Background
Our client — a European industrial IoT equipment manufacturer — was using off-the-shelf battery packs that were oversized and expensive relative to the device’s real duty profile. The packs increased device weight, raised BOM cost, and required frequent maintenance in field deployments.
Challenge
- Existing packs were >20% larger than required by the device’s actual energy usage.
- Thermal management was inadequate for outdoor operation (–20°C to 60°C range required).
- Client needed a cost target to enable scalable deployments.
Our Solution
Huawen New Power designed a tailored 3S2P NMC-18650 pack with an integrated BMS and improved thermal strategy. The design focused on three pillars: right-sizing, safety, and cost efficiency.
Key technical changes
- Optimized capacity to match measured device consumption profile (avoid overcapacity).
- Improved BMS logic: precise SOC estimation, balance strategy and configurable charge profiles.
- Mechanical redesign: compact enclosure, terminal arrangement and better mounting.
- Thermal measures: thermal pads and airflow channels tuned for outdoor temperature extremes.
- Supply chain optimization: direct procurement and batch negotiation for cells and PCBs.
Results
| Parameter | Previous Solution | Huawen Custom Solution | Improvement |
|---|---|---|---|
| Cost per Unit | 100% baseline | 85% | ↓ 15% |
| Pack Volume | 100% baseline | 80% | ↓ 20% |
| Operating Temperature | 0°C ~ 45°C | −20°C ~ 60°C | Wider range |
| Cycle Life (to 80%) | ~600 cycles | ~1000 cycles | +66% |
Why these changes mattered
- Right-sizing removed unused capacity (reduces cell count / BOM cost).
- Thermal design prevented premature aging in hot climates (major driver of capacity fade).
- Enhanced BMS improved long-term SOH management and reduced need for manual servicing.
- Supply optimization lowered procurement costs without compromising quality.
Technical highlights (data & checks)
Chart is illustrative (normalized values) to highlight relative improvement in cost and volume after the redesign.
Client testimonial
"Huawen New Power delivered a pragmatic, production-ready battery solution quickly. The cost and volume improvements directly improved our unit economics and field uptime." — Head of Product, Industrial IoT Client
Conclusion & next steps
This project demonstrates how focused engineering — combining right-sizing, thermal strategy, BMS optimization and procurement leverage — can reduce unit cost while improving reliability. Huawen New Power offers turnkey services from feasibility studies to pilot runs and SOP ramp-up.
Interested in a similar optimization? Contact our solutions team for a feasibility assessment:
