PCM design can be divided into basic protection, communication, and BMS.
Basic protection: Basic protection includes overcharge, over-discharge, over-current and short-circuit protection, and can add over-temperature protection according to product requirements.
Communication: Communication protocols can be divided into I2C, RS485, RS232, CANBUS, HDQ, SMBUS, etc., and simple power display can be used with LED indicators powered by a watt-hour meter.
BMS: Battery management system, commonly known as battery nanny or battery steward, is mainly used for intelligent management and maintenance of each battery unit, preventing overcharging and overdischarging of the battery, extending battery life, and monitoring battery status. Its main functions include: real-time monitoring of physical parameters of the lithium camper battery, battery state estimation, online diagnosis and warning, charge, discharge and pre-charging control, balance management and thermal management, etc. This system is widely used in electric vehicle batteries.
The design of the lithium camper battery housing can be divided into PVC heat sealing, plastic, and metal.
PVC heat sealing: The specific external shell packaging form of the lithium camper battery pack is mainly determined by the specific needs of the customer's product. For packaging forms that use PVC heat sealing, it is generally suitable for cases where the number of cell connections is small and the overall weight is light (≤2kg). However, for battery packs with an overall weight of ≥1kg, fixed brackets need to be added between the cells. After being protected by glass fiber board, PVC heat sealing can be used.
Plastic: Using a plastic shell, mainly due to the different external shells involved after the shaping of different battery packs may require mold opening, which is a significant cost. If the product is not shaped during the early development stage, hand-sketched shells (hand-sketched strength is not as strong as the material strength after shaping) can be used. Different requirements for shell material and technology (especially with waterproof requirements) will also affect costs.
Metal: Like plastic shells, for lithium camper battery products that are not shaped or require a small quantity, it is recommended to use sheet metal samples. This is mainly because the sample production time is shorter. If the batch is large, it is also recommended to open molds. Requirements for metal shells with waterproof grades and special materials (such as titanium alloys) will result in higher costs.
The cost of lithium camper battery mainly consists of battery cells, PCM, and structural components, and also includes corporate PACK costs, aging costs, management costs, etc. At the same time, due to differences in product technology difficulties, procurement volume, and defect rate requirements, lithium-ion battery prices will vary greatly.