In this article, Excell Battery shares its learnings from 40+ years of custom battery pack manufacturing and therefore cell and cell provider selection. 

What OEMs Need to Know About Choosing Battery Cell Providers

There are three important questions that OEMs need to ask when choosing a cell provider:

1. Can the provider consistently and reliably supply the necessary cells?
2. What are the technical specifications required for the application (e.g. discharge rate and capacity requirements)?
3. Can the provider produce cells that meet the required specifications?

When selecting battery cells and a cell provider, it’s important to be aware of some common pitfalls and misconceptions that OEMs might face. One significant challenge is limited market awareness. While conducting market research and identifying a cell provider offering a suitable product is a good start, it is important to recognize that the battery market is vast and diverse. Many ideal options for a specific application may not even appear in a Google search, requiring a more comprehensive approach.

Often, past experiences and time constraints may also limit the decision-making process. Without a dedicated battery expert, these factors can restrict an OEMs choice to a handful of preferred brands, none of which carry a cell that fits the ideal profile for the application.  

An experienced custom battery pack manufacturer such as Excell can help OEMs overcome these obstacles, bringing the depth of knowledge and time needed to explore the cell and cell providers in the market.

Considerations for Choosing a Cell

It can often be challenging to recognize the specifications that are most important. An OEM engineer might prioritize capacity, while overlooking the factors that are critical to performance in their application. For example, selecting a high-capacity cell without considering its discharge rate can lead to reduced performance under high-load conditions.

Lithium-Ion Cell Considerations

Packs composed of lithium-ion batteries require a protection circuit. They also can’t be charged or discharged below zero degrees unless they are expensive, specialized cells. While some online vendors offer low-cost lithium-ion batteries, these may not meet the required specifications, or may not be capable of combining multiple specifications. OEMs should be aware that some of these cheap lithium-ion batteries are even known to simply have a tiny cell at the top of the can while the remainder is filled with sand. Any cells purchased from Excell will be sourced from a reputable supplier that stands behind their product and will be able to meet all the required specifications.

Cell Considerations for Hazardous and Extreme Environments

Cells that will be used in extreme environments or hazardous locations also necessitate specialized battery solutions. Devices used in these environments may require certification to identify safety hazards and reduce the risk of accidents. For example, they must pass a short circuit test without exceeding a set temperature. Although it might seem counterintuitive, cells with lower discharge rates often work best for applications in these environments. Higher-rate cells, capable of delivering high currents can rapidly heat up, potentially reaching these limits. On the other hand, older lower-rate cells release the same amount of energy over a longer period, resulting in lower peak temperatures.

There are various strategies that can be employed to achieve certification compliance, depending on the device and the certification requirements. One approach involves adding redundancies to increase internal resistance. Cells may also be encapsulated in thermally conductive potting compounds to help dissipate heat more effectively, reducing peak temperatures. However, these solutions come with trade-offs, such as reduced energy density or increased weight.

How Excell Battery Can Help

By partnering with Excell Battery, OEMs gain a reliable and knowledgeable partner in battery solutions. Our cell-agnostic approach and our deep understanding of battery technology enable us to deliver customized solutions that optimize performance, reduce costs, and meet the most stringent safety and environmental standards.

Let us help you navigate the complexities of battery technology and select the ideal solution for your specific needs. Contact us today to discuss your project requirements.

The post Cell and Cell Provider Considerations for OEMs appeared first on Excell Battery Co..

Why Lithium-Ion Battery Safety Needs Attention

The potential safety risks associated with mishandled lithium-ion batteries are causing concern. Incidents during transport or storage within residential or commercial buildings can lead to devastating property losses and significant increases in insurance premiums. Some residential buildings, hospitals, and transit systems are preemptively banning e-bikes and other products powered by these batteries within their facilities. Stakeholders in the battery industry must address these concerns to ensure the continued adoption of lithium-ion technology.

