Explanations of the custom battery box process and ...

 

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The custom battery box is for equipment with special needs, lithium battery products used in our daily life do not need to be customized. What needs to be customized is a lithium battery with special requirements.

 

Generally speaking, it is in the demand for lithium battery volume, capacity, protective measures, etc. Or according to different use scenarios, custom battery box can meet many needs.

1. What parameters need to be provided for custom battery box

&#; Input and output ports for lithium batteries

It is necessary to determine the IP protection level of the lithium battery pack and the method of battery hookup.

&#; How to install a lithium battery pack

This will play a big role in the design of lithium batteries. The size of the space will affect the capacity of the lithium battery pack. It is best to communicate with lithium batteries manufacturers before ordering lithium batteries to avoid situations where ideals and reality are very different.

&#; Expected service life of the battery box

You need to know how long the device will be used. Because it affects the capacity of lithium battery packs that require customization.

&#; Maximum power at load

For motor-like devices, when supporting lithium batteries, it is necessary to know the maximum power when starting these inductive loads.

 

&#; The corresponding voltage value

Since the voltage of the lithium battery pack is not a fixed value, but a wide range, it is necessary to ensure that the equipment can withstand the corresponding voltage value.

&#; Size and shape

Determining the size and shape of the batteries allow lithium battery manufacturers to reduce the range when developing and designing.

2. How long it takes to customize a battery box

Safety testing, packaging and shipping. The whole process of lithium battery customization is completed within 15 days. As an emerging industry, lithium batteries have developed rapidly in the past two years. The top 10 lithium battery companies in the world are applying custom lithium battery box to their products.

Packaging customization of lithium batteries is generated in this environment. Committed to lithium battery packaging, lithium batteries UPS customized solutions, and committed to providing users with more competitive lithium battery customized solutions and products.

3. The making process of custom lithium battery box

&#; Volume customization

The volume of cylindrical lithium batteries can be flexibly customized, and the maximum or minimum can be required within the specified specifications of the batteries.

&#; Voltage and capacity

customization The voltage and capacity of cylindrical lithium batteries can be customized according to requirements, and users can customize lithium batteries suitable for equipment according to their own needs.

 

&#; Secure customization

Custom lithium batteries manufacturers will increase battery protection measures according to the environment of the lithium batteries equipment you use or according to your requirements. The next are process of the custom battery box.

• Carry out product core selection and circuit structure design.
• After all the designs are completed, samples will be done.
• Complete preliminary functional testing and debugging.
• Test and verify the electrical properties and cycle aging of lithium battery packs.
• Review and discuss the customer's requirements, and then quote the sample.
• After the price, the product will be approved.

Lithium batteries are widely used, from digital, communication products to industrial equipment to special equipment, etc. are used in batches, and different products require different voltages and capacities. Therefore, custom battery box is unavoidable.

There are many applications for series and parallel connection of lithium-ion batteries, and the application batteries formed by installing the protection circuit, shell, and output is called pack. The pack can be a single battery or a series and parallel combination batteries.

4. What are the benefits of custom battery box

&#; Equalize charging

In daily life, according to various needs, 3.7V lithium-ion single cells are connected or paralleled to connect high-voltage and high-capacity lithium-ion battery packs. Every lithium-ion battery requires charge overvoltage, discharge undervoltage, overcurrent, and short-circuit protection. In the charging process, it is necessary to achieve the problem of equalizing the charging of the entire set of batteries.

&#; With different characteristics

You can choose different movements according to your needs for custom battery box. Different batteries have different characteristics, such as battery performance, service life, and safety.

 

&#; Freely arrange the voltage

The custom battery box the voltage range that the device can withstand. custom battery box can freely arrange the voltage according to your own needs, and you can flexibly use the voltage of custom battery box.

Therefore, it is necessary to ensure that the customized lithium battery equipment can withstand the corresponding voltage value. custom battery box can change the performance, volume, function and other characteristics of lithium batteries on the basis of the original batteries to meet the different needs of customers for batteries.

5. Advantages of custom battery box

Custom battery box is a customized service designed and manufactured according to customer needs according to actual application scenarios. Compared with standardized products, custom battery box has the following advantages.

&#; Meet customer needs

Battery pack customization can be designed and manufactured according to customer needs, which can meet the individual needs of customers.

