We are proud to announce that we have achieved ISO 45001 certification. The globally recognised standard reinforces our commitment to health and safety while delivering high-quality solutions to customers worldwide and supporting future growth.
This certification comes as ABT builds on over 40 years of manufacturing excellence across the UK and abroad. With more than 15 million battery products delivered globally, the company has proven its ability to scale operations to meet demand, including ramping up production to nearly 300% during the Covid 19 pandemic. By embedding safety and efficiency into its operations, the manufacturer remains a trusted partner for industries such as medical devices, robotics, eVTOL and industrial power tools.
As the company continues its growth trajectory, it’s on track to reach £20M+ in revenue by 2026 and is targeting £30M in 2028, driven by ongoing investments, an expanding team and long-term projects that provide sustained revenue.
Mark Rutherford, Chief Executive Officer at Alexander Battery Technologies, said: “This certification is a key milestone for our business. It not only demonstrates our commitment to a safe, supportive workplace for our team but also positions us to meet the growing demands of our customers. Safety and quality are at the heart of what we do, and this investment strengthens our capability to scale and innovate in line with future opportunities.”
ABT’s recent investments in safety and training demonstrate its practical approach to improvement. An intensive IEC 61508 Functional Safety course equipped engineers with advanced knowledge to embed safety principles across products and processes. This aligns directly with ISO 45001’s framework and supports the manufacturer’s ability to operate confidently in high-stakes markets.
Rutherford adds: “We’re focused on expanding our workforce, pursuing additional international standards such as ISO 14001 and ISO 27001 by 2025 as we continue to enhance our reputation as a partner of choice for global OEMs. Achieving ISO 45001 reinforces our position as a forward-thinking manufacturer and sets a strong example for other businesses both nationally and internationally.”
To start a discussion about a battery pack manufacturing project please fill out our contact form.
The recent 25% tariff on Chinese batteries has significantly disrupted U.S. companies, particularly in consumer electronics and electric vehicles. This tariff has led to rising costs and uncertainty, forcing OEMs to reconsider their battery supply chain. With the possibility of further tariff increases, especially with the U.S. presidential election on the horizon, American firms need to find stable and cost-effective battery supply solution.
The 25% tariff on Chinese batteries, part of a broader U.S. strategy to protect domestic industries, has sharply increased costs for companies relying on these imports. Tariffs may not have reached their peak, with former President Trump suggesting they might reach 60% if re-elected. Rising geopolitical tensions, especially between China and Taiwan, add to the complexity. Centralized decision-making in China has led to significant disruptions in the past, such as during the COVID-19 pandemic. These factors are prompting many U.S. companies to re-evaluate their dependence on Chinese battery supplies.
In light of these challenges, U.S. OEMs are exploring alternative supply chain options, with the UK emerging as a promising alternative. UK manufacturers are known for their high-quality, reliable battery solutions and have invested in advanced technology. Their commitment to environmental sustainability aligns with U.S. companies’ green goals, supported by strict UK regulations. The UK’s strategic location in Europe also ensures efficient logistics and timely deliveries, making it an attractive partner for U.S. firms looking to diversify and stabilize their supply chains.
To adapt to the current disruptions, U.S. OEMs should start by assessing their supply chains to identify vulnerabilities caused by tariffs and geopolitical issues. Exploring alternative suppliers in stable regions like the UK can offer cost savings and enhanced stability. Engaging with potential new suppliers to ensure they meet specific needs is essential. This proactive approach will help U.S. companies navigate market uncertainties and strengthen their supply chains.
The evolving landscape presents both challenges and opportunities for U.S. OEMs. By diversifying their supply chains and considering UK partnerships, American companies can mitigate risks, reduce costs, and secure a reliable source of battery technology. As the election approaches and further tariffs loom, strategic decisions made now will shape the future stability of U.S. supply chains.
For a deeper dive on the solutions available for U.S OEMs, read our full article here and explore our CCO, Alex Stapleton’s thoughts on the recent tariff increase in his recent interview here. Contact us to discuss how our UK-based production can support your battery supply chain needs.
The e-mobility market has rapidly expanded over the past decade, driven by environmental concerns from consumers and governments, technological advancements, and a growing preference for newer technologies. This shift in buying habits has led OEMs to increasingly electrify their product offerings, with most Tier 1 e-mobility OEMs now offering both fossil-fuelled and electrified products.
A significant catalyst for this growth was the 2016 Paris Agreement, which marked a major turning point for the global e-mobility sector. The agreement saw 195 United Nations members commit to keeping the rise in global surface temperature well below 2%. Governments worldwide recognized the potential of the e-mobility sector to reduce emissions and achieve net-zero targets, leading to significant investments in infrastructure, including widespread installation of charging points. Additionally, tax incentives for both consumers and businesses have further encouraged the adoption of EVs.
As a result, the market is projected to demonstrate a steady worldwide compound annual growth rate (CAGR) of 9.82% between 2024 and 2028. This steady growth rate is expected to expand the market to an estimated $906.7 billion by 2028, with EV ownership reaching 17.07 million units.
To meet these optimistic forecasts, the battery supply chain must continuously improve, with custom battery packs playing a crucial role in this evolution. Cell manufacturers are focusing on innovations that enhance battery performance, tailoring custom battery packs to meet specific needs, such as extending vehicle range, reducing the weight of battery packs, and lowering overall production costs. Emerging technologies like solid-state batteries, which promise higher energy densities and faster charging times, could be integrated into custom battery solutions, offering OEMs the flexibility to design products that meet precise specifications. Moreover, the emphasis on sustainability is driving efforts to develop custom battery packs with longer lifespans and improved recyclability, ensuring they not only perform optimally but also align with environmental goals.
For OEMs, advancements in battery technology and a supportive regulatory environment present both opportunities and challenges. Integrating the latest battery technologies into their products will be crucial for staying competitive. This will require close collaboration with battery manufacturers and significant investment in research and development. Additionally, OEMs must navigate the complexities of the supply chain, ensuring a stable and sustainable supply of the raw materials necessary for battery production.
Battery manufacturers are at the forefront of the expanding e-mobility market, facing both significant opportunities and challenges. As both OEMs and consumers demand continual improvements, battery experts must push the boundaries of technology to drive the market forward. Success in these endeavors will prove lucrative, given the rising demand for EVs. To remain competitive and meet the evolving demands of the e-mobility industry, battery manufacturers must prioritize collaboration with OEMs and invest heavily in research and development.
To discuss your specific needs and explore how our UK-based production facilities and global expertise can help you navigate the evolving battery landscape, contact our battery experts.
ISO 13485 is an internationally recognised standard that sets out the requirements for a comprehensive quality management system (QMS) for the design and manufacture of medical devices. For the medical battery manufacturing industry, this standard ensures that products are consistently designed, produced and delivered to meet both customer and regulatory requirements. As a global battery pack manufacturer, Alexander Battery Technologies (ABT) aligns its operations with ISO 13485 to cater to the stringent demands of the medical sector, which is crucial for maintaining the highest levels of safety and efficiency in medical devices.
ISO 13485 compliance is particularly critical for manufacturers dealing with medical devices across various classifications. The standard applies to devices categorised into four classes:
Our focus lies primarily on Class 2A, 2B, and 3 devices. This emphasis on higher-risk categories necessitates the implementation of robust quality management systems to ensure that our custom battery packs and OEM chargers meet the precise needs of our clients across the medical industry.
For medical device manufacturers, ISO 13485 is not just a regulatory requirement. It is a framework that guarantees product safety and effectiveness. This standard affects various aspects of operations including machinery, process controls and documentation practices. By adhering to ISO 13485, organisations can ensure that their products are designed and manufactured consistently to meet customer and regulatory expectations.
We utilise customer specifications as the foundation for our battery pack designs. This customer-centric approach ensures that our products are not only compliant with regulatory standards but also meet the specific performance requirements of our clients. For instance, when developing a battery pack for an infusion pump or a bone saw, we meticulously follow the customer’s specifications to design a product that is robust and reliable, thus ensuring patient safety and device effectiveness.
Adopting ISO 13485 poses several challenges, particularly in establishing and maintaining robust procedures and comprehensive documentation. One significant challenge is ensuring that all documentation outputs align with the standard. For example, manufacturers of medical devices must demonstrate adherence to stringent cleanliness and cross-contamination protocols, which requires presenting valid data during audits to prove that these procedures are followed correctly.
For ABT, this means implementing stringent controls throughout our manufacturing process. We need to ensure that each step, from initial design to final production, meets the rigorous requirements of ISO 13485. This includes validating all manufacturing steps, performing thorough tests at various stages and maintaining detailed records of all activities. This level of diligence is crucial for achieving compliance and maintaining the trust of our clients and regulatory bodies.
To illustrate the practical implications of ISO 13485, consider the development of a battery pack for a Class 2A device, such as a blood pressure monitor. The process begins with receiving and understanding the customer’s specifications, which detail the required power output, voltage and other critical parameters. Based on these specifications, our design team creates a prototype that fits within the device’s spatial constraints and meets its power requirements.
Once the design is finalised, we move to the manufacturing phase, where each component undergoes rigorous testing. For instance, our battery packs are subjected to various welding processes, including resistance welding, laser welding and TIG welding, to ensure strong and reliable connections. We also conduct drop tests to assess the durability of the battery packs in real-world conditions.
Throughout the manufacturing process, we maintain full traceability of each component, from raw materials to finished products. This traceability is crucial for addressing any issues that may arise and for ensuring that each battery pack meets both our internal standards and those of ISO 13485.
In conclusion, ISO 13485 is an indispensable standard within the medical battery manufacturing industry, providing a comprehensive framework for quality management that ensures the highest levels of safety and efficacy for medical devices. Its adoption is crucial not only for regulatory compliance but also for developing trust among healthcare providers and patients.
The implementation of ISO 13485 requires manufacturers to maintain stringent controls and robust documentation processes, addressing challenges such as cleanliness, cross-contamination prevention and full traceability of products. These stringent requirements necessitate continuous improvement and vigilance in quality management practices, ultimately leading to superior product reliability and performance.
For the medical industry, the benefits of adhering to ISO 13485 are multiple. Enhanced product quality and consistency contribute to better patient outcomes and increased confidence in medical devices. The standard also drives operational efficiencies and reduces the risk of product recalls or failures, thereby protecting manufacturers’ reputations and minimising financial liabilities.
ISO 13485 also facilitates innovation in medical technology. By setting clear guidelines for quality management, it allows manufacturers to focus on developing advanced solutions that meet the changing needs of the healthcare sector. This, in turn, supports the growth and advancement of the medical industry as a whole, enabling the delivery of cutting-edge medical devices that improve patient care and outcomes.
At ABT, our adherence to ISO 13485 demonstrates our commitment to quality and reliability. By aligning our processes with this standard, we ensure that our battery solutions not only comply with regulatory requirements but also meet the highest expectations of our clients in the medical sector. This dedication to maintaining rigorous quality standards helps us deliver innovative and dependable products that support the critical work of healthcare professionals.
In an industry where precision, reliability and safety are paramount, ISO 13485 serves as a cornerstone for ensuring that medical devices meet the rigorous demands of both regulatory bodies and end-users. The commitment to this standard highlights the industry’s commitment to maintaining the highest quality standards, thereby safeguarding public health and enhancing the effectiveness of medical treatments worldwide. Contact our battery experts to discuss your specific needs and explore how our UK-based production facilities and global expertise can help you navigate the evolving battery landscape and achieve a secure, cost-effective, and future-proof supply chain.
In today’s global market, reliable access to high-quality battery technology is crucial for a wide range of industries, from consumer electronics to electric vehicles. Supply chain professionals, particularly in the United States, are facing increasing challenges in managing the risks associated with their traditional battery supply chains which involve China. With tariffs on the rise and geopolitical instability creating uncertainty, it would be prudent for US companies to review their sourcing solutions and explore regions with stable trade relations with the US. Partnering with a UK battery pack manufacturer can help American businesses to mitigate risks, safeguard their supply chain and secure cost-competitive, stable, and sustainable battery supply solutions.
The recent imposition of a 25% tariff on Chinese battery imports by the US government has significantly increased costs for businesses reliant on these products. According to an article on Energy Storage News, this tariff hike is part of a broader trade war strategy aimed at protecting domestic industries, but it has left many companies grappling with higher expenses. Furthermore, with the upcoming presidential election, there is a potential for even higher tariffs. Donald Trump, one of the leading candidates, has suggested that rates could soar to 60% or more if he is re-elected, as reported by The Washington Post.
These uncertainties make the cost and availability of batteries increasingly unpredictable. Additionally, geopolitical tensions, such as the possibility of China challenging Taiwan’s sovereignty, further threaten the stability of supply chains. The centralised decision-making approach in China has also led to significant disruptions during crises, as seen during the COVID-19 pandemic when supply chains were put on hold indefinitely. This behavior has led to speculation that relying solely on China for supply chain needs is no longer a viable strategy for US companies. These factors highlight the need for US companies to explore alternative sourcing strategies.
Many US companies are exploring strategies to diversify their battery supply chains and build resilience. This may involve partnering with suppliers in regions with stable trade relations with the US. Once such region that procurement professional are turning to is the United Kingdom.
With UK and US manufacturers often sharing common ground on topics such as innovation, quality, sustainability and safety, the synergies are obvious. A move towards UK-based manufacturing partners can help US OEMs to strengthen their supply chains and provide long-term price stability and supply security.
Beyond geographic diversification, partnering with a reliable and experienced supplier is crucial for a secure battery supply chain. Established players with a global presence, like UK battery pack manufacturer, Alexander Battery Technologies (ABT), bring several other advantages to the table:
1. Proven Track Record: With 40 years of expertise, and a strong history of supporting US companies across various technically-demanding sectors such as medical, health and safety, electrification, and communication. The company is well-versed in the latest technologies, ensuring that battery products meet the highest standards of quality and performance. Their low return rate under warranty (0.07%) demonstrates a commitment to quality and reliability.
2. Skilled Workforce and Cutting-Edge Technology: Alexander Battery Technologies leverages the UK’s strong engineering talent pool, ensuring access to a skilled workforce and advanced battery technology. Their recent investments in new R&D labs and state-of-the-art production facilities including a world-first laser welder further solidify their commitment to innovation.
