By continuing browsing this website, you accept the use of cookies or other tracers for statistics of visits to optimize the functionality of the site. For more information and for tracers settings

Select language
  • Deutsch
  • Español
  • Français
  • 中文
  • 日本語

We energize the world

Contact us
Follow us
  • Home
  • About us
    • Who is Saft
      • Saft In Brief
      • Our Strategy
      • Our History
      • Saft Worldwide
      • Code of Conduct
    • Manufacturing our batteries
      • Battery Chemistries
      • Research & Development
      • Environmental Responsibility
      • Certifications
  • Market sectors
    • Aerospace & Defense
      • Aviation
      • Space
      • Defense
    • Buildings & Industries
      • Data Centers
      • Mining, Cement, Chemicals
    • Medical
      • Hospital Buildings
      • Medical Devices
    • Telecom & Networks
      • IoT
      • Metering
      • Security Systems
      • Telecom
    • Oil & Gas
    • Transportation
      • Industrial Vehicles
      • Marine
      • Rail
      • Racing
      • Transportation Infrastructure
    • Utilities
      • Power Generation
      • Transmission & Distribution
      • Renewables & Microgrids
      • Off-Grid
  • Products & solutions
    • Product Search
    • Training Courses
    • Services
  • Media & resources
    • Press Releases
    • Our Stories
    • Energizing IoT Blog
    • Customer Magazine
    • Events
    • Knowledge Hub
      • White Papers
      • Webinars
      • Technical Articles
  • Careers
    • Current Opportunities
    • Our People
    • Our Values
    • Our Company Culture
Home » Energizing IoT » Custom pack-making: designing your IoT batteries to the best standards

Custom pack-making: designing your IoT batteries to the best standards

Back to all articles
Share on
All about batteries - Antoine Derouet, Primary Lithium Battery Development Manager Connected Energy Division - November 24, 2021

Looking into batteries at the very start of your design process is a prerequisite as they have a major impact on your IoT device’s electronics. You can easily avoid power pitfalls by anticipating key parameters. Once you know how many batteries you need to power your device as per your lifetime target, the time comes to consider the actual design of the battery pack. Transportation restrictions and the environment in which the device will be deployed have an impact on the design of the battery pack, thus on its size and cost.

Antoine Derouet is Primary Lithium Battery Development Manager for the Connected Energy Division at Saft. His job? Designing the best battery pack for your complex applications, with the help of his skilled and experienced team of mechanical and electronic engineers, prototypists, technicians and project managers. We’ve invited him to explain what exactly battery assembly is and why you should make sure to submit your design to his team…
 

What is battery pack-making?

Cells are commonly called batteries, although strictly speaking, only an assemblage of cells should be called a battery or battery pack. To provide the requested voltage and current for your application, we might recommend the use of an assemblage of cells electrically connected in series and/or parallel: a battery.

Connecting two cells in series allows for higher voltage, whereas connecting them in parallel will offer a higher capacity or lifespan.
In series (S), the positive terminal of the cell is connected to the negative terminal of another cell so that the current flows through each cell. You will therefore benefit from the voltage of all connected cells.
In parallel (P), the positive terminals are connected together, as are the negative terminals. The current is divided among the cells which means that the capacity of each of the cell is accumulative. For example, if 1 cell offers 5 years lifetime in the field, two will give you 10 years, 3 will give you 15 years in the field, etc.

After the lifetime calculation performed by our applications engineers, you know how many cells you need to power your device:

  • 1S 2P= 1 cell in series, 2 branches in parallel. (1x2)
  • 2S 1P = 2 cells in series, 1 branch in parallel. (2x1)
  • 2S 2P = 2 cells in series, 2 branches in parallel. (2x2) …

From there, many combinations are possible, depending on your device design: cube, stick or block. 4S1P side by side 2S2P in stick 2S2P in bloc

2S2P in bloc4S1P side by side2S2P in stick 

 

 

 

 

     2S2P in bloc                                                         4S1P side by side                                        2S2P in stick               

If your device requires only one cell, things are pretty straightforward. Once you’ve consulted our Application Engineers to have the best cell recommended to you, just read our article about “How to best integrate your battery into your smart object”, apply our recommendations and you should be all set to go!

However, as soon as you need two or more cells, get in touch with our battery development team: it will save you time, energy and money.
 

What do you need to consider when planning your battery assembly?

Your project might require a custom designed battery to meet extreme pressure, heat, vibrations, or transport requirements.

Transportation

Transport is one of the most common —and often overlooked— constraints to consider for the battery pack. Under current transportation regulations, Lithium batteries are classed as dangerous goods and as such, they are subject to several safety requirements. Airfreight forwarders will ask you to provide a UN38.3 Test Summary Report to allow the shipping of lithium cells. It consists of a series of 8 safety tests simulating transport conditions such as: pressure, temperature, shock, vibration, impact, altitude, etc.
To pass these tests, batteries must feature a robust design and protections against short-circuits and explosion. Therefore, we may have to add fuses, sheaths, specific connectors or adhesive foams to match transport standards. All these take some space that needs to be accounted for in the electronic design.

Climate and environmental constraints

If your device is deployed in a very humid or warm environment or subject to shocks or vibrations, as is often the case for industrial or ATEX applications, additional insulation may be needed. The goal here is to make sure that your battery can work as planned, even in tough conditions.

Here are some solutions to consider to protect and insulate the battery.

Solutions to consider to protect and insulate the battery

2s2p_lsh20_blc_eclat2s2p_lsh20_pm_eclat4s1p_lsh20_ccc_eclat    

 

 

    

 

 

 

Additional electronic components

We’ve already mentioned the electronic constraints, especially the power and capacity requirements of your device, but depending on how your device has been conceived, specific additional components might be need.

For example, if you don’t want a connector but prefer to solder the battery directly on to the electronic board, a PTC, (positive temperature coefficient or reversible fuse) can be added to protect the device from excessive current or heat generation.
If the battery isn’t the only power source, we might add diodes on the backup battery to protect it against charging. The diode allows the current to pass in one direction, but not in the other.
Also depending on the battery location in your device, the wire length might need to be extended.
Last but not least, we usually offer advice on connector prices and availability to avoid the possibility of you choosing a component that cannot be purchased at an affordable price.

 

Your project is unique. That’s why Saft’s Battery Development team provide a wide range of design services for Lithium Primary and Lithium-ion batteries, covering most specific needs of your applications. Turning to us to help design your battery pack is the guarantee that your device will meet safety standards, and work as planned once deployed in tough environments, at controlled costs.
Pre-design estimations, lifetime calculations, application criteria and NRE estimates are provided at no cost to you, in all confidentiality. Because your success is our priority. Don’t hesitate to contact us.

#Saft #Battery #battery pack assembly #battery pack #batteries #Battery Development #battery assembly #battery design #safety #power source #IoT #Internet of Things #Energy management #prototyping #pack making #pack maker
Share on

Newsletter

By signing up, you’ll be the first to hear about our news and receive exclusive advices.

We use your email address solely for sending our IoT newsletter. You can unsubscribe at any time using the unsubscribe button at the bottom of the newsletter.

For further information on how your data is managed, please consult our privacy policy.

Thank you for subscribing! A confirmation email has been sent to your mailbox.

Most popular items

  • Choosing the right battery for your IoT device and making the most of it: 20 resources you can’t miss.

    Céline Bernard - Inside Sales and Marketing - Connected Energy Division - 4 minute read
  • Smart water management: 5 innovative solutions to water scarcity offered by the IoT

    Céline Bernard - Inside sales and Marketing - Connected Energy Division at Saft - 4 minute read
  • From the sensor to the datacenter, providing reliable power to secure your data all along the IoT value chain

    François Danet, Global Business Development & Ricardo Nunes, Li-ion Product Manager | Data Center Power solutions & Services - 4 minute read

Not to be missed

Download the IoT Cheatsheet

TRENDING TWEETS

@Saft_batteries 🌞🔋🎓 What is the difference between #Power & #Energy? Here is the perfect visual to explain this last and particularly tricky question of our #SummerBatteryAcademy. Need more resources to master #battery basics? 👉https://bit.ly/Saft_technical_tools #batteries #saft
@Saft_batteries Under extreme weather conditions and on tough terrain, Saft #batteries contribute to protecting endangered #wildlife in the most isolated areas of the world! Find out more on how #IoT devices are being used to benefit vulnerable ecosystems Right pointing backhand index https://saftbatteries.com/energizing-iot/how-can-iot-help-us-solve-our-ecological-issues-episode-2-biodiversity
@Saft_batteries #DigitalTwins ♊️solutions such as @deutschetelekom #IoT Solution Optimizer can help in reducing the time to market and also creating less defective devices🚀. Miguel Rodriguez explains how 🔋 http://bit.ly/Saft_Blog_e09
Follow us on Twitter

Related Articles

  • Empowerment - April 1, 2022

    Choosing the right battery for your IoT device and making the most of it: 20 resources you can’t miss.