&#; Improve price-performance ratio

A custom battery box can be optimized according to actual application scenarios to improve battery life and energy density, thereby improving cost performance

&#; Ensure quality and safety

Battery pack customization can control material selection and process flow according to customer needs to ensure the quality and safety of lithium battery packs.

 

&#; Meet the demands of energy storage

Lithium battery customization can solve the capacity needs of energy storage. Capacity is an important metric in large-scale energy storage projects. Through custom design and manufacturing, it can be tailored to the specific needs of the project and energy storage capacity targets. Design and manufacture lithium battery systems with larger capacities to meet energy storage needs.

&#; Have higher power and cycle life

For some applications, such as grid peak shaving and e-mobility, high power output and frequent charge-discharge cycles are required. Through customized design, the cell structure and management system of lithium battery, especially lifepo4 battery can be optimized, power output and cycle life can be improved, and the system can be operated stably.

&#; Higher security performance

The safety of lithium batteries has always been the focus of attention. Through customized design, more safety protection measures can be added, such as temperature monitoring, short circuit protection and overcharge and overdischarge protection, etc., to ensure the safe operation of lithium batteries systems and reduce potential safety risks.

6. How to maintain the lithium battery box

&#; Timely charge and discharge every day

Charge every day, according to the standard time and procedure. You can use the power of the lithium-ion battery pack for 2 to 3 days. It is recommended that you charge it every day. Because lithium-ion batteries are in a shallow cycle, daily charging will extend the life of lithium-ion batteries in electric vehicles.

The deep discharge of the lithium-ion battery pack also facilitates the "activation" of the batteries, which can slightly increase the battery capacity. The general method is to discharge the batteries once at regular intervals.

 

&#; Use the original charger

Generally, each manufacturer's charger has individual needs. In case of uncertainty, do not change the charger at will. The charger used is perfectly matched to the lithium-ion battery.

The charger current breaks through the protection system of the lithium-ion battery pack, causing a short circuit and causing a lithium-ion battery safety accident. The charger voltage is too low, the charging efficiency is low, and it takes too long.

&#; Maintain the environment

Lithium-ion battery packaging should be stored in a cool, dry and safe environment to prevent lithium-ion batteries from approaching heat sources, open flames, flammable and explosive gases, liquids, which may cause lithium-ion batteries to leak, heat, smoke, fire, explosion, explosion and explosive nature.

&#; Temperature range

At room temperature, the storage temperature of lithium-ion battery packs is usually 255C. Temperature affects the activity of lithium ions. The higher the temperature, the higher the activity, but the temperature exceeds 60, and the battery is scrapped. A custom battery box has superior performance, higher capacity, longer service life and more reasonable price.

So it has won the recognition and love of many consumers. Within the scope of user needs, do everything possible to meet all the needs of users, and truly realize the more cost-effective products they want.

7. Conclusion

Different battery box materials have their own characteristics. Consumers should choose their own battery box according to different needs when purchasing batteries. custom battery box is important in solving energy storage challenges.

Through customized design and manufacturing, lithium batteries can be customized to meet the capacity, power and safety needs of different application scenarios, providing efficient and reliable solutions for energy storage, and promoting the development of renewable energy and sustainable development.

 

Related articles: lithium vs alkaline batteries, battery stores nearby, Top 10 energy storage battery cell companies

Chapter 1 &#; What is the Battery Cable Assembly?

Battery cable assembly or harness is a set of cables of varying lengths. You can use the cables to hook up one or more batteries to the electrical system of cars, trucks, boats, solar power systems, and other equipment.

The battery cables come with terminated ends to easily connect with your battery. You can also choose from a wide range of terminals and boots based on your application to meet different jobs&#; needs.

The battery cables are generally exposed to harsh conditions like vibration, heat, corrosion, or moisture as they run from the battery to different automobile parts. For this reason, they make use of good quality and thick wires which can withstand extreme conditions.

Battery cables are built according to specifications dictated by OEMs and manufacturers. But you can also order custom battery cables of varying size, length, types, terminals, and color.

Unlike other cables

Battery cables are meant for use only with batteries and electrical systems. They are not general-purpose wires that you can use to connect a device to the power source.

Battery cables often come in the form of harnesses and provide many advantages over loose cords and wires. They are bounded into a harness so that even you can save space and make them withstand adverse conditions like corrosion and vibration. If they came in the form of loose wires, you would need to extend them all over your automobile.

