Causes of Thermal Runaway in Lithium Ion Batteries
Thermal runaway in lithium ion batteries is a dangerous chain reaction where the battery's internal temperature rises uncontrollably, potentially leading to fire or explosion. Thermal runaway is typically triggered by one or more of the following factors:
1. Internal Short Circuit
Manufacturing defects, such as impurities, damaged separators, or dendrite growth. Localized heating within the cell, which can ignite internal components.
2. External Short Circuit
Damage to the battery casing or contact with conductive materials.
A large current flow leads to rapid heating and potential ignition.
3. Overcharging
Charging the battery beyond its voltage limit (typically beyond 4.2V per cell). Decomposition of the electrolyte and release of oxygen, triggering exothermic reactions.
4. Overdischarging
Discharging the battery below its safe voltage level. it can cause copper dissolution and internal shorts during future charging.
5. High Temperatures
Hot environments, poor ventilation, or inadequate thermal management. Accelerates chemical reactions, potentially triggering runaway.
6. Mechanical Damage
Crushing, puncturing, or dropping the battery. Damaged internal structure may lead to short circuits or chemical leaks.
✅ CTS Battery How to Effectively Prevent Thermal Runaway
1. High-Quality Battery Design & Manufacturing
Use durable, high-purity materials.
Employ robust separators to prevent internal short circuits.
Use thermally stable electrolytes and electrodes.
2. Battery Management System (BMS)
Constantly monitors voltage, current, and temperature.
Provides protections such as Overcharge protection/Overdischarge protection/Overcurrent and short-circuit protection/Thermal cutoff.
3. Thermal Management
Use cooling systems (air or liquid) to maintain safe operating temperatures. Design battery packs with ventilation and heat dissipation structures.
4. Safe Charging Practices
Use certified chargers that match the battery specifications. Avoid fast charging in hot environments. Do not charge damaged or swollen batteries.
5. Avoid Mechanical Stress
Protect batteries from impacts, punctures, and crushing forces.
Use rugged enclosures for battery packs in harsh environments.
6. Environmental Controls
Store and operate batteries within recommended temperature ranges. Avoid exposure to direct sunlight, fire, or freezing conditions.
7. Regular Inspection and Maintenance
Check for bulging, corrosion, or unusual behavior. Replace aging or damaged batteries promptly.
Europe's home storage market explodes? CTS has new solutions
In 2022, the Russian-Ukrainian conflict exacerbated Europe's energy crisis, gas prices remained high, residential electricity prices were rising, and the European home storage market exploded on a massive scale. By the end of 2023, the average price in the spot market of the European Power Exchange will be around €130/MWh. However, at the beginning of 2024, the European electricity spot price once exceeded 300 EUR/MWh, equivalent to RMB 2.2-2.7 Yuan/kWh.
According to relevant data, from 2021 onwards, the annual European home storage installation of about 1GW/2GWh, a year-on-year growth of 56%/72%, but at present the European home PV distribution and storage penetration rate is actually still less than 10%. Combined with the encouragement of local policies, the European home storage market will have an extremely considerable growth space.
At the time of energy change in Europe, CTS is willing to provide more families with economical, efficient and stable clean energy. Among them, single-phase hybrid inverter is one of the "star products" of CTS. It has IEC/EN62109-1/-2, IEC/EN62477-1, IEC61727/62116/6168, and recently passed the EU EN61000-6-1, EN61000-6-3 new standard EMC certification, UK G98, G99 and Italy CEI0-21 grid connection certification, product reliability and safety. The reliability and safety of the products are recognised by the industry's authoritative third-party institutions, with a good foundation for large-scale and standardised production, and can become the preferred choice for the majority of European home storage users.
Friendly and flexible is the highlight of CTS inverter. It supports parallel connection of multiple machines and accepts simultaneous inputs from PV, battery, diesel, grid and load, which is suitable for self-generation and self-consumption, peak shaving and valley filling, backup power and other home application environments.
CTS 51100-200 battery, safe and affordable, suitable for 10+ kWh applications:
The CTS Rack Mounted Lithium Battery batteries represent a versatile battery system suitable for a wide range of applications, whether it be for domestic use, optimising self-consumption, managing charging stations or performing multiple functions simultaneously. One of the main advantages of this range is its modularity. Depending on the energy requirements, cells can be added or removed. This scalability ensures that the system can be adapted to changing requirements, offering unrivalled flexibility. Not only is it designed to operate in emergency mode, it ensures reliable power even during network outages. It combines sophisticated design with cost optimisation to provide superior cost-effectiveness without compromising on quality or efficiency.
