We create dedicated solutions and support our clients at every stage of the project. Quality and close cooperation is very important to us.
That is why we stay in close contact with you throughout the project process and inform you about all relevant stages.
1 Requirement analysis
We analyse your technical requirements and find the solution that best meets your demands: We determine the parameters required for your battery pack: electrical (e.g. voltage, capacity, resistance, operating and charging currents), mechanical (e.g. size, weight, mechanical stresses) and electronic (e.g. related to the electronic monitoring system).
2 Design & housing
Our experienced engineers assist you with the latest CAD software to ensure your demands are fully met.
3 Research & Developement / Prototyping
The R&D department designs systems and their components and software in accordance with UN-38.3, IEC 62133, UL 2054, UL 2595, UL 2271, UL 1998, UL 991, ISO 26262, EN 50604 and EN 15194 standards. We always take into account the application and specific requirements for the specific market to ensure the products’ functional safety.
Prototyping: At this stage, the first design is built using 3D printing before undergoing further examinations and necessary tests. The structural build of the packs is checked during the development phase. For example, we conduct pretests (shake and collision tests) for UN-38.3 certification. During this phase, we can still adapt or amend details to achieve the desired product features. The aim is to create a pack that’s as close to production as possible in order to test and validate its characteristics and functionality.
4 BMS programming
Highly advanced products using the Li-Ion technology are always equipped with a multistage electronic Battery Management System (BMS) to ensure complete safety of the system. BMS measures all parameters of the cells and, where necessary, disconnects the circuit and conducts cell charge balancing, which significantly increases the efficiency and extends the life of the power source.
5 Tests & certifications
We conduct tests, frequently using the final application, to verify the durability of the pack (tests in accordance with the client’s load profile, cycle and climatic tests). The tests also include a thorough analysis of technical requirements for the device and a detailed assessment of the materials, methods and technologies used in the pack. We conduct several tests at our own laboratory, while UN certification is also carried out in-house.
Thanks to our external independent partners, we also assist our clients with safety and transport certification – an important factor, in particular for international markets. This includes EMC tests as part of the EU declaration of conformity as well as IEC and UL test reports.
6 Series production
After successful tests, we initiate batch production. We use the Lean Manufacturing Method to ensure efficient use of human and material resources and optimise manufacturing costs.
We pay special attention to the following factors:
- high quality and stability of cell parameters
- correct sizing of cells before assembly (in terms of voltage, capacity and resistance)
- high-quality cell connections to ensure long life of the pack (from 300 to several thousand charge/discharge cycles)
- using professionally manufactured components designed by Battery-Kutter
7 Recycling concepts
At Battery-Kutter, we are conscious of our responsibility when it comes to substances that might be harmful to the environment. Therefore, the safe disposal of batteries is an important aspect of our work. In order to spread awareness and simplify the disposal process, we provide a cost-free battery disposal service for our customers.
We look forward to working with you to find a solution tailored to your needs!
Call us and we will be very happy to assist you: +49 40 611 631-0
Alternatively, feel free to send us an e-mail: email@example.com