Another issue arising as lithium-ion batteries become more popular is consumer awareness of proper disposal methods. Disposal of lithium-ion batteries in regular waste bins can be dangerous. Crushing during trash collection and handling can cause them to ignite and potentially cause fires. These batteries not only power electric vehicles, e-bikes, e-scooters, and small personal devices like phones and laptops, but also unexpected items like singing greeting cards. Some argue that their use in unexpected products is irresponsible by manufacturers, as consumers may unknowingly dispose of them improperly. 

EU New Battery Regulation 2023/1542

To combat these issues the European Union (EU) published the EU New Battery Regulation (EU) 2023/1542 on July 28, 2023, in the Official Journal of the European Union. Just weeks later on August 17, 2023, the Regulation was officially put into effect. It covers all batteries available on the EU market and aims to improve sustainability, safety labeling, and waste management. The Regulation supports the shift to a circular economy and increases the security of supply for raw materials. 

Scope of applications and battery sizes

The EU New Battery Regulation includes both rechargeable and non-rechargeable batteries. It is relevant for manufacturers of cells, modules, battery packs, energy storage systems, EV battery systems, and end products utilizing batteries. The regulation itself casts a broad net, encompassing battery categories such as waste portable batteries, electric vehicle batteries, industrial batteries, starting, lightning, and ignition batteries, and batteries for light means of transportation such as e-bikes, mopeds, and e-scooters. While specific rules within the regulation place stricter requirements on larger batteries exceeding 2 kWh, batteries of all sizes are affected.

However, small to medium-sized enterprises with less than 250 employees and an annual turnover of up to 50 million Euros or a balance sheet total of no more than 43 million Euros are exempt from many of these requirements unless they produce batteries over 2 kWh capacity. This includes Excell Batteries as their largest rechargeable battery in 540Wh, and the largest primary stick packs are approximately 2kWh. 

Key requirement: replaceable batteries for portable devices

As part of the Regulation, the EU will require all portable devices sold within the bloc to have replaceable batteries by 2027. This applies to all smartphones, laptops, and tablets, including those produced by Apple, Samsung, and Google. This is just one example of how the Regulation will likely significantly impact the rest of the world, despite being an EU directive. It is unlikely that manufacturers will produce two different versions of their products – one for the EU and one for the rest of the world.

Key requirement: battery passport

To ensure compliance with the EU New Battery Regulation, EV and industrial batteries over 2 kWh will be required to have a unique digital battery passport accessible via a QR code integrated into their label. The battery passport will include relevant data from the entire battery lifecycle including battery chemistry, capacity, performance, safety, cycle life, carbon footprint, and calendar data.

Key requirement: label markings

The EU New Battery Regulation also imposes new requirements for CE markings. An abbreviation of “Conformité Européenne,” or European conformity—the CE mark has been around since 1993, and serves as a way for manufacturers to declare that their product complies with all the applicable legal requirements within the European Economic Area. 

All portable batteries sold within the EU market will need to carry the CE marking by August 2024. Compliance is self-declared and obligations depend on the type of battery. 

The current best practices for battery label compliance are:

• CE Mark,
• Makers mark,
• Assembly site
• Serial number,
• Model number,
• Warning/safety information,
• Battery chemistry
• Ah, 
• Wh (best practice, but also mandatory for Li-Ion batteries), 
• Voltage (best practice, but also mandatory for Li-Ion batteries),
• Crossed-out waste bin symbol
• Lithium battery recycling symbol
• IEC series/chemistry/parallel coding

For lithium primary (non-rechargeable) batteries, the amount of lithium in grams is also required.

Those best practices are highlighted on the portable battery example label below:

Figure 1: Current Battery Labeling Best Practices (Portable Batteries)

Key requirement: responsible sourcing

The EU New Battery Regulation echoes existing initiatives like RoHS and REACH by including language that discourages battery manufacturers from using certain materials. Additionally, the regulation mandates responsible sourcing of base materials, prohibiting the use of conflict minerals obtained through practices like slave labor, environmentally damaging mining, or practices that violate health and safety standards.