Diversifying options for more home users in a variety of scenarios. At a time when the European home storage market is booming, CTS always believes that the only way to seize the high ground in the market and construct a new advantage for the enterprise is to have the power of ever-advancing technology and ever-improving customer service.
Applications of CTS Lithium Batteries
Lithium batteries are a common rechargeable battery technology. CTS lithium batteries have the advantages of high energy density, lightweight, and long service life. Due to these characteristics, CTS lithium batteries have a wide range of uses in various fields.
The following are two major application areas of CTS lithium batteries:
Electric Vehicles (EVs): CTS lithium batteries are the main energy storage device for electric vehicles. High-energy density lithium batteries can store a large amount of electrical energy, providing strong power support and a long driving range for electric vehicles. Different models of electric vehicles use lithium battery packs of different capacities and configurations to meet different driving range requirements.
Hybrid Electric Vehicles (HEVs): CTS lithium batteries are also widely used in hybrid vehicles, which are equipped with both internal combustion engines and electric motors. CTS lithium batteries act as energy storage in hybrid systems, receiving and storing electrical energy generated by brake recovery and engine power, and providing power assistance when needed.
Energy Storage System: CTS lithium batteries play an important role in the field of energy storage and are used in home and commercial energy storage systems, grid energy storage, and microgrid applications. In energy storage systems, CTS batteries can store electricity from renewable energy and release it when needed to balance grid loads, cope with peak and valley electricity prices, and provide backup power.
CTS also portable lithium battery devices that provide power support and fault starting are small and light, easy to carry and operate. When the car battery is low or cannot be started, CTS lithium batteries can start the engine by providing additional power to get the vehicle running again.
In addition to the above fields, CTS lithium batteries are also widely used in solar photovoltaic applications, medical equipment, aviation, and communication equipment.
If you want to know more details, please feel free to contact us.
Let's Meet in INNOPROM 2024 in Yekaterinburg Russia
On July 8-11, 2024 The International Innovation Industry Exhibition INNOPROM 2024 will be hold in Yekaterinburg, Russia. As an important industry, trade, and export platform for Russia, over 800 companies from 35 countries around the world will participate this year . CTS Battery have already participated in Innovation 2023, and we will continue to participate in Innovation 2024 as a lithium battery supplier.
CTS established in 2011, which is a manufacturer specializing in the R & D, production, sales and service of lithium battery packs, focusing on one-stop customized lithium battery products for electric bus, electric trucks, passenger cars,agricultural equipments and industrial equipments etc..
if you have any battery inquiry, welcome to visit our Booth 4S41 (Exhibition Hall 4).
Differences Between Pure Electric Vehicle, Range Extended Electric Vehicle and Fuel Cell Vehicles
1. Pure Electric Vehicle (PEV)
This is what we often refer to as a pure electric vehicle, only a lithium battery (no combustion engine) provides power with the help of an electric motor to drive the car forward.
Advantages:
(1) Very little energy is lost from charging into the battery, to the battery driving the motor, driving the vehicle at low cost and emissions;
(2) The sources of electricity are varied. It is less polluting and less costly than thermal power;
(3) There are peaks and valleys in social electricity consumption. Many of the country's unit capacities are wasted during idle power hours, while charging vehicles at this time can cut the valley and fill the peak, optimising the demand for electricity on the grid and saving social costs;
2. Extended-Range Electric Vehicles (EREV)
Generate electricity through fuel, charge the battery and the electric motor drives the car. The electric motor drives the car and has the good characteristics of an electric car. It can be equipped with smaller capacity batteries, low weight and low cost. Because it can generate electricity through fuel, there is no mileage anxiety. The disadvantage is that it cannot provide power at the same time as HEV fuel and electricity, and the power is not as good as HEV.
Advantages:
The advantages of supercharged electric vehicles are similar to pure electric, the difference is that the engine can be used to power the battery. It has the advantages of quietness and high starting torque of electric vehicles, and can be used as a pure electric vehicle, with lower cost of use by only charging and not refuelling under convenient charging conditions.
3. Fuel cell vehicles (FCV)
Fuel cell vehicles (FCVs) provide the energy needed for driving by converting the chemical energy of fuel into electric energy, and the vehicle is driven by an electric motor. Currently, the main type of fuel is hydrogen. The energy of fuel cell is replenished by adding fuel, so the time is similar to refuelling. In addition, the fuel cell energy conversion process is highly efficient, noiseless, and has no pollutant emissions. The biggest difficulties at present are the difficulty in obtaining fuel, the difficulty in storing and transporting fuel, and the scarcity of hydrogen refuelling stations.
Advantages:
(1) There is no problem of range and energy refilling. No range anxiety.
(2) No problems of high-capacity battery life and cost of pure electric vehicles, and high pollution from high-capacity battery end-of-life like pure electric vehicles.
Differences Between Hybrid Electric Vehicle and Plug-in Hybrid Electric Vehicle
Hybrid Electric Vehicle (HEV)
Hybrid Electric Vehicle (HEV) here refers to a traditional hybrid vehicle, which is powered by a fuel engine and an electric motor in parallel. Generally the battery capacity is small and cannot be charged externally, and the energy of the battery is obtained through energy recovery.
Advantages:
(1) No mileage anxiety compared to pure electric vehicles because of the reliance on fuel to provide energy;
(2) Low fuel consumption compared to traditional internal combustion engine vehicles and longer range than regular fuel vehicles with the same tank size. Low-speed and congested roads in urban areas are dominated by electric motors, which are smooth, quiet, and significantly reduce emissions, making them relatively cleaner.
Plug-in Hybrid Electric Vehicle (PHEV)
Unlike HEVs, PHEVs have an on-board power battery that can be recharged by an external power source. Power is provided by the fuel engine and electric motor. This model can switch between pure electric, pure fuel and hybrid fuel-electric modes in real time, etc. For details, refer to Super Hybrid Technology DMi, DHT, and so on.
Advantages:
(1) Plug-in hybrid cars are the perfect transition from pure petrol to pure electric cars, refer to BYD A-class sedan laurel BYD Qinplus dmi, fuel saving and electricity saving, fill up a tank of fuel ran 1250 km, if daily work, can be completely used as a tram.
(2) Handling and comfort, the motor-driven model, with no gearbox, is smooth and powerful.
Let's Meet in Electric&Hybrid Marine Expo Euro in Next Week !
On June 15, 2024, the passionate UEFA European Football Championship will kick off in Munich, which attracting global fans. CTS Battery will participating in the Electric&Hybrid Marine Expo Europe in18th~20th in Amsterdam. CTS will bring our batteries to experience the hot atmosphere of June in Europe.
CTS Battery will showcase its innovative battery technology at the Electric&Hybrid Marine Expo, CTS marine battery has high energy density and excellent discharge performance, its long cycle life feature is suitable or long-term ocean navigation of ships, IP67 waterproof 316 stainless steel case prevent seawater corrosion, we also can provide customized service for different ships.
CTS Battery welcome all exhibitors of the Electric & Hybrid Marine Expo Europe to visit our booth NO.1426 to meet with our engineer team , and know more about our battery products and solutions.
CTS can provides customized technical services for lithium batteries with 12 years of research and development experience. our battery packs are widely utilized in electric vehicles, electric buses, electric boats, and energy storage system. Additionally, CTS factory has obtained the ISO9001 and IATF16949 certifications, showcasing our commitment to quality.
For more information, please visit www.ctsbattery.com. CTS powers the global motorization.
CTS Booth No.1426 in Electric & Hybrid Marine Expo Europe 2024
Electric & Hybrid Marine Expo Europe will be held in Amsterdam Netherlands in June 18~20th, 2024, it will showcase new electric and hybrid marine transportation and propulsion solutions, shore charging equipment and efficient emerging technologies .
CTS is a professional manufacturer of marine/boat batteries, and we are happy to be attending Electric & Hybrid Marine Expo Europe 2024 . If you are interested in our battery, stop by Booth 1426 and have a deep discussion with us, thank you.
CTS can provides customized technical services for lithium batteries, with 12 years of research and development experience. Our battery packs are widely utilized in electric vehicles, electric boats, electric trucks, and energy storage systems. Additionally, the CTS factory has obtained the IATF16949 certification for automotive quality management systems, demonstrating our qualification and experience in manufacturing automotive-grade products. CTS powers the global motorization.