Battery cables are designed to last for a long time and reduce the risk of shorts. You can also expect a standard installation process as the terminals can easily connect to the battery and the electrical system without any confusion.

Without battery cables, all our vehicles, boats, and equipment would sit idle. You will need battery cables to provide power to the electrical system and make them functional.

Now that you know what a battery cable is let us discuss the different types of battery cables.

Chapter 2 &#; Types of Battery Cable

Battery cables can be of different types, and you must know their specific uses. This section will find out the difference between battery leads, automotive primary leads, welding leads, and marine duty wires.

Cloom provides cable assembly solutions that ensure the correct functioning while optimizing cost, space, and quality. 

Tapered Post Battery Cable Assembly

The company offers tapered post battery terminals in stamped brass, lead, and forged bronze, granting all the pros each material has. Cable assemblies come in many cable configurations, including lengths, different plating options, and even with or without double-headed nuts.

Ring to Ring Battery Cable Assembly

Many ring-to-ring plating combinations are available to fit your needs, including brass and copper options with both open or closed barrel terminals. These cable assemblies have the capability to crimp various wires at a time in one single terminal. Also, they are corrosion-resistant and endure pulling.

Flat/Ground Strap Battery Cable Assembly

Wires come in flat and round presentations and terminals made of stamped thimble, lead cast, open barrel, and lug are also available. 

Booster Battery Cable Assembly

These booster battery cables are perfect to transfer electrical power from the battery to a vehicle without requiring a big space. Cables come in many presentations and offer molded and printed stripe markings to help conductors differentiate the wires.

Fused Battery Cable Assembly

 It&#;s possible to customize the fuses to fit your power supply needs at all times. Also, they endure temperatures of up to 125ºC.

Chapter 3-Battery Terminals

Said current stability depends on the type of battery terminals. There are four main factors that define battery terminal types. Let&#;s have a look.

Material of manufacture

There are four metallic materials that manufacturers use for making battery terminal connectors. 

Lead ones are the most common, as they&#;re cheap and are strong enough to make the job done. However, current conductivity is not as high as other materials and it could melt in high-temperature environments.

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Brass battery terminals are easy to install, and almost anyone could put them in place. In addition, they&#;re highly resistant to water and moisture, making them rust slowly. Nonetheless, brass battery connectors bend and break if you put extra strength or pressure while tightening.

Bronze ones are fairly similar to brass battery connectors but they are stronger, more durable, and more resistant to corrosion.

Copper ones are some of the best options available thanks to its material&#;s high current conductivity and resistance to corrosion. Yet, they are expensive and difficult to find. In addition, it&#;s important to check you&#;re getting the real deal and not a steel clamp with a copper coat copycat.

Installation diagrams

When it comes to the wiring diagrams, battery connectors have it easy. Simply look on the top of the battery and look for the small &#;+&#; and &#;-&#; symbols. Also, to avoid users and mechanics from damaging both the vehicle and the battery terminal clamps, bolts have different widths. 

The positive battery terminal connector is wider than the negative battery terminal. However, it&#;s important to know if you&#;re getting an Asian or European/American car. Asian car battery terminals and bolts are narrower than their European/American counterparts. Knowing this will save you some time and effort when looking for a replacement later on.

Battery polarity

The battery polarity also plays a big part in defining the type of battery terminal you&#;ll need. As batteries provide current directly, it&#;s vital to know that the positive pole goes with the positive battery terminal and the negative pole goes with the negative battery terminal. Usually, the positive is on the left and the negative is on the right side of the battery. However, in Asian cars, it is the other way around. 

Forms of compound

Selecting the right car battery and battery terminals is vital for the car&#;s proper function. Be aware of the size and shape of both the battery and battery terminal before making the purchase. 

Chapter 4-Car Battery Terminal Corrosion

For more custom battery assembly equipmentinformation, please contact us. We will provide professional answers.

Additional resources:
How Does Biodegradable Packaging Impact the Environment?

Car battery terminal corrosion is, unfortunately, unavoidable. This chemical reaction is bound to happen sooner than later. When it happens, it leaves a white or blue-is powdery residue that covers both the bolt and the terminal that reduces the current conductivity to the machine.

Types of Battery Terminal Corrosion

Battery terminal corrosion starts in the inside of the car battery when the chemicals start to interact with the gasses said chemicals emit. However, battery terminal corrosion means different things depending on which terminal is present.