3. Commitment to Sustainability: Alexander Technologies shares the commitment of its US customers to sustainable manufacturing practices. The UK has stringent environmental regulations and resources supporting environmentally-responsible manufacturing, aligning with the sustainability goals of many US companies.
4. Strategic Location: The UK’s central location within Europe provides efficient access to European markets. For US companies with global operations, this proximity ensures timely delivery and logistical efficiency.
5. Commitment to Quality Standards: ABT are on track to achieve several new IATF16949 (Automotive), ISO14001 (Environment), and ISO27001 (Cyber Security) certifications by the end of 2024. This pursuit underscores the battery manufacturer’s dedication to meeting the highest quality, environmental, and cybersecurity standards.
By prioritizing diversification, partnering with established suppliers like Alexander Battery Technologies, and carefully evaluating needs, US companies can navigate the evolving battery supply chain landscape and ensure a secure, cost-effective, and future-proof source of battery technology.
To transition to a more stable and cost-effective supply chain, US companies should undertake the following steps:
1. Evaluate Current Supply Chain Vulnerabilities: Conduct a thorough assessment of your current supply chain to identify vulnerabilities and potential risks. This will help you understand the areas where you are most exposed to tariff increases and geopolitical instability.
2. Explore Alternative Suppliers: Look into alternative suppliers that offer strategic advantages. ABT’s UK-based production is one such option that can provide cost savings and supply chain stability.
3. Engage with your chosen trusted supplier: Reach out to the supplier you have identified. A reputable battery pack manufacturer will be open to to discussing your specific needs including how they can support your transition to a more secure supply chain. Alexander Battery Technologies has supported business through this process before and can provide detailed information on the benefits of switching to a UK battery pack manufacturer to help you assess the feasibility of making the switch.
The evolving battery supply chain landscape presents both challenges and opportunities for US companies. By proactively addressing risks associated with tariffs and geopolitical instability, companies can build resilience and secure their access to critical battery technology. Diversifying sourcing strategies and partnering with established suppliers in regions with stable trade relations are key considerations. Additionally, aligning with partners that prioritize sustainability, R&D, and quality assurance further strengthens a company’s competitive edge. US companies could avoid potential pitfalls of switching lithium-ion battery suppliers by selecting a battery manufacturer with experience of supporting customers through the same process.
For a comprehensive understanding of these challenges and solutions, contact our battery experts to discuss your specific needs and explore how our UK-based production facilities and global expertise can help you navigate the evolving battery landscape and achieve a secure, cost-effective, and future-proof supply chain.
The demand for battery-powered products has increased exponentially during our lifetime and in more recent years has been booming in the industrial sector. With more processes relying on battery-powered vehicles and devices which have wide-ranging jobs to do in varied environments, it is inevitable that the design and development of the batteries that power these products has also changed. There are now more considerations than ever when making design decisions during battery pack development, one of the critical decisions is which cell chemistry is best suited to the application of the battery pack. The knock-on effect is that more OEMs are choosing custom lithium-ion battery pack designs to enhance the performance of their products, because off-the-shelf solutions often don’t meet the specific requirements of their application.
Mobile robotics is a relatively new technology that is in increased use across various industrial sectors and as organisations become more reliant on robots performing crucial roles, getting them to perform to an optimum level has never been more important.
Popular devices include automated guided vehicles (AGVs) used in materials handling and other applications; automated mobile robots (AMRs) for last-mile deliveries: and frame climbers in automated warehouses.
This automation of more processes means the robotic devices require portable battery power systems that can maintain a continuous output, without running out of charge, or failing prematurely because of a fault or breakdown.
Consequently, battery pack technology is developing at a fast pace to keep up with the development of robotics in the workplace. Choosing the right battery chemistry has become critical to ensuring reliable performance.
Lithium-based batteries are the most common choice for new industrial batteries today, because of their high energy density and capacity, giving much longer run-time between charges than any other battery chemistry. With so many types of lithium chemistries used in battery cells, it is important to consider and specify the correct cell type, pack design, and quality for different environments.
The proliferation of lithium chemistries, and of the components such as battery charge controller ICs that support lithium battery packs, mean that a robot OEM can be faced with a complex set of trade-offs to consider. The decision about the best set of trade-offs needs to be made on an application-by-application basis.
A reliable custom battery pack manufacturer, like Alexander Battery Technologies, will work in collaboration with OEMs to provide detailed guidance about these and every other performance attribute of each lithium chemistry, and to advise on the best choice for the OEM’s specific mobile robot application.
Sometimes, this means looking outside of the latest in cell chemistry and battery technology.
For example, when it comes to mobile robotics which are required to perform in extreme temperature ranges, we often turn to one of the older chemistry technologies – lithium titanate (LTO).
Mobile robots that operate in a cold environment, such as a refrigerated warehouse, need to take account of the battery temperature: a lithium cell cannot normally be charged when it is colder than 0°C. This might require the use of active in-pack heating technology to raise cell temperature above 0°C in preparation for charging. In many applications, active heating is a better solution than depositing the pack in a space at room temperature and waiting for it to draw heat from the ambient air.