CTS Bus Conversion Project in Indonesia
In July 2023, CTS's Sales Manager Rebecca and Electrical Battery Engineer Jon visited a customer in Indonesia and assisted the customer on-site to commission and test the battery system. The customer is a famous vehicle manufacturer in Indonesia.
Recently, this customer shared a good news with us and expressed their appreciation and gratitude for CTS's products and services. The customer said:
"Your peace of mind will come when you have Dealer with Full of Support,When you purchase a parts or vehicle, paid in full, and after a while you need dealer support and the dealer still serve you well, provide parts you need, provide advise you want, then it is your best dealer would be. Simply, reliability does matter and strong (Dealer) support is essential. Always thanks the support of Rebecca and Jon at CTS. "
This Hino R260 intercity was originally an bus powered by diesel fuel, With the assistance of Hunan CTS battery, it was completely converted into a 100% pure electric bus. The entire 320kWh lithium iron phosphate battery system was provided by CTS, We have employed a standardized modular design, where each module operates at 76.8V and 412Ah. The battery system consists of 10 modules arranged in a 5S2P configuration, resulting in a total voltage of 384V and a capacity of 824Ah. This modular design allows for greater flexibility in battery installation, making it suitable for most buses available in the market.
This bus conversion project was successfully completed after more than 9 months of installation and commissioning, followed by 450 kilometers of road testing.
CTS is a company that provides customized technology services for lithium batteries, with 12 years of research and development experience. Our customized lithium batteries are applied in various fields such as electric trucks, vans, buses, electric boats, and clean energy vehicles. CTS factory has obtained the IATF16949 certification for automotive quality management systems, demonstrating our qualification and experience in manufacturing automotive-grade products.
CTS powers the global motorization.
If you have any battery inquiry , please send email to emily@ctsbattery.com , thank you.
How to deal with the inconsistency of lithium batteries
The inconsistency in battery cell performance is formed during the production process and deepened during use. The cells within the same battery pack remain weak and accelerate to weaken. The degree of dispersion of parameters between individual cells increases with the deepening of aging.
Currently, engineers mainly consider three aspects when dealing with inconsistencies in individual battery cells. Single battery sorting, thermal management after grouping, and balancing function provided by the battery management system in case of a small amount of inconsistency.
1) Sorting
Different batches of battery cells should not be used together in theory. Even cells from the same batch need to be screened and the cells with relatively concentrated parameters should be placed in one battery pack and the same battery pack.
The purpose of sorting is to select cells with similar parameters. Sorting methods have been studied for many years, mainly divided into two categories: static sorting and dynamic sorting.
Static sorting involves selecting characteristic parameters such as open circuit voltage, internal resistance, and capacity of the cells, selecting target parameters, introducing statistical algorithms, setting screening criteria, and finally dividing the cells of the same batch into several groups.
Dynamic screening refers to the screening of the characteristics exhibited by the battery cells during the charging and discharging process. Some choose the constant current and constant voltage charging process, some choose the pulse impact charging and discharging process, and some compare the relationship between their own charging and discharging curves.
Combining dynamic and static sorting, static screening is used for preliminary grouping, and dynamic screening is carried out on this basis. This results in more groups being divided and higher screening accuracy, but the cost will also increase accordingly.
This reflects the importance of the scale of lithium battery production. Large scale shipment allows manufacturers to conduct more refined sorting and obtain battery packs with closer performance. If the production is too small and there are too many groups, a batch cannot be equipped with a battery pack, and even the best method cannot be applied.
2) Thermal management
In response to the issue of inconsistent internal resistance and heat generation in battery cells. The addition of a thermal management system can adjust the temperature difference of the entire battery pack to maintain it within a small range. Cells that generate more heat still have a higher temperature rise, but they will not widen the gap with other cells, and there will be no significant difference in degradation level.
3) Equilibrium
Inconsistency in the individual cells results in some cell terminal voltages always exceeding those of other cells and reaching the control threshold first, resulting in a decrease in the overall system capacity. To address this issue, the battery management system BMS has designed a balancing function.
A certain battery cell reaches the charging cut-off voltage first, while the voltage of the other battery cells lags significantly. The BMS starts the charging equalization function, or connects a resistor to release some of the electricity from the high voltage battery cell, or transfers the energy to the low voltage battery cell. In this way, the charging cut-off condition is lifted, the charging process resumes, and the battery pack is charged with more electricity.
