Custom Battery Pack Engineering
for EV Applications

Battery pack architecture is determined by the application requirements: voltage range, capacity, available space, and weight constraints. We evaluate cell-level chemistry (LFP, NMC, NCA), determine series/parallel configuration, and design the mechanical structure for the specific vehicle and duty cycle. Architecture decisions directly impact safety, longevity, and performance — they are not interchangeable.

• Cell chemistry selection based on application
• Series/parallel configuration analysis
• Voltage and capacity sizing to duty cycle
• Mechanical layout and enclosure design
• Weight and center-of-gravity optimization

The Battery Management System is the intelligence layer of the pack. Proper BMS selection, configuration, and integration is critical to pack safety and longevity. We specify and configure BMS for cell balancing, state-of-charge estimation, protection functions (over-voltage, under-voltage, over-current, temperature), and communication with the vehicle control system.

• BMS selection matched to cell chemistry and pack voltage
• Cell balancing configuration (active/passive)
• Protection threshold settings
• SOC/SOH estimation setup
• CAN/UART communication integration
• Data logging configuration

Lithium cells operate within a specific temperature window. Operation outside this window degrades performance and accelerates capacity loss. For Indian climate conditions — ambient temperatures ranging from near freezing in northern winters to above 45°C in summer — thermal management is a design requirement, not an afterthought. We design appropriate cooling and insulation strategies based on the duty cycle and operating environment.

• Operating temperature range analysis
• Passive thermal management for moderate applications
• Active cooling design for high-power applications
• Thermal runaway propagation mitigation
• Indian climate condition considerations
• Thermal modeling for pack layout

Battery pack safety encompasses electrical, thermal, and mechanical protection. Our designs incorporate multi-level protection: cell-level protection from BMS, pack-level fusing and contactors, mechanical enclosure integrity, and ventilation or containment for thermal events. Safety design follows established standards and is documented for certification support.

• Multi-level electrical protection
• Manual service disconnect
• Current interruption devices (fuses, contactors)
• Enclosure IP rating for intended environment
• Thermal event containment
• High-voltage interlock loop (HVIL)

Pack performance — available energy, peak power, and cycle life — is a function of design choices made at every stage. Cell selection, temperature management, charge/discharge rate limits, and BMS calibration all interact to determine real-world performance. We optimize for the specific use case: urban stop-start delivery is a different requirement from long-haul highway operation.

• Charge/discharge rate (C-rate) optimization
• Capacity vs. cycle life trade-off analysis
• Regenerative braking integration
• Charging protocol specification
• State of health monitoring
• Performance validation testing