Timeline

The EU New Battery Regulation encompasses a significant number of mandates that will gradually roll out over the next few years with the goal of reaching climate neutrality by 2050. Stakeholders in the battery industry should be aware of the following timeline for the Regulation. It is of note that most of the upcoming requirements of 2023/1542 only apply to batteries greater than 2 kWh at this point. As we approach the following dates, it is important to check the criteria for any regulatory implementations:

February 18, 2024: Mandatory enforcement of the Battery Regulations

August 18, 2024: Mandatory enforcement of safety requirements for stationary battery energy storage systems, performance and durability requirements for rechargeable industrial batteries with a capacity greater than 2 kWh, LMT batteries and electric vehicle batteries, conformity assessment procedures, and economic operator obligations

February 18, 2025: Mandatory enforcement of carbon footprint requirements for electric vehicle batteries

August 18, 2025: Mandatory enforcement of supply chain due diligence / Mandatory enforcement of waste battery management

February 18, 2026: Mandatory enforcement of carbon footprint requirements for rechargeable industrial batteries

February 18, 2027: Mandatory enforcement of battery passports for rechargeable industrial batteries larger than 2Kwh and electric vehicle batteries / Removability and replaceability of portable batteries and LMT batteries

August 18, 2028: Mandatory enforcement of requirements for recycled materials in rechargeable industrial batteries with a capacity greater than 2 kWh, except those with exclusively external storage, electric vehicle batteries, and SLI batteries, conformity assessment procedures, and economic operator obligations.

What EU New Battery Regulation (EU) 2023/1542 Means for OEMs

OEMs that may be impacted by the EU New Battery Regulation (EU) 2023/1542 should involve their battery suppliers early in the product design process to ensure timely compliance. All companies doing business within the European market must undergo IEC 62133 testing to verify their batteries meet safety requirements. Additionally, they need to meet labeling requirements and best practices, including affixing the CE mark. The complete directive can be found here.

The EU New Battery Regulation isn’t the only set of rules that manufacturers and users need to be aware of. A few examples include the previous EU Battery Directive, which has been in effect since 2006. It focuses on the chemical content of batteries, and recycling practices, and establishes requirements for battery capacity, and rating. 

Another important directive is the Electromagnetic Compatibility (EMC) Directive (2014/30/EU). It ensures that electric and electronic equipment, including those powered by batteries, don’t interfere with the functionality of other devices through electromagnetic emissions.

Applicable both inside and outside of the EU, the International Air Transport Association (IATA) and the International Civil Aviation Organization (ICAO) are introducing new regulations specifically for the transport of lithium-ion batteries. These regulations, effective on January 1, 2025 , limit the state of charge for all lithium-ion batteries transported by air, land, or sea to 30%. It applies regardless of whether the batteries are shipped loose or packed as part of an end product. 

Excell Battery Company: Your Partner in Compliance

With over 30 years of experience, Excell Battery Company has established itself as a trusted partner for OEMs navigating the complexities of battery regulations. Through a commitment to continuous learning, Excel maintains a strong understanding of the ever-evolving regulatory landscape. This includes changes in regulations, training requirements, label requirements, and packaging requirements. Excell works closely with their customers to ensure compliance and create a better battery industry for everyone.

The EU’s New Battery Regulation 2023/1542 marks a significant step toward a more sustainable and responsible future for lithium-ion batteries. By addressing safety concerns, promoting responsible sourcing, and ensuring steps toward circularity, the Regulation will ensure the continued growth of lithium-ion technology. While the regulation targets the EU market, its impact will likely be felt globally as manufacturers strive for consistency across their product lines.