Until now, the inconsistency of battery cells remains an important area of research within the industry. No matter how high the energy density of the battery cell is, encountering inconsistencies to disrupt the situation will greatly reduce the capacity of the battery pack.
Hazards of Inconsistency in Lithium Batteries
The consistency of lithium batteries mainly refers to the consistency of capacity, internal resistance, and open circuit voltage. Inconsistent battery cell strings used together can cause the following problems:
1) Capacity loss refers to the formation of a battery pack consisting of individual cells, which conforms to the "barrel principle" in terms of capacity. The capacity of the worst cell determines the capacity of the entire battery pack.
To prevent overcharging and discharging of the battery, the logic of the battery management system is set as follows: during discharge, when the lowest individual voltage reaches the discharge cut-off voltage, the entire battery pack stops discharging; When charging, stop charging when the highest unit voltage touches the charging cutoff voltage.
Take two batteries connected in series as an example. One battery has a capacity of 1C, while the other has a capacity of only 0.9C. In a series connection, two batteries pass through the same amount of current.
When charging, batteries with small capacity must first be fully charged, reaching the charging cut-off condition, and the system will no longer continue to charge. When discharging, batteries with small capacity will inevitably discharge all available energy first, and the system will immediately stop discharging.
In this way, cells with small capacity are always fully charged and discharged, while cells with large capacity are always using a portion of their capacity. A portion of the entire battery pack's capacity is always idle.
2) Life loss, similarly, the lifespan of a battery pack is determined by the battery cell with the shortest lifespan. It is highly possible that the battery cell with the shortest lifespan is the one with a small capacity. Small capacity battery cells are always fully charged and discharged, with excessive output, which is likely to reach the key point of their lifespan first. When the lifespan of a battery cell ends, a group of battery cells welded together will also die with it.
3) As the internal resistance increases, different internal resistances flow through the same current, and cells with high internal resistance generate relatively more heat. If the battery temperature is too high, it will accelerate the degradation rate and further increase the internal resistance. Internal resistance and temperature rise form a pair of negative feedback, accelerating the degradation of high internal resistance cells.
The above three parameters are not completely independent. Cells with deep aging have higher internal resistance and more capacity decay. The inconsistency in battery cell performance is formed during the production process and deepened during use. The cells within the same battery pack remain weak and accelerate to weaken. The degree of dispersion of parameters between individual cells increases with the deepening of aging.
How to use electric motorcycle batteries safely?
As we know ,the charging temperature of lithium battery is 0℃~45℃, and the discharging temperature of lithium battery is -20℃~60℃. Lithium batteries do not have a memory effect, can be used with charging, but it should be noted that lithium batteries can not be over-discharged, over-discharge will cause a very large loss of capacity. NMC lithium battery single safe working voltage range is 2.75 ~ 4.2V, LiFePO4 battery single safe working voltage range is 2.5 ~ 3.65V, lower or higher than this voltage range of lithium ions in the battery becomes very unstable, and even cause accidents. In order to ensure that the battery is in the safe range, so you need a special charger, do not mix lead-acid charger for its charging.
When the lithium battery is left unused for a long period of time, it needs to be charged and discharged once every six months to restore its original performance. Lithium batteries need to be checked before use to see if they meet the requirements of the load, in the case of not meeting the requirements of the load or high current (more than 1C) will cause damage to the battery or shorten the life of the battery. Lithium batteries avoid frequent use in high or low temperature environments. Preferably at room temperature, temperature will have a great influence on the characteristics of lithium battery.
How to use lithium battery safely?
The low-priced lithium batteries on the market are mostly assembled from dismantled and substandard battery cells, the safety risk is great. These substandard cells are combined with substandard BMS, which is the main reason for the safety issues of lithium batteries.
How to use the lithium battery correctly ?
1, the use of lithium battery charger matched with the battery pack.
2, do not use the lithium battery pack in illegal modification of high-power electric vehicles.
3, do not let the lithium battery long-term exposure to high temperatures (≥ 65 ℃).
4, in the electric car just after riding due to the high temperature of the battery pack, please let it cool down naturally for about half an hour before charging it.
5, Lithium battery can be used between 20% ~ 90% SOC to greatly extend the life of the lithium battery pack.
6, lithium battery in the winter temperature is lower than 15 ℃ temperature, the electric car range has a certain amount of shrinkage is a normal phenomenon. When the temperature returns to about 25 ℃, the range of the electric car back to normal.