LTO batteries offer some distinct advantages over traditional lithium-ion batteries, particularly those using lithium cobalt oxide (LCO), lithium manganese oxide (LMO), or lithium iron phosphate (LFP) chemistries. The primary strengths and benefits of LTO batteries stem from their unique electrochemical properties, which provide superior performance in several critical areas.
One of the most notable strengths of LTO batteries is their exceptional safety profile. Unlike other lithium chemistries, LTO batteries exhibit a minimal risk of thermal runaway, a condition that can lead to overheating and potential combustion. This safety advantage arises from the stable LTO anode, which operates at a higher voltage (around 1.55V versus 0.5V for graphite anodes). This higher voltage reduces the risk of lithium plating and dendrite formation, which are common causes of short circuits and battery fires in traditional lithium-ion batteries.
LTO batteries are renowned for their cycle life. They can endure between 7,000 to 10,000 charge-discharge cycles or more, significantly surpassing the cycle life of other lithium chemistries. This longevity is due to the minimal volume change in the LTO anode during cycling, reducing mechanical stress and degradation over time. Consequently, LTO batteries offer lower total cost of ownership, especially in applications demanding frequent cycling.
The fast-charging capability of LTO batteries is another key benefit. These batteries can be charged at rates up to 10C, allowing for full recharges in as little as 6 to 10 minutes. This rapid charging is facilitated by the high surface area and excellent conductivity of the LTO anode, which enhances ion transport and reduces resistance. This feature is particularly advantageous in applications where downtime for charging must be minimised.
LTO batteries perform well over a wide temperature range, from as low as -30°C to as high as 55°C. This thermal tolerance makes them suitable for environments where other lithium batteries would struggle, either losing capacity or failing altogether. The stable electrochemical properties of LTO in extreme temperatures ensure consistent performance and reliability.
In industrial settings, mobile robots are used for tasks such as material handling, inventory management, and assembly line support. The long cycle life of LTO batteries ensures these robots can operate continuously over extended periods, reducing the need for frequent battery replacements and maintenance downtime. Additionally, the rapid charging capability allows robots to quickly recharge during short breaks, maximising operational uptime.
Mobile robots in warehouses and logistics centres often operate in shifts and require batteries that can be quickly recharged between operations. LTO batteries’ fast-charging ability ensures robots spend minimal time docked and more time performing tasks such as picking, packing, and transporting goods. The wide temperature tolerance of LTO batteries also allows these robots to function effectively in cold storage environments.
AGVs (autonomous guided vehicles), commonly used in manufacturing and warehouse automation, rely on robust and reliable power sources to navigate complex environments and transport heavy loads. LTO batteries’ long cycle life and ability to withstand high discharge rates without significant capacity loss make them ideal for AGVs. The quick recharge capability ensures that AGVs remain operational with minimal downtime, enhancing overall productivity.
Lithium Titanate (LTO) batteries offer numerous advantages over other lithium chemistries, including superior safety, extended cycle life, rapid charging, and reliable performance across a wide temperature range.
These strengths make LTO batteries an excellent choice for powering mobile robots in industrial and business environments. Their use in industrial automation, warehouse logistics, service robots, and AGVs highlights the practical benefits of LTO batteries in enhancing efficiency, safety, and reliability in various demanding applications.
The guidance above shows how careful attention to cell and battery specification, design and production, and the choice of a dependable battery pack manufacturer, can ensure reliable and predictable performance for the life of the robot.
In the fast-evolving landscape of smart, digitalised factories and warehouses, the integration of mobile robots is pivotal for achieving efficiency, maximising throughput, ensuring safety, and minimising operating costs. This surge in automation, particularly with various mobile robots like AGVs and AMRs, underlines the critical role of an industry-leading robust battery pack. Alexander Battery Technologies provides 40 years of expertise and insights into the essential considerations and best practices for acquiring the right battery pack for mobile industrial robots.
Mobile robots possess a distinct advantage, operating tirelessly without breaks. This perpetual functionality necessitates a dependable and durable battery pack capable of sustaining continuous output without premature failures or depletion of charge. To address these specific application requirements, a bespoke custom battery pack tailored to factors such as capacity, size, durability, peak power output, cycle life, and temperature tolerance is often indispensable.
The abundance of lithium chemistries introduces a matrix of trade-offs that demand careful consideration. Parameters like energy density, peak power output, operating temperature, cycle life, nominal output voltage, and maximum charge rate vary across different chemistries. The selection of optimal trade-offs is contingent upon the specific application. For instance, smaller AGVs or AMRs, where battery size and weight are critical, may favour NMC cells for their high energy density. Conversely, larger lifting platforms may opt for LFP cells, prioritizing longer cycle life over energy density.