Negative Terminal

When the negative terminal corrodes, means that the car battery is not charging properly or is undercharged. This usually happens if the car stops or its owner doesn&#;t drive it regularly anymore, leading to lead sulfation.

Positive Terminal

On the other hand, when the positive terminal corrodes, it means the car battery is overcharged. This happens after repetitive use of the car for long, consecutive hours leading to copper sulfation.

Car Battery Terminal Corrosion: the Reasons for It

There are a few variables to consider as reasons for corrosion on the battery terminal. These will be vital in the hopes to avoid it from happening so soon.

Aging Battery

This applies to any machine or device running on batteries whether it&#;s a car, truck, or even cellphone. After 4+ years of consecutive and extended use, the battery will corrode and show poor performance. If you experience this, it&#;s time to go for a new battery before it&#;s too late.

Charge Disbalancing

As you saw earlier, charge disbalance happens on any or both battery bolts. However, it all starts on the inside of the battery. Car batteries charge and discharge depending on the use of the car. If users don&#;t drive the vehicle properly, it will lead to the battery charging poorly, and finally, to corrosion.

Electrolyte Spillage

Car batteries hold water or Sulfuric Acid on the inside to speed up the chemical reaction needed to make it work. However, if the liquid filters out of the battery, it will lead to corrosion and poor battery performance on lead-acid batteries.

Hydrogen Discharge

This is one of the car battery terminal corrosion&#;s most common reasons, especially on batteries that use Sulfuric Acid instead of water as the electrolyte. It happens due to the interaction between the hydrogen discharged and the battery terminals while being under the cap.

Car Battery Corrosion: the Problems it Causes

As a result, it will come in handy when experiencing the poor performance of the vehicle.

Failing Electronics

All electronics inside the vehicle depend on the car battery, and when this is faulty, all electronics will start to fail as well. This includes the sound system, air conditioner, automatic windows, and even automatic car doors.

Engine Starting Troubles

It&#;s possible to damage your engine starter and experience malfunction due to low voltage. This translates into a mandatory check-up or even engine starter replacement.

Malfunctioning Transmission

Cars commonly use a computer system that depends on the battery to fully manage the car&#;s transmission. When the battery sends a low current to the system, it fails and leads to missing gearshifts and ultimately, accidents on the road.

How To Fix Car Battery Corrosion

Chemistry plays a big role in fixing car battery corrosion and it&#;s easier than you think. In any of the following solutions, it&#;s important to have the engine off and know there&#;s no issue on which battery terminal to disconnect first.

Baking Soda Solution

For mild battery terminal corrosion, using a baking soda solution is a great battery terminal cleaner. Mix enough baking soda or Sodium Bicarbonate with water to make a slush-like consistency mixture. Then pour it over the terminals and scrape it around with a brush until the corroded battery terminal is clean. Finally, clean the terminals with water and a cloth.

Soda Water

On another hand, if you look for a corrosion quick fix, using soda water is the solution. If you&#;re on the road and experience car battery issues, pouring soda water or any soft drink on the terminals for a while can help you. Let it rest for a few minutes, clean with a towel or sponge, and that&#;s it.

Baking Soda Immersion

Finally, for extreme battery corrosion, immersing the terminals in a baking soda for about 20 to 30 minutes will cause the corrosion to fade. If after this the corrosion is still present, change the clamps completely as shown in the next video.

Battery Terminal Corrosion: How to Prevent It?

Prevention is key to fight battery terminal corrosion. Here are some tips to keep corrosion at ease.

Corrosion Preventive Materials

Using Vaseline or spraying anti-corrosive products will extend your car battery&#;s life.

Resolve Battery Charging Issues

Another option is to regularly check your battery terminals for corrosion. If present, go to the mechanic to find the main source of the battery&#;s over-or undercharge.

Regular Maintenance

Checking your entire vehicle regularly will prevent any minor and major issues from happening. Visit the mechanic and keep your check-ups to date.

Chapter 5 &#; Battery Wire Applications

Battery wires have a wide-ranging application in different industries and equipment like cars, boats, battery banks, and golf carts. Let&#;s check out some of the applications-

5.1. Automobiles

Battery cables are most commonly found in automobiles and transfer electric current from the battery to the vehicle&#;s electrical parts. You will generally find two cables- the positive cable, which connects to the starter, and the ground cable, which connects to the engine block or the chassis.

