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..

Over our 35 years, we have honed the ideal balance between innovative design and unyielding safety standards. Customers operating within hazardous locations (HAZLOC) face a host of safety-related complexities. All of the manufacturing – from the largest machinery, down to the smallest battery unit, must comply with the governing country’s safety requirements. The HAZLOC classification was the standard in North America. However, the US and Canada are moving towards the IECEx system, which closely resembles its EU counterpart, the ATEX system.

How do we do it? At Excell, the design process and regulatory requirements work in tandem with each other. All battery pack components are designed to operate seamlessly within their intended environments. Our engineers design with the larger safety picture in mind. Understanding that these certifications are stand-alone is a guiding factor in the engineering process. Despite their regulatory similarities, IECEx and ATEX-certified products cannot automatically be used together. Products must be rigorously re-tested in a certified lab before they are approved for use together in a specific hazardous environment. This process can be incredibly costly and frustrating for HAZLOC customers. With our world-class lab testing facilities, our Excell team helps customers navigate their unique safety requirements. 

The ability to provide an integrated battery solution that satisfies the strictest safety standards is one of the cornerstones of our business. Customers operating under HAZLOC/IECEx/ATEX guidelines can rest assured that Excell products meet the most exacting standards.

The post Thoughtful Design for Hazardous Environments 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.

The post Smart Engineering appeared first on Excell Battery Co..

To prevent unexpected combustion, equipment has evolved and is designed to be safe in these situations. Devices must undergo testing and certification before being distributed and used, which depends on the geographic location of the area of consideration. 

In the US and Canada, these locations are termed hazardous locations or HAZLOC, and devices qualified to be used in these locations are known as HAZLOC-rated devices. However, Canada and the US are moving towards the IECEx system of classification, and all new devices must fit the IECEx code of standard. European countries use the ATEX system, which is similar to the IECEx system. It is required for devices to be evaluated based on the location in which they will be used. 

Each system is based on different qualifications. The HAZLOC-based system is a class and division-based system:

• I – gases may be present
• II – dust may be present
• III – fibres may be present

The division is based on how often the hazard is present, which is either the hazard is always present or the hazard may exist under abnormal conditions. The IECEx and ATEX systems differ from the HAZLOC system in that they are zone-based. The degree to which hazardous gases or dust are present is classified by numerical zones. 

A common factor of these systems, and international systems, is that they are end-product standards. The products are evaluated based on the explosive environment’s regulations alone. This means that two HAZLOC/IECEx/ATEX certified products cannot be plugged into each other and used. Their certifications stand-alone, and if they are to be used together they must repeat the testing and certification process to ensure they can be used together in that specific location. 

Testing is an expensive and time-consuming process and requires a specialized lab that has the knowledge to evaluate these types of products. Consulting a lab should be one of the first steps in the process of designing such a device. Once a product is evaluated and approved, it will bear certification marks from a well-known certification company. Depending on the certification, it will also have markings depicting explosive atmospheres in which the product can be used.

The post A Quick Introduction to HAZLOC and ATEX Requirements appeared first on Excell Battery Co..

Manufacturers should be aware that products containing dangerous goods like lithium batteries must be shipped within the guidelines of multiple regulations. Individual countries’ transportation regulations such as the USDOT, Transport Canada, the International Air Transport Association (IATA)

Transporting lithium batteries can be dangerous if not packaged and handled safely because they present both chemical and electrical hazards. The UN Manual of Tests and Criteria, Sixth Revised Edition, SubSection 38.3 was created to ensure safe transportation of batteries. Frequently known as UN 38.3, these recommendations are enforced by all regulatory bodies and must be followed when shipping lithium batteries.

The Hazards of Lithium Batteries

Lithium batteries may pose significant hazards if mishandled or abused. Consequently, safety practices must be followed when packaging and handling lithium batteries for transport. Abusive conditions can cause lithium batteries to catch fire, leak corrosive liquids, or explode in certain situations.

To help explain the various hazards that may occur if batteries are mishandled, Excell Battery has made our Safety Training Course available online for free. 

The Steps to Follow

As outlined in the above regulations, several things must be in place before a business is allowed to ship lithium batteries. These include:

Training

All persons involved in preparing, packaging, and completing paperwork must be formally trained in these procedures before offering batteries for transport. Specific training requirements are outlined in the UN 38.3, but they generally include the following:

• General awareness/familiarization training of regulations
• Function-specific training on shipping lithium batteries
• Lithium battery safety
• Security awareness training

Many training organizations and companies offer this type of training either online or in person.

Testing Requirements 

Lithium batteries must be tested safe for transport in accordance with UN 38.3. A variety of tests is performed, from altitude to forced discharge, to ensure the batteries can be transported safely. For more information, review the US DOT/IATA lithium battery testing requirements. 

Packaging/Labeling Requirements       

Performance tested shipping containers must be tested in accordance with the above regulations. These boxes must contain the proper UN marking in order to be used for shipping lithium batteries. In addition, labeling of boxes (Class 9, Cargo Aircraft Only if applicable) must be properly applied to the packaging.

