids in selecting
the most suitable battery for a particular
device or application.

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Why Are All Of Those Things Important?
 They directly affect the cost of the
pack.
 The amount of control of these
directly impacts the amount of
design time.
 The more features or larger the
size = higher cost and longer time.

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Definitions – Standard Battery Pack
 Pre-Designed Configuration:
– Predetermined design, specifications, and features that cater to a wide
range of applications.
 Limited Customization:
– Come in fixed sizes, capacities, voltages, and form factors.
 Cost-Effective:
– Preferred choice for applications where unique features are not critical.
 Quick Turnaround:
– Materials are readily available so there is typically a shorter lead time.

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Standard Packs
What Are The Benefits and Limitations

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Standard Battery Pack – What It Doesn’t Mean
 Off-the-shelf
– Not an endless design of finished packs
 Still requires some design work
– BMS features need to be programmed
 Pre-certified
– No UL or UN 38.3
 Some distributors do have these available

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Standard Battery Pack – Features/Limitations
 Battery Management System (BMS) in Standard Packs
– Standard battery packs typically feature basic Battery Management
Systems (BMS).
 Characteristics:
– Predetermined charge and discharge parameters.
– Limited diagnostic capabilities.
– Generic safety features such as overcharge
and over-discharge protection.
 We can provide different options.

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Standard Battery Packs – Features & Limitations
 Temperature Monitoring in Standard Battery Packs
– Temperature monitoring in standard battery packs is typically basic
compared to custom packs.
 Characteristics:
– Limited to simple temperature sensors
to monitor overall pack temperature.
– Threshold-based temperature protection.
– Lack of detailed temperature profiling
and control.

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Benefits of a Standard Battery Pack
 Reduced time and cost of development
 Lower per unit cost
 Giving up features but gaining in cost
 NOTE: Still must go through certifications

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Custom Battery Packs
There Is So Much More To It Than Meets The Eye

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Definitions – Custom Battery Pack
 Tailored Design:
– Designed from the ground up to meet specific requirements of a particular
application. This includes considerations such as voltage, capacity, size,
level of performance monitoring, communications, and performance
characteristics.
 Highly Customizable:
– Highly designed management systems and software/firmware tailored to
the application's demands. Often involve developing custom connectors
and housings to meet specifications.
 Optimized Performance:
– Engineered for optimal performance in the target application. This ensures
the best possible efficiency, lifespan, and power delivery.

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Custom Battery Packs - Features
 Designed according to precise voltage, capacity,
and form factor specifications.
 Engineered to deliver optimal power output for
specialized applications.
 Fine-tuned control over charging and discharging
which improves overall battery efficiency and
lifespan.
 Comprehensive monitoring and protection
mechanisms minimize the risk of safety incidents.
 Remote access and control capabilities enable
proactive maintenance and troubleshooting.
 Allows for devices to be controlled very precisely.

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Custom Packs - Features
 Battery Management System (BMS) in Custom Packs
– Incorporate advanced Battery Management Systems (BMS).
 Characteristics:
– Programmable charge and discharge profiles tailored to specific
application requirements.
– Real-time monitoring and data logging capabilities.
– Enhanced safety features such as cell balancing,
temperature monitoring, and fault diagnosis.
– Involves significant custom firmware/software
development.

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Parameters Monitored by Advanced BMS
1. Cell Voltage:
• Monitoring individual cell voltages ensures
balanced charging and prevents overcharging or
over-discharging.
2. Temperature:
• Monitoring cell and ambient temperatures helps
prevent thermal runaway and ensures safe
operation.
3. State of Charge (SOC):
• Accurate SOC estimation enables better
utilization of battery capacity and extends
battery lifespan.
4. State of Health (SOH):
• Assessing the battery's SOH provides insights
into its overall condition and remaining lifespan.
5. Current:
• Monitoring charging and discharging currents
allows for precise control and optimization of
battery usage.
6. Internal Resistance:
• Measuring internal resistance helps identify
degraded cells and assess overall battery health.
7. Charge and Discharge Rates:
• Controlling charge and discharge rates optimizes
battery performance and enhances safety.
8. Fault Diagnosis:
• Detecting and diagnosing faults in real-time
ensures prompt troubleshooting and maintenance.

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Advantages of Monitoring Advanced BMS Parameters
 Optimized Performance:
– Fine-tuned control over critical parameters enhances battery efficiency and extends
lifespan.
 Enhanced Safety:
– Comprehensive monitoring helps prevent safety incidents such as thermal runaway
and overcharging.
 Predictive Maintenance:
– Early detection of anomalies allows for proactive
maintenance, reducing downtime and costs.
 Data Insights:
– Data logging facilitates analysis of battery behavior
and performance trends for continuous improvement.

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Enhanced Temperature Monitoring in Custom Packs
1. Safety Assurance:
• Comprehensive temperature monitoring is crucial for preventing thermal runaway
and ensuring safe operation.
2. Performance Optimization:
• Detailed temperature profiling enables better optimization of charging/discharging
rates and overall battery performance.
3. Longevity:
• Effective temperature management prolongs battery lifespan by minimizing thermal
stress.
4. Regulatory Compliance:
• Advanced temperature monitoring may be necessary to comply with industry
standards and regulations.

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Challenges with Custom Battery Packs
 Take time to develop
– All custom software/firmware
– Custom enclosures to ensure precise temperature management
 Usually involves trial and error in final application
– Adds time to development
 Significant development cost

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Differences in Timing
 Standard battery pack, we have …
– Catalog model BMS designs that we can select to support
– Established programming
– Commonly used cell models available
 Custom battery pack …
– BMS needs to be designed to meet specifications
– Custom programing and test programs/fixture developed
– Enclosure and other custom parts design and tooling
 Standard can be very quickly done where custom takes substantial
time

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Development and Certification Timelines For Each

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Development Timelines
 Standard Packs
– As little as 4 weeks
 Custom Packs (will vary)
– 8-12 weeks for design
– 4-6 weeks for prototypes

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Regulatory Timelines
 All the costs and lead times of these tests will vary depending on the
battery construction, capacity, pack size, cycle requirements, and
where the battery will be certified.

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How To Minimize The Development Timeline?
 Work with your battery pack supplier EARLY.
– Especially on component/cell selection
 Understand the cost/timeline ramifications of all added features.
 You can have anything you want, but it adds cost and time.
 List of must vs. nice-to-have in terms of features.

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Summary

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Summary
 Key Differences
 Standard packs offer quick, cost-effective solutions with established designs and
components.
 Custom packs allow tailored specifications to meet unique operational requirements and
regulatory standards.
 Considerations
 Cost: Custom packs involve higher initial costs for design/development.
 Time: Longer development and certification timelines.
 Specifications: This may include stringent regulatory compliance.
 Engage Early
 Talk to your battery pack supplier to balance trade-offs between features, cost, and
timeline.

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Our Products
Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards
CNC Machining User Interfaces Flexible Heaters EC Fans & Motors

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Q&A
 Questions?
– Enter any questions you may have
in the control panel
– If we don’t have time to get to it, we
will reply via email

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Thank You
Check out our website at www.epectec.com.
For more information email sales@epectec.com.
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