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In this webinar, we will provide current and up-to-date information for procurement professionals in the medical device industry on the dynamic medical battery market. We will explore the latest trends and supply challenges, equipping you with the knowledge and risk mitigation strategies to overcome today’s and tomorrow’s obstacles. The following topics will be covered:

• Understanding medical equipment battery applications, the importance of reliable power sources, and key factors to consider when evaluating supply options,
• Regulatory considerations, including costs and expected timelines
• Current trends in the medical battery industry/market from supply chain and technical standpoints, including those driven by EV development,
• Q&A session, including perspective on the new EU Battery Regulation 2023/1542

The post 2024 Medical Battery Market Insights appeared first on Excell Battery Co..

We will be posting all the answers in this YouTube playlist:

Current questions Bob has answered:

• How safe is a Li-Ion Battery Pack?
• How susceptible are battery packs to shock and vibration?
• How does a battery pack fuel gauge work?
• Is battery pack protection circuitry needed?
• What will happen if I puncture a Li-Ion Battery Pack?
• What is the shelf life of a Li-Ion battery pack in storage?
• What types of batteries are used in downhole drilling?
• What are the different types of lithium-ion battery cells?
• Is a LiFePO battery safer than a polymer or lithium-ion battery? 
• What battery recycling facilities should I recommend to my customers?
• Can lithium-ion batteries become overcharged?
• Why would I need a custom lithium-ion battery pack?
• What’s an ideal battery State of Health (SoH)?

The post Battery Bob: Your Battery Questions Answered in This Q&A Series appeared first on Excell Battery Co..

The Logistical Benefits of Onshoring

In any industry, the greater the distance required to move components through a supply chain, the greater the risk for delays. During the last few years, ports have been plagued by congestion, with shipping containers sometimes waiting weeks to be unloaded. When it comes to batteries, delays in the supply chain can have dire consequences for tech OEMs. In response to logistical delays and tariffs, there is a current movement amongst manufacturers toward “onshoring” their choice of suppliers. By partnering primarily with North American suppliers, Excel Battery substantially reduces the risk of shipment delays, avoids costly tariffs, and ensures a constant and reliable flow of essential components. 

At Excell Battery, we take a strategic approach to our engineering and manufacturing operations by positioning them in key North American hubs. Our Canadian facilities in Vancouver, Calgary, and Toronto, coupled with our American facility in Houston, Texas, enable us to meet the demands of North American entities. 

The Engineering Benefits of Onshoring

Localization goes beyond the physical location of our manufacturing facilities. Excell Battery boasts a close-knit North American engineering team, allowing us to oversee the entire design process with unrivaled speed and efficiency, free from offshore complications. Even small hurdles like managing workflow amongst different time zones are eased or eliminated when a core team is centralized. This facilitates quick design iteration cycles, enabling us to respond promptly to rapidly changing market demands and stay at the forefront of technological advancements. As a result, our product development chain is characterized by agility, responsiveness, and reliability. 

The 2023 North American Advantage

As we settle into the post-COVID era, the persistent reality of supply chain disruptions looms large, fueled by ongoing geopolitical conflicts, inflationary pressures, and unforeseen challenges. Consequently, the accessibility and smooth flow of goods may be affected, leading to port delays, reduced freight availability, price surges, and other concerns. However, at Excell Battery, we are well-positioned to meet these challenges head-on.

Addressing the Challenges of Supply Risks and Rapidly Changing Technology and Conditions.

The surge in EV (electric vehicles) sales over recent years has intensified the demand for critical materials, putting tremendous pressure on battery component supply chains. As road transport electrification efforts continue to expand, driven by the global commitment to achieve net-zero emissions, the demand for essential materials is expected to further escalate, and technology is expected to advance rapidly. To mitigate the risk of disruptions, one effective strategy is to establish long-term contracts and partnerships with local suppliers, ensuring stability and a reliable supply of crucial resources. Keeping any design operations close to home also enhances our adaptability and responsiveness, so we can navigate any economic or product development challenges with resilience.