Most of your automobile&#;s electrical components will be ground to the chassis or engine block. Battery cables enable you to start your engine and provide power to different electrical parts.

5.1.1.Advantages and Disadvantages

One of the main advantages of battery cables is that it is used to power the electrical of your automobile. You will not be able to operate your automobile without a proper battery cable assembly.

A disadvantage of automobile battery cable is that you cannot use it for other purposes. You may also need to replace them after some years as they withstand harsh conditions, vibrations, and abrasion daily. 

5.2. Gauge Golf Cart Cables

Golf Carts form a unique application of battery cables. You will need a battery wire for your golf cart to connect the electrical parts if you have installed extra batteries. People who modify their golf carts with larger motors will also require battery wires.

You can customize the terminals to match the needs of your final application.    

5.3. Cables for Solar Battery Banks & RVs

Solar panels are connected to sets of batteries to store the power generated from the sunlight. You will have to use a battery cable to connect the solar panels to the battery banks for transferring the power.

If you drive an RV, you may also require battery cables to connect extra batteries to various electrical peripherals like lights, TV, and other gadgets.

5.4. Braided Ground Cables

Braided ground cables come into use when you are mostly dealing with restoration projects. You can order flat braided cables that perfectly match the stock cables in your vintage car, including the terminals.

They come with a ring terminal on one end and a top post terminal on the other. 

5.5. Booster (Jumper) Cables

The booster cables, also known as jumper cables, are necessary when you need to jump-start another vehicle.

Booster cables can have either universal clamps or parrot clamps. Universal clamps are suitable for connecting to side post terminals in restricted spaces.

Parrot clamps come in handy when you are connecting to top post terminals. 

In the last chapter of our post, we will discover the implications of positive and negative battery cables.

Chapter 6 &#; Positive Battery Cable Vs. Negative Battery Cable

6.1What is a Positive Battery Cable?

You will need a positive and negative battery cable to power your car&#;s electrical systems. The positive cable is red and connects to the battery&#;s positive terminal and the car&#;s motor and electrical system.

6.1.1Termination

You can purchase a pre-terminated positive battery cable or use a crimper to terminate your connectors. If you are buying pre-terminated cables, ensure that the terminators match your vehicle&#;s electrical systems, battery, and starter motor.

6.1.1.1. Battery Cable Crimper

You can use a crimper to terminate positive and negative battery cables manually.

6. 1.1.2. Battery Clamp

Battery clamps enable you to hook the battery cable with the positive or negative ends of your battery. The size of the clamp should match the end of your battery for an appropriate connection.

6. 1.1.3. Battery Cable Lugs

You can find O-shaped and U-shaped lugs on positive battery terminals to connect to your engine block and car&#;s chassis. O-shaped lugs are mainly used for bolt-on applications, while U-shaped lugs are suitable for screw terminals.

6.2 What is a Negative Battery Cable?

Negative battery cables are marked with a negative sign and generally black. It is a large cable and may have smaller wires coming out of the battery connector side.

Negative cables connect to the engine block and supply grounding for the ignition system. The smaller wires go into the chassis and enable a return path for the electrical components.

6.2.1 How to Replace Negative Battery Cable?

1. First&#;trace the negative battery cable where it connects to the electrical parts and your battery.
2. Secondly&#;remove the cap from the terminal of the battery and use a wrench to undo the clamp.
3. Now twist and turn the cable to detach it from the battery post.
4. Next, detach the smaller wires from the electrical parts and unbolt them from the engine block.
5. Remove the negative cable.

6.2.2 Difference between Positive and Negative Cables

Positive battery cables are larger and red. They are used to connect the battery to the starter motor and the electrical system.

The negative cable is smaller and black. It is used to ground the electrical parts and connect to the negative post of the battery.

So, If you want to connect the battery to different electrical parts, you will need a positive battery cable. On the other hand, negative cables are suitable when you want to ground your ignition system and provide a return path for the current from the electrical components.

Conclusion

We can help you zero in on the right type of battery cable to use in your car or solar panels. You can also place custom orders and specify the length, width, diameter, colors, terminators, and other specifications. Cloom Tech provides tailor-made services to match your quality demands- contact us today to find out more!

Want more information on custom lithium ion battery pack assembly? Feel free to contact us.