    How to best power your IoT device for a long lifetime and a better return on investment? Discover the list of our top 20 resources to help you get the most of your battery. #Saft #Battery #Lithium

    4 minute read

    See more
  • IoT applications - March 22, 2022

    Smart water management: 5 innovative solutions to water scarcity offered by the IoT

    Less waste, less consumption, and a better management of the water’s quality can improve the preservation of our planet’s resources. Find out how the Internet of Things can help. #Battery #Lithium #IoT

    4 minute read

    See more
  • All about batteries - March 16, 2022

    From Sensor to Space: how Saft batteries support Satellite IoT connectivity to ensure continuous communication everywhere on earth

    Follow us to discover how satellites are used for communication and how the IoT is benefitting from our space experience… #Space #Satellites #Rechargeable battery

    4 minute read

    See more
  • Our products - March 10, 2022

    From the sensor to the datacenter, providing reliable power to secure your data all along the IoT value chain

    Read how Saft is powering the IoT all along its value chain, making sure the data is effectively captured by sensors, then stored securely to be available whatever happens. #Data Centers #cloud #Hyperscaling

    4 minute read

    See more
  • Sustainability - February 10, 2022

    How can IoT help us solve our ecological issues? Agritech

    The Industrial Revolution was instrumental in the development of ecological issues. Can the current technological revolution —and IoT in particular— help us find some solutions? #Environment #Internet of Things #Innovation

    5 minute read

    See more
  • IoT applications - February 3, 2022

    In the eye of the storm – When IoT helps predict natural catastrophes

    Making weather forecasts right as rain: Discover how IoT can help predict the weather more accurately #Meteo #IoT #Internet of Things

    4 minute read

    See more
  • All about batteries - January 25, 2022

    Lithium-ion batteries in use: 5 more tips for a longer lifespan

    In this article, we focus on how to care you for your Lithium-ion battery while in use to extend their lifespan. #Rechargeable battery #Li-Ion battery #battery care

    5 minutes read

    See more
  • All about batteries - January 13, 2022

    Charging your lithium-ion batteries: 5 expert tips for a longer lifespan

    In this article, we explain how lithium-ion batteries work and share our 5 top tips on how to charge your industrial-grade lithium-ion batteries to optimize their lifespan. #Rechargeable battery #Li-Ion battery #battery care

    3 minute read

    See more
  • IoT market & trends - December 15, 2021

    6 exciting IoT power optimization trends to watch out for in 2022

    We have gathered some of the main power optimization trends that are getting us all excited in 2022: 5G, DevOps, harvesting technologies and more! #IoT #InternetofThings #batteries

    3 minute read

    See more
  • IoT applications - December 8, 2021

    Powering the Industrial Internet of Things (IIoT)

    The Industrial Internet of Things (IIoT) has transformed the way industries operate. Batteries have been an integral part of this development. Find out how... #Battery #IoT #Industrial Internet of Things

    6 minute read

    See more
  • All about batteries - November 30, 2021

    The impact of the temperature on your IoT application’s power consumption

    Did you know that temperature is the main factor impacting your battery’s power consumption? A slight change can affect your battery’s capacity and service life. Find out why. #Battery #IoT #Internet of Things

    4 minute read

    See more
  • Empowerment - September 29, 2021

    Lithium batteries in hazardous locations: ATEX and IECEx explained

    What are the ATEX directives and the IECEx conformity assessment system and why do you need batteries that comply with them? #Saft #ATEX #IECEx

    3 minute read

    See more
Copyright © Saft2022
  • Terms & Conditions
  • Privacy Policy
  • Site Map
  • Saft4U
  • Stock Check (North America only)
FOLLOW US