Addressing the Challenges of Economic Instability

Economic instability has triggered a cascade of challenges across global supply and product development chains. Fluctuations in demand have become unpredictable, making it challenging for businesses to effectively plan and produce goods. Rapid shifts in demand can lead to excess inventory or shortages, disrupting the supply chain flow. Additionally, the rise in interest rates is compounding the cost of corporate debt, further driving up the cost of labor and goods.

Fluctuating currency exchange rates add another layer of complexity, making it difficult for companies to forecast and manage costs for importing and exporting goods. The constraints of financial uncertainties weigh heavily on businesses, restricting their capacity to invest in crucial areas such as technology, infrastructure, and workforce. Excell Battery’s decision to center our operations within North America offers stability and efficiency. By utilizing local facilities and personnel, we maintain greater control over our supply and product design chains, reducing our vulnerability to external economic pressures.

Addressing the Challenges of Geopolitical Tensions

Amidst current geopolitical tensions, the prospect of material scarcity and soaring raw material prices looms large, presenting challenges to supply chains worldwide. As nations re-evaluate their relationships with global partners, exploring new strategies becomes a necessity. By reducing reliance on overseas suppliers, Excell Battery can maintain a stable flow of materials and minimize the risk of demand fluctuations. In their article, “The Supply Chain Trends Shaking up 2023,” KPMG explained, “Governments and industry leaders are exploring domestic self-sufficiency in material supply and manufacturing. Short of this, they are looking to build ‘friend-shoring’ relationships – trade links with like-minded and most likely geographically close countries (‘nearshoring’) where the supply of goods will likely be more secure.” Taking advantage of friendshoring or nearshoring has additional benefits such as enabling Excell Battery to reduce lead times, lower costs, and improve the speed of our products to market. 

The advantages of a North American supply and product development chain are clear – reduced risks of delays, avoidance of costly tariffs, efficient engineering processes, and a focus on local talents and resources. Additionally, local manufacturing offers greater control over production, ensuring consistent quality and timely delivery. By prioritizing these aspects and exploring new supply chain options, Excell Battery is well-equipped to navigate the challenges of a rapidly changing landscape and emerge stronger and more resilient in the face of economic instability, material scarcity, geopolitical issues, and any other challenges that the future may bring.

The post The North American Edge in Supply and Product Development Chains appeared first on Excell Battery Co..

In this webinar, Ian Kane (CEO of Excell Battery), Caron Craig (Excell Battery Regional Manager – Vancouver), and Mike MacWillie (Excell Battery Director of Engineering) discuss:

• Industry trends that drive the need for intelligent battery packs.
• Steps and best practices to design a device with an intelligent battery pack
• Information on Excell Battery’s Criterion iQ intelligent Li-Ion battery pack

Industry trends that drive the need for intelligent battery packs

Steps and best practices to design a device with an intelligent battery pack

You can download a copy of the checklist discussed in this portion here:

Information on Excell Battery’s Criterion iQ intelligent Li-Ion battery pack and Q&A

The Criterion iQ intelligent Lithium-Ion battery pack provides the data needed to ensure the devices is always ready. For more information (including the product’s spec sheet), click here.

The post The Next-Generation of Intelligent Battery Packs (WEBINAR) appeared first on Excell Battery Co..

As the battery application demands increase rapidly, battery hardware and chemistry are struggling to keep up. Software known as Battery management Systems are becoming increasingly important for meeting these demands through performance optimization. Intelligent battery packs that incorporate these systems can improve battery lifespan, reduce waste, and enhance reliability and safety.

Download the Design Checklist

Click the button below to download Excell’s Intelligent Battery Applications Design Checklist for a step-by-step guide to the process of designing an intelligent battery pack, such as Excell’s Criterion iQ, into your next application.

The post Intelligent Battery Applications – Design Checklist appeared first on Excell Battery Co..

Introduction to Battery Management Systems for Medical Devices:

Battery Considerations for Medical Device Design

Q&A: Battery Management Systems: Designing for Safe and Reliable Medical Devices

The post Battery Management Systems: Designing for Safe and Reliable Medical Devices appeared first on Excell Battery Co..