The battery pack selection extends beyond chemistry to encompass features critical for efficient operation. Thermal management features play a pivotal role in dissipating heat efficiently, ensuring safe operating temperatures. Data can help manage a felt of AGV’s through the use of wireless connectivity integrated into advanced custom battery packs. Wireless connectivity such as Bluetooth & low energy radio can provide real-time data about charge status and temperature to efficiently manage your fleet.
Once the chemistry and features are determined, the battery pack manufacturer initiates a design that undergoes rigorous testing and approval before entering production. Quality and reliability are not merely end-of-line considerations but integral to the entire manufacturing process. Starting with the selection of high-quality lithium cells from reputable manufacturers like Samsung, LG, and E-One Moli Energy, meticulous attention is paid to assembly details, particularly critical elements prone to failure, such as welds.
Alexander Battery Technologies emphasizes transparency by inviting customers to inspect manufacturing facilities, fostering confidence in the production process. Incorporating quality principles ensures swift validation and certification of battery packs, aligning with the stringent standards prevalent in industries like automotive.
The paradigm shift towards digitalized and smart manufacturing practices necessitates a substantial increase in mobile robot deployment. Ensuring uninterrupted 24/7 operations relies significantly on the reliability of the battery power supply. By meticulously selecting the right cell and battery specifications, designing with precision, and choosing a dependable pack manufacturer, industrial operators can ensure consistent and predictable performance throughout the robot’s operational life. The battery power supply emerges as a cornerstone, guaranteeing seamless operation and peak efficiency for a mobile robot in the new era of industrial automation.
This is only a small summary from a technical in-depth piece titled ‘How to procure the right battery pack for a mobile industrial robot’. If you would like to read the full in-depth article, please fill in the contact form below to receive it via email.
Long cycle life, high energy density and resistance to shock and vibration are common requirements in AGVs and other types of mobile robots. How do they affect the choice of chemistry, cell, and battery pack design?
Efficiency, maximisation of throughput, safety and operating cost reduction are the watchwords of today’s smart, digitalised factories and warehouses. To meet these business objectives, industrial companies are automating ever more processes, and deploying more robotic devices, particularly various types of mobile robots. These include devices such as automated guided vehicles (AGVs) used in materials handling and other applications, automated mobile robots (AMRs) for last-mile deliveries (see Figure 1), and frame climbers in automated warehouses.
One of the advantages of mobile robots in comparison to their human counterparts is the ability to continue working 24 hours a day without the need for breaks. But this calls for a portable battery power system that can maintain a continuous output, without running out of charge, or failing prematurely because of a fault or breakdown.
This highlights the importance of specifying a mobile robot’s battery pack the right way. In nearly all cases, a mobile robot will require a custom battery pack, to meet the application’s requirements for capacity, size, durability and ruggedness, peak power output, cycle life, temperature tolerance, and other factors. This means that choosing the right custom battery pack manufacturer is also a critical decision.
Lithium-based batteries have become the most common choice for new industrial batteries today, because of their high energy density and capacity, giving much longer run-time between charges than any other battery chemistry. In fact, many types of lithium chemistries may be used in battery cells, and the technology and production of battery cells and packs is constantly advancing, giving OEMs the benefit of improved specifications year-on-year.
So what is the latest best practice for battery pack specification, and what are the key considerations that mobile robot OEMs should be taking into account today when specifying the cell type, pack design, and quality criteria?
Fig. 1: AMRs are beginning to be used to replace human drivers for last-mile deliveries of packages to homes and offices.
The proliferation of lithium chemistries, and of the components such as battery charge controller ICs that support lithium battery packs, mean that a robot OEM can be faced with a complex set of trade-offs to consider. Cell chemistries such as NMC (lithium nickel manganese cobalt oxide), LFP (lithium iron phosphate), LTO (lithium titanate), LMO (lithium manganese oxide) and LCO (lithium cobalt oxide) vary on a range of parameters:
• Energy density, affecting the size and weight of the battery pack
• Maximum peak power output
• Maximum safe operating temperature and susceptibility to thermal runaway
• Cycle life
• Nominal output voltage
• Maximum charge rate
The decision about the best set of trade-offs needs to be made on an application-by-application basis. For instance, in a small AGV or AMR carrying light loads, the battery pack will typically make up a large proportion of the total robot’s weight and take up a large space relative to the robot’s enclosure: here, high energy density is a key requirement, to produce the smallest and lightest possible battery, a requirement that would generally call for the use of NMC cells.
On the other hand, in a large mobile lifting platform capable of shifting loads of as much as 1,000kg, the battery pack will make a negligible contribution to total size and weight. Here, energy density is of little importance, so the platform OEM could instead choose LFP cells: their energy density is at least one-third less than that of NMC, but cycle life is much longer – more than 2,000 cycles, compared to as few as 500-600 cycles in some NMC implementations. LFP cells also operate safely at much higher temperatures than NMC, easing the design requirement for thermal dissipation, thermal monitoring, and safety circuitry.
