How to customize 24V130Ah size lithium battery packs

Traditional lead-acid batteries are being accelerated to be replaced by lithium batteries in the fields of RV energy storage, industrial equipment and outdoor emergency power supply. With high energy density, long cycle life and highly flexible BMS customizability, customized 24V130Ah lithium battery packs have become the preferred power source for AGVs, energy storage systems and special vehicles.

I. Ternary lithium battery customization: high energy density solutions

With its high nickel cathode material, NMC/NCA can realize energy density as high as 200-220 Wh/kg, which is about 30% higher than that of lithium iron phosphate (LFP). Taking a typical 24V 130Ah ternary battery pack as an example, it has a total energy of 3.12 kWh and performs as follows in practical applications:

• 6-8 hours of continuous power supply for RV air-conditioning system; 
• supports 4 hours of continuous high-intensity operation of electric forklifts; 
• In a logistics AGV project, the range of the battery is increased from 12 km to 18 km, and it supports 2C fast charging, which can charge 80% of the power within 1 hour.

II.lithium iron phosphate battery customization: high safety and long life preferred

Although lithium iron phosphate (LFP) batteries are slightly inferior to ternary (usually 160-180 Wh/kg) in terms of energy density, their cycle life of more than 6,000 times (capacity retention rate of >80%) and intrinsic safety are favored by high-reliability scenarios:

• The thermal runaway temperature is as high as 800℃, far exceeding the 200-300℃ of ternary; 
• supports a higher sustained discharge rate (usually up to 3C), which is suitable for equipment with high start-up current; 
• has a wider operating temperature range (-30℃~60℃), which makes it fearless of severe cold and high temperature.

III.The key customization dimension: to adapt to multiple application scenarios

Customization is the key to achieving optimal performance for both Li-ion and Li-CePo:

1. Structure and shell: 

Material can be aluminum alloy (high strength, good heat dissipation) or flame retardant ABS (light weight, corrosion resistance); 

Protection level up to IP67, meeting the needs of harsh environments such as marine and mining.

2.BMS Intelligent Management: 

supports CAN/RS485 communication for data interaction with the host device; 

has active equalization function, controlling the pressure difference of the battery cell at <50mV; 

optional Bluetooth/Wi-Fi remote monitoring, realizing parameter setting, fault warning and historical data export.

3. Thermal management design: 

Basic: passive heat dissipation and heat insulation materials; 

Enhanced: built-in cooling fan or heating film to realize -20℃~60℃ wide temperature range.

IV. Safety and Reliability Engineering

The safety performance of customized battery pack is built on the triple guarantee of battery cell, BMS and structure:

• Cell level: A-grade cells are used, all of which have passed UL1642 and UN38.3 certifications; 
• BMS level: multiple protections such as over-charging/over-discharging/over-current/short-circuit/temperature protections; 
• system level: robust structure, anti-vibration and anti-impact, and laser welding is used in the key connection points.

Tests show that the capacity retention rate of a well-designed 24V 130Ah battery pack can still be >85% after 2,000 cycles, which is far better than 300-500 cycles of lead-acid batteries.

V. Typical Application Scenarios

1. RV energy storage system: 

can supply power for air conditioner, refrigerator and lighting system, reducing the dependence on generator.

2. Industrial AGV/forklift: 

supports fast charging and opportunity charging to realize 24/7 continuous operation.

3. Ship and special equipment: 

waterproof and corrosion-resistant design, used as auxiliary power supply, power supply for navigation, fishfinder and other equipment.

VI. Summary and Technology Outlook

As the cost of battery cells continues to drop (currently below $100/kWh), 24V 130Ah customized Li-ion battery packs have become an economical and high-performance alternative to lead-acid batteries. Whether to choose Li-ion ternary or lithium iron phosphate is a matter of weighing the four major factors: energy density, safety, lifetime and cost.

In the future, with the maturity of new technologies such as semi-solid-state batteries and sodium-ion batteries, customized battery packs will achieve greater breakthroughs in energy density and safety, providing core power for a wider range of applications.