Comparison of Different Types of Lithium Batteries
Now Lithium batteries are a new trend , there are kinds of lithium batteries, what is the difference?
The lithium batteries used more widely on the market are mainly divided into three Types: ternary lithium-ion batteries(NMC batteries), lithium manganate batteries(LiMnO batteries), Lithium iron phosphate battery(LiFePO4 batteries). Among them, ternary lithium batteries and lithium iron phosphate batteries are more popular in the market. Among the three, the safety of lithium iron phosphate and lithium manganate is higher.
Ternary lithium-ion batteries, generally lithium nickel cobalt manganese or nickel cobalt aluminate lithium-ion batteries as the cathode material. Unlike other lithium-ion batteries, the capacity of ternary lithium-ion batteries is higher than other lithium-ion batteries, and the cycling performance of ternary lithium-ion batteries is better than that of ordinary lithium cobalt oxide lithium-ion batteries. The nominal voltage of ternary lithium-ion battery is 3.7v, and the working voltage is 2.75v-4.2v. However, the thermal stability of ternary lithium is poor, so the safety is not as good as that of lithium iron phosphate and lithium manganate.
Lithium manganese acid battery, refers to the battery using lithium manganate material in the positive pole, the nominal voltage of lithium manganate battery is 2.5~4.2v, lithium manganate battery is widely used for its low cost and good safety. Li-Mn2O4 battery has the advantages of low cost, high stability and low temperature performance, but it also has the disadvantages of low energy density, poor high temperature performance and fast attenuation.
Lithium iron phosphate battery, is a lithium ion battery that uses lithium iron phosphate as the cathode material. Lithium iron phosphate power battery, the cycle life reaches more than 3000 times, standard charging (5 hours rate) use, can reach 2000 times. Theoretical life will reach 8~10 years, which is the preferred type of battery cell with both safety and cost-effectiveness.
For our CTS Battery , we are using NMC and LiFePO4 materials , NMC batteries are usually used on EV , e-bike applications ,its has higher energy density ,lighter ,smaller . and LiFePO4 materials are more widely used due to its excellent safety and cost-effectiveness. CTS battery can OEM battery pack from 12v-1000v, 10-1000ah, which can be used in electric vehicle, E-bike, UPS, energy storage system, telecommunication base station,E-scooter,golf cart,electric boat, cleaning car , electric wheelchair, etc.
If you have any inquiry , feel free to contact CTS battery , thank you .
CTS Battery In Russia International Innovation Industry Exhibition
On July 10-13, 2023, the international high-end professional exhibition "Russia International Innovation Industry Exhibition" was held in Yekaterinburg, Russia. As an important industry, trade, and export platform for Russia, over 1000 companies from 35 countries around the world participated this year. On July 10, Mikhail Vladimirovich Mishuskin, Prime Minister of Russia, visited the exhibition site for inspection. Our CTS general manager, as a lithium battery supplier,was also invited to participate in this exhibition.
Prime Minister of Russia Mishuskin said that since 2010 Russia International Innovation Industry Exhibition has been held in Yekaterinburg, a large industrial center in the Ural region. The exhibition has become an important platform for all parties to exchange experience and ideas and explore the development path of key industries.
Mishuskin, Prime Minister of Russia, visited the exhibition site
We received many old and new customers at this exhibition. Emily said that Russia is friendly to the Chinese people, and the language instructions at the airport are in Russian, English, and Chinese. At Russian industrial exhibition, and we saw many displays of heavy industrial equipment. Russia's industrial development level is beyond our imagination, which is a very promising market. We will continue to have high expectations for the Russian market.
Emily with customers
We have gained a lot from this exhibition, and there are a lot of customers who came to our booth to inquire about battery products. There are several high intention customers who say they will immediately place sample order for testing. Lithium batteries，as green energy and new trend, are slowly replacing Fuel engine and lead-acid batteries. We saw many heavy equipment using lithium batteries at the exhibition. As a professional lithium battery manufacturer, CTS can provide professional one-stop lithium battery services for industrial equipment such as electric bus, electric trucks, passenger cars, and agricultural equipment etc..
If have any inquiry of lithium batteries, please feel free to contact us at any time.
