Your Lithium Partner

NCPOWER's lithium battery manufacturing process and high level of customisation

NCPOWER's lithium battery manufacturing process and high level of customisation

1 August 2023

Customising the production of a lithium battery pack means tailoring it to the specific needs of each customer. In other words, it is about understanding what the customer requires and designing appropriate solutions for their particular use.

At NCPOWER, we have developed hundreds of different lithium battery models, each of which has followed our customisation process. We work with companies that manufacture electric vehicles and want to make the transition from lead-acid batteries to lithium batteries, or switch from an internal combustion engine to an electric or hybrid engine, or customers that already manufacture vehicles with lithium batteries and want to make an change of supplier for different reasons. During this technological change, our customers need guidance and support, and we provide it.

Below we explain in detail the steps we follow in the process of customising lithium batteries for each specific need.

Lithium battery production in 6 customisation steps

Before proceeding with the production of a customised lithium battery pack, the first step is a consultation with our sales and engineering team. In this way, the customer's requirements are examined and a preliminary analysis of the feasibility of the project is carried out.

These steps allow us to carry out the production and delivery of customised lithium battery packs efficiently and in record time.

Concept Phase

In the first step, we carried out a comprehensive analysis ad hoc to assess the feasibility of the project. Our commercial and engineering team examines the requirements in detail: duty cycles, sector of application, voltage, capacity, dimensions, etc.

Our goal is to determine whether the project is feasible and whether we can effectively meet the client's expectations. From this information, we develop a solution that solves the customer's problem. In addition, we contextualise every detail that will be used in the production of the customised NCPOWER lithium battery pack.

2. Design Phase

In the first step, we collect key information by gathering relevant data and filling in a detailed form containing the specifications of the customised battery operation, the mechanical size, the most suitable connectors for the specific project, the charger, etc. In addition, we define how the different devices will communicate within the vehicle in question. 

Every time we start a new project, we treat it as something completely unique and special. This applies to all teams and departments involved in the technological development of our company. Our goal is to provide our customers with a completely customised solution designed specifically to electrify their particular vehicle. By tailoring each solution so precisely, we achieve more efficient and high-performance designs. 

How do we achieve this? All the resources, materials and devices we use are focused exclusively on meeting the needs of the solution to be implemented in the customer's vehicle. 

This stage allows us to obtain all the data necessary to understand the requirements and objectives of the project precisely and to be able to manufacture the solution according to the customised needs of each client.

NCPOWER's customer service team issues a provisional order confirmation that provides the customer with a clear overview of the production steps and estimated delivery times. This confirmation includes information on the delivery of the lithium battery, the receipt of the delivery specifications and the approval of the specifications. 

In this way, the customer can have a complete understanding of the timescales and processes involved in the production of their customised battery pack.

3. Prototyping phase

To create a complete SDF (System Design File), the commercial and engineering teams meet initially to plan the priorities and activities related to the project. 

The customisation team then creates a technical project folder, where the electrical and mechanical specifications of the lithium battery pack are defined.

In addition, a 3D representation of a mechanical test and an electrical schematic showing the system configuration in terms of electrical connection and operation is also included.

In this step, customer approval is obtained on the supply specifications provided by NCPOWER's customisation office. The customer can confirm that the specifications are adequate or request modifications or updates. This mutual approval marks an important milestone before moving on to the next step of testing the battery's correct operation with the application in use.

4. Functional testing phase

After having adjusted the battery capacity, the electronic programming and the adaptability of the battery to the controller and the other components, we enter the final phase of the process. 

Our goal at this stage is to perform extensive testing to ensure compatibility and proper operation of the battery pack in the specific application of use. 

We want to ensure optimal performance and seamless integration with the application. To achieve this, we subject the battery pack to various tests and simulations to verify its operation under real-life conditions. Only when we have confirmed that everything works as it should, can we ensure that our product meets the highest standards of quality and performance.

This includes:

  • Electrical and mechanical production specifications
  • Functional test
  • Mechanisation of the serial battery in our application NCPOWER Data Center
  • All the manuals required for the sale of the lithium battery pack
  • Special tests on request or considered by NCPOWER according to customer needs (cycles, durability, battery health, etc.).

5. Mass production and mass production

At this point, we start production of the battery packs according to the approved specifications. At the end of production, we subject the battery packs to extensive testing. These tests follow a checklist specific to lithium batteries, evaluating the charge and discharge cycles as well as the overall functions of the battery pack.

Once all tests have been successfully completed, we proceed to ship the battery packs to the customer. 

Once we reach this point, according to the agreed terms for the monthly delivery of battery packs, we will begin to consistently and regularly supply customised lithium battery packs to the customer. This means that we will establish a continuous flow of supply to ensure that the customer receives their battery packs on a regular and consistent basis according to their needs and prior agreements. In this way, we guarantee a stable and reliable relationship in the supply of customised battery packs.

6. Support. Remote control and service centre

Once we have delivered the battery packs, the technical project is transferred to the support and after-sales department. Here, a thorough follow-up is carried out with the aim of improving future upgrades and product performance. This stage is crucial to ensure continued customer satisfaction and optimise system performance.

We perform daily remote monitoring of the battery pack, sending data from each charge and discharge cycle to the NCPOWER Data Centre. This data is automatically analysed to ensure efficiency throughout the life of the battery pack.

In case the battery pack does not include remote monitoring, our NCPOWER after-sales service team is fully available to provide any necessary support to the customer. We are committed to ensuring continued customer satisfaction even after delivery of the battery pack.

In short, our work process is based on personalised attention to customer needs, in-house manufacturing and continuous monitoring to ensure optimal performance and a trouble-free experience.

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