In the tradition of many great partnerships, this one started with a problem. How could we meet the increased demand of a pandemic climate? Pushing internal teams is one factor, but gaining the buy-in of external partners often presents a greater challenge. The challenge was to produce batteries at a rate several orders of magnitude higher than previous production rates required by the MOVES® SLC integrated, portable life support system. MOVES® SLC is a portable life support system that provides the highest level of patient care in extreme and rugged transport and emergency settings. Battery-powered, the MOVES® SLC integrates the functions of a ventilator, oxygen concentrator, physiological monitoring, and suction, making it an invaluable tool in the fight against COVID-19 in Canada and around the world. We worked together with Thornhill Medical to optimize the manufacturing process for high volume production and improve both throughput and data capture on battery final assembly testing.

At the outset, both Thornhill and Excell teams emphasized the importance of a clear, detailed, and consistent communication channel between engineering and production. Both teams quickly engaged in a daily cadence to meet deadlines. In rapid and efficient succession, we worked with Thornhill to source components, built and deployed fixtures and designed a new final-assembly testing system to accommodate the increased demand pressures. The data from the new testing system enabled rapid improvement to production throughout. We tapped into our extensive industry network to build a multi-channel automated cycling system in a matter of weeks, instead of months. Our combined expertise resulted in a testing plan that captured all product application needs within our timeframe. 

After partnering with Excell, Thornhill Medical is successfully delivering MOVES® SLC life support systems to support the ongoing response to COVID-19. Our team understood not only the timelines but the vital importance of delivering a battery and testing system that supports a complex medical device. As the partnership continues, we look forward to future innovation with Thornhill, always striving to produce the highest quality devices for an ever-changing global medical landscape.

The post Case Study: Meeting The Increased Demand of a Pandemic Climate appeared first on Excell Battery Co..

Choices made at the cell level have consequences on the entire manufacturing process. Our engineers design with the supply chain in mind. The ripple effects of each design choice are carefully weighed against their impact on the overall demand flow. We use our extensive North American resources to inform both our design and manufacturing decisions. Offering multiple cell and component alternatives allows production to move forward, unimpeded by material shortages. A quick internet search for cell vendors will pull up hundreds, if not thousands, of results. The quantity of results is not always accompanied by trustworthy rankings on the quality of these cells and vendors. A seasoned team of engineers provides the best oversight on supplier and product quality. 

Curating a healthy catalogue of raw materials is often where some manufacturers stop. Smart engineering goes a step beyond by establishing quality control procedures to test all cell and component alternatives. Qualification of cells through rigorous in-house lab testing should be second-nature to battery suppliers. Even the most reputable cell vendors are not immune to quality issues. Before signing on with a supplier, OEM clients should ask tough questions regarding quality control and safety procedures. In addition to testing the quality and safety of individual cells, an established lab program also provides assurances that all manufacturing quality standards are followed. North American standards are particularly stringent so any manufacturers operating within the continent should be well-versed in protocols such as ISO 9001, ISO 13485, UN38.3, etc.

Strong supplier relationships are one of the most crucial differentials separating top-tier manufacturers from their competitors. When a demand spike forces a supplier to pick and choose which orders to fill, the tipping point is often the strength of the customer-supplier relationship. This scenario continues to play out frequently across industries weighed down with pandemic pressures. The trust and reliability forged with our suppliers over many pre-pandemic years became critical factors when the ultimate stress test of COVID-19 hit. Our supply chain is built to support our clients through the entire design and manufacturing process, regardless of external disruptions. We partner with suppliers who share that same methodology. 

An infrastructure built on smart engineering principles provides the sturdiest foundation for OEM clients. Highly-specialized training does not have to translate to a hyper-narrow perspective. Engineers with a realistic approach to design and an awareness of the broader supply chain set clients up for the best chance of success.

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