Cycle life and charge time are crucial parameters for many mobile robots: AGVs in a smart warehouse, for instance, might work 24/7 all year round. A typical configuration uses a removable battery pack, allowing the AGV to return to a charging point for the removal of a discharged pack and its replacement by a newly charged pack. In this case, packs are continually cycling through the charge/discharge process. In this case, the cells in the pack need to be able to withstand many charge cycles, and to withstand fast charging so that they are available for use quickly after removal from an AGV in a discharged state.
A reputable battery pack manufacturer will be able to provide detailed guidance about the these and every other performance attribute of each lithium chemistry, and to advise on the best choice for the OEM’s mobile robot application (see Figure 2).
Fig. 2: many custom battery packs for robots are assembled with 18650 (black) or 21700 (green) lithium cells. (Image in the public domain.)
The choice of chemistry is just the start of the process of procuring the right battery pack for a mobile robot.
The evaluation of a custom battery pack manufacturer will normally be centred on the questions of features and quality.
The pack manufacturer should support the robot OEM’s application with the appropriate set of capabilities and features. These could include:
• Thermal management features – as they discharge, batteries generate waste heat, which needs to be dissipated to keep the pack at a safe operating temperature. Sophisticated designs use innovative cell array configurations to draw heat out efficiently, reducing or eliminating the need for a heat sink. This saves space, weight and cost. Equally, mobile robots that operate in a cold environment, such as a refrigerated warehouse, need to take account of the battery temperature: a lithium cell cannot normally be charged when it is colder than 0°C. This might require the use of active in-pack heating technology to raise cell temperature above 0°C in preparation for charging. In many applications, active heating is a better solution than depositing the pack in a space at room temperature, and waiting for it to draw heat from the ambient air.
• Telematics – a factory operator can exercise control of a fleet of AGVs or other mobile robots more effectively if it has access to data about each battery pack’s state of charge and state of health. Advanced custom battery packs can include wireless connectivity such as a Bluetooth® Low Energy radio, configured to provide real-time data about charge status, battery temperature, and other key parameters.
• Regulatory compliance and approvals – the regulatory framework in which a battery design is made will depend on the countries or regions in which the pack is intended to be used. Regulation is a fast-moving field on which the battery pack manufacturer should be able to provide up-to-date advice. For instance, changes to US regulations have tightened the compliance requirements for cells and battery packs in mobile robots such as AGVs, bringing them into line with the regulations applying to battery electric cars. A custom battery pack manufacturer’s design should provide a smooth path through testing, approval and certification for any part of the world in which the robot OEM intends to market its products.
Quality and reliability: how to evaluate the production process
After specifying the cell chemistry and the right set of features, the battery pack manufacturer will generate a pack design. When testing and approval of final prototypes have been completed, the pack will go into production. At this point, the OEM is at the mercy of the battery pack manufacturer – there is no second source for a custom battery pack.
So how is an OEM to assure itself of the quality of the battery pack that it has specified?
In battery pack manufacturing, quality is not a bolted-on feature, or a control process applied at the end of the production line: if quality is not built into the entire process from the start of its design, there will be shortcomings in the production units coming off the line.
Attention to quality starts with the choice of lithium cell: the world’s three largest manufacturers – Samsung, LG and E-One Moli Energy – test all cells for compliance with all relevant safety and compliance requirements. There is a unit cost premium to pay for the quality and safety of the best cells compared to cells from unbranded cell manufacturers, but this up-front cost is more than recovered in the longer lifetime and superior safety assurance of the more expensive cells.
Alexander Battery Technologies has secure supply arrangements with the three premier cell manufacturers, and its packs use cells only from them.
The application of quality principles should also be evident throughout the production process. In assembly, high-quality pack manufacturers will pay particular attention to the elements of the structure that are most prone to failure, such as welds: for instance, advanced optical inspection techniques should guarantee that welds exceed high minimum thresholds for size and integrity, ensuring that the pack’s electrical connections remain sound even when exposed to the extremes of shock or vibration specified in the application.
Some manufacturers will follow the practice that Alexander Battery Technologies has instituted, of inviting customers to inspect its manufacturing facilities in detail. Modern ERP (enterprise resource planning) software systems may also be used to enable the customer to perform unit-by-unit monitoring and inspection of production output of their packs.
High-quality design and production also support rapid, first-time-right validation and certification of battery packs according to industry standards (see Figure 3).
Battery pack production for a new era of mobile robotics
The advance of digitalised and smart manufacturing and warehousing practices is leading to a rapid increase in the number and variety of mobile robots deployed in industrial settings. Operators rely on these robots to maintain unbroken operation 24/7; unforecast downtime severely impairs throughput and efficiency.
The battery power supply can be as reliable as any other component of a mobile robot: the guidance above shows how careful attention to cell and battery specification, design and production, and the choice of a dependable pack manufacturer, can ensure reliable and predictable performance for the life of the robot.
The rise of warehouse Automated Guided Vehicles (AGVs) has been facilitated by advancements in battery technology. The advancement in battery technology has led to increased efficiency of the AGVs that power an OEMs (original equipment manufacturers) warehouse. The adoption of AGVs from OEMs starts with the role the battery plays, ending with OEMs seeing costs lowered and efficiency raised.
It is no exaggeration to say that the battery pack is the heart of the AGV, without the battery the AGV doesn’t function. This is why companies spend millions perfecting the battery pack that will go into their AGV, the better the battery pack, the better their AGV will be able to achieve its primary purpose. The battery packs provide the power needed to drive the AGV’s motors, sensors, and other components.
Our engineers can design the perfect battery for your automated guided vehicle to perform its task, a key design decision is always the power storage capability of the battery pack. The power storage system in the battery pack is what allows the AGVs to operate continuously in warehouse environments. An OEM may want their AGVs to operate for a long time between charges, therefore we would design the battery pack to have high-power storage capabilities.
Our expert engineers can design your pack with a smart BMS (battery management system) to enable your pack to be fast charging. This system will enable rapid battery replenishment during short breaks or between tasks, minimising your guided vehicle’s downtime. This ensures that your guided vehicle is available for as much of their working hours as possible. Alongside fast charging capabilities, our engineers can use energy-dense cells to formulate your pack. This reduces the frequency of recharging, thus maximising the AGV’s productivity to provide greater results for OEMs.
The battery packs is attributed as a significant portion of the AGV’s weight, therefore it’s crucial the pack is as light as possible to allow the battery pack to perform efficiently. A lighter design will help optimise the guided vehicles payload capacity. Our engineers have had experience designing ultra-lightweight packs whilst still being in a suitably robust casing. To ensure your battery pack is maintained properly, an integrated BMS can monitor and manage battery health, charge, cycles and temperature. These additions can help ensure the battery packs longevity and health.
OEMs that make the switch to AGVs will gain a competitive advantage over their competitors due to the increased efficiency provided by an automated fleet. Although there is an initial large outgoing expense, the return on investment (ROI) will be ongoing due to the lengthy usage amount you will obtain from AGVs. This long-term ROI will be seen through increased levels of efficiency they will bring to any OEM.
Here are some of the benefits of an Automated guided vehicle that will recoup an OEMs initial investment:
At Alexander Battery Technologies we know that AGVs are the future of warehousing. With the battery pack itself being one of the most crucial aspects of the AGV, battery packs play a huge role in the advancement of warehouse logistics. We have 40 years of experience designing bespoke battery packs for all applications . We want to help you get ahead of your competition by designing and manufacturing your perfect AGV battery pack. If you want to know more on how we can help your AGV battery project, please contact us.
Yes, you should. We are having discussions with large OEMs, many having the same question. Is now the right time to electrify our product range?
With battery power being the power source for the future due to upcoming legislation, there has never been a better time to discuss your electrification needs. The sudden spike of interest in E-mobility battery packs from OEMs, has been accelerated by the government’s efforts to reduce their carbon footprint. These OEMs are achieving this through the process of electrification, which is the practice of replacing technologies that use traditional fuels with electric power.
With the UK government targeting net zero by 2050, incentives for consumers and businesses are already in place.
Some of these incentives are;
Furthermore, the UK government announced that sales of new petrol and diesel cars and vans will be banned from 2030. This has led to funding to build 1000s of EV charging points to cope with the infrastructure that will need to be in place to make this efficient. These incentives and impending laws have seen a 60% YoY growth for E-mobility sales in the UK, with a target set for 22% of new manufacturer sales to be electric in 2024.
Vehicle OEMs need to decide their production schedules years in advance. With current and future government incentives pushing consumers and businesses toward Electric Vehicles, OEMs need to consider electrifying their range to meet an ever-rising level of demand. The current rate of reducing carbon emissions will not achieve net zero for the UK by 2050, making further incentives increasingly likely to encourage the demand for electric vehicles before new laws in 2030 come into place.
There has never been a better time for OEMs to electrify their ranges. With the increased desire for consumers and businesses to switch to battery power, there has been a significant investment in battery technology globally seen from; Jaguar Land Rover, Recharge Industries and our very own Battery Technology Centre. This increased level of investment has led to improvements in the quality of batteries produced.
What this means for you is that your fleet of electric vehicles will start with a high-quality custom battery pack that will only improve as newer models are added to your range. With our 12 research and development labs open and operational, we produce battery packs with increased energy density, allowing for increased range on your vehicle. We are also working on designs and materials that will enable your battery pack to have faster charging times without hindering the overall life span of the battery pack. This results in increasing quality and consumers’ willingness to buy your product and continue to buy different products you offer when they want to upgrade.
Yes, we believe so for two significant reasons:
If you are electrifying your existing applications or developing a new range of electric applications, talk to our battery experts to see how we with your electrification process.