Paperwork Requirements

HAZMAT Bill of Ladings, Airway Bills, and other Dangerous Goods paperwork, such as a Shipper’s Declaration of Dangerous Goods, must be completed before lithium batteries are offered for transport. Failure to comply can result in costly delays, the shipment being rejected by carriers, or even fines for failure to follow the proper paperwork requirement.

About Excell Battery

Excell Battery has a proven track record of manufacturing safe, reliable battery solutions for over 35 years. When it comes to shipping safety and regulations, it’s important to have a professional team partnering with you to ensure the safety of your product. Contact us today and let us help you bring your product to the world! 

The post How To Safely Ship Lithium Ion & Lithium Metal Batteries appeared first on Excell Battery Co..

The global supply chain has been disrupted by multiple factors that are unravelling. This disruption is driven from multiple directions, including the surge in EV demand, disruption in shipping, trade imbalances, backlog in new product design and manufacturing due to COVID-related shutdowns.

As automakers continue to grapple with a semiconductor shortage, some experts say the next supply chain crisis for the US could involve lithium-ion batteries. China is far ahead of the US regarding the manufacturing of Li-ion batteries and therefore can support the demand from the supply chain. 

As companies like GM, Ford and a slew of start-ups ramp up their electric vehicle ambitions, current battery production in the US won’t keep up with demand. Existing global cell suppliers are shifting their production toward the EV market and constraining other industries’ cell supply.

Dealing with component product challenges

In addition to the lack of manufacturing of Li-ion batteries in North America, the lack of production of anode and cathode material is solely dependent on producers overseas. To navigate the shortages, the US must begin mining from raw materials from within the US. Another option is recycling batteries, but at the moment, this is not a cost-effective option. The only solution is for our current administration to push for additional cell manufacturing here in North America.

Additionally, the surge in the EV market also places strain on the component market, creating a shortage in critical components that support custom battery packs. The surging demand for new automobiles has prompted an industry-wide semiconductor production shortage. Since then, the situation has been exacerbated by a shortage of raw materials used in making components. Consequently, motor vehicle production has become severely disrupted, and component procurement has become more expensive. 

Because of the shortage’s multi-sector impact, original equipment manufacturers (OEMs) should expect across-the-board pricing volatility, extended lead times, and stock-outs in the near future. This is only going to become worse before improving. The big question is, how do you de-risk your supply chain?

How we’re managing supply issues

To stay ahead of the forthcoming shortages, at Excell Battery, we are working closely with our customers and suppliers to understand the demand/supply equations over the next few years. Furthermore, developing a risk mitigation strategy includes stocking programs and risk buys to ensure that our customers receive their products when needed. 

As we understand the ongoing threat of shortages in both batteries and components, we will continually adjust as the market evolves and changes. Please contact us for more information on how we’re managing our supply chain to meet our customers’ production requirements.

The post Mitigating Risks Created by Lithium-Ion Battery Supply Issues appeared first on Excell Battery Co..

Most battery companies would agree that this is a battery pack.   

Visualize a power tool battery pack, which is basically a black box with LEDs and electrical contacts attached. If you were to take a battery pack apart, you would find inside a collection of single cells connected together. A cell is a single electrochemical unit, which when connected to other cells, forms the battery pack.  

The best visualization for a cell is the commonly available AA cells that are used in a TV remote or in a flashlight. Much confusion in the battery world occurs when the terms battery, battery pack, battery cell and cell are used incorrectly.

Once you know what you’re looking for, it’s best to consult an expert on how to navigate the battery market.

Here are our top tips for buying quality battery packs. 

1. Always use cells and batteries from well-known reputable firms, with a known fixed address and as many certifications as possible. Battery companies with certified battery packs (UL, IEC, PSE, ATEX, etc.) typically have higher build qualities. Very inexpensive cells and batteries purchased on the internet from companies with no certifications are problematic and can result in a catastrophic event.  
2. Be aware that counterfeit batteries exist all over the internet, and many are of very poor quality.
3. Always determine a battery’s operating window and warn customers to only use it inside its operating window. Batteries used outside their operating window can lead to catastrophic failure.
4. Always use components suited to the intended application. Connectors designed to function for low currents should not be used for high current applications. Connectors designed as single-use connectors should not be used in an application where many plug-ins and pull-out cycles will occur.
5. Use a hard case enclosure. Hard case enclosed battery packs are generally more robust and resilient and maintain more consistent ‘form and fit’ characteristics.
6. For rechargeable battery packs, always choose a high-quality charging system that is correctly matched to the battery type. A low-quality or mismatched charging system can lead to as many problems as low-quality cells.
7. Do not be in a rush to have your product designed and made. High-quality designs take time.
8. Finally, always leave time in your schedule for testing and validation. Untested, unvalidated battery packs inevitably lead to customer returns and complaints.          

Have more questions? Our design team at Excell Battery is ready to assist with developing your power solution.

The post A Battery Buyer’s Guide: Tips for Buying Quality Battery Packs and Cells appeared first on Excell Battery Co..