Key process of power battery assembly
As an important component of electric vehicles, power batteries have very high requirements on temperature, safety and performance. Therefore, the assembly of power batteries has also become the focus of electric vehicle assembly.。
Key process of power battery assembly:
The power battery system is a complex system, which consists of BMS battery management system, multiple battery modules and housings. Among them, the battery pack is composed of multiple modules, and each module is composed of multiple battery cells connected in series and parallel.
The assembly of the power battery pack is mainly to arrange and fasten multiple modules and check the junction box. During the assembly process, many stations are involved in safe connections, and these assembly processes are directly related to the safety of the vehicle and its occupants.
The key assembly process of the power battery pack is as follows:
1.High and low voltage connector assembly:
There are many high and low voltage connectors on the battery pack and BMS. The assembly features of these interfaces include:
> Security parts need to collect data feedback, and sensor tools must be used;
> When tightening, it is usually a hand-held tool and a hand-held tool. It is best to use a gun-type tool for easy grip and tightening;
> The torque range is not wide, so it is best to choose a compact tool.
2.Installation of high voltage wiring harness
There are total positive and total negative high-voltage wire harnesses in the battery pack that need to be connected and assembled. When the module is charged, the voltage connected to this part is as high as hundreds of volts. Usually the ground of the work station will be insulated, which is a high-voltage protection work station.
In addition, insulation treatment is also required in the assembly. The insulation treatment of this part of the work station not only affects the safety of the battery, but also affects the safety of the operator.
3.Connection and installation of high-voltage busbar
The high-voltage busbar is used to connect the conduction between the modules. The current is large and intensively used, and the assembly is complicated. As the key structure of the battery conduction, the safety of assembly is also very important. The negligence of assembly may cause the battery to short circuit.
4.Module Installation
The battery pack is composed of multiple battery modules. The assembly of the battery modules requires moderate tightness, and each structural component has sufficient strength to prevent deformation or damage due to external forces inside the battery.
The battery module is composed of multiple power cells connected in series and parallel. The assembly of the battery module needs to fix the battery module in the aluminum box. Generally, long bolts are used to go through the module and fix it to the nut at the bottom of the box. In order to save space, some battery packs adopt the form of double-layer modules, and there will be mounting module brackets to fix the upper module.
5.Cover installation
In order to meet the needs of light weight and improved efficiency, battery packs usually use aluminum casings. Dozens of bolts are used to connect and assemble the upper cover and the lower box of the battery pack aluminum case. The number of bolts is large and the distribution is regular, and the tightening direction is vertically downward. During assembly, they need to be tightened sequentially to ensure that the tightening stress of the upper cover is evenly distributed.
Understanding the Lithium Battery Energy Storage System PACK
With the formulation and promotion of China's strategic goal of "carbon peaking, carbon neutrality", the proportion of clean energy such as photovoltaic , wind power and power from energy storage systems will be significantly increased, which has brought huge development space for the energy storage market.
The main technical route in electrochemical energy storage is lithium-ion battery energy storage, and lithium-ion battery PACK technology is an important part of industry skills. Below, let's learn some basic knowledge of battery PACK with CTS.
1. Definition
Lithium ion battery PACK is a manufacturing process for lithium-ion batteries, which means packaging, packaging, and assembly. It refers to the connection of multiple lithium ion battery celsl groups in series, taking into account system mechanical strength, thermal management, BMS matching, and other issues. Its important technologies are reflected in overall structural design, welding and processing process control, protection level, and active thermal management system. If two batteries are connected in series or parallel to form a specific shape according to customer requirements, it is called a PACK.
2. Composition of battery pack
The battery pack consists of several important components, including individual battery modules, electrical systems, thermal management systems, cabinets, and BMS .
▶ Battery module: If battery PACK is compared to a human body, then the module is the "heart" responsible for storing and releasing electrical energy.
▶ BMS: Battery management system can be seen as the "brain" of batteries. Mainly responsible for measuring parameters such as voltage, current, and temperature of the battery, as well as balancing functions. Data can be transmitted to MES.
▶ Electrical system: mainly composed of connecting copper strips, high-voltage harnesses, low-voltage harnesses, and electrical assurance devices. The high-voltage harness can be seen as the "artery" of the battery PACK, transmitting the battery power to the end load continuously, and the low-voltage harness can be seen as the "neural network" of the battery PACK, transmitting the detection signal and control signal in real time.
▶ Thermal management system: There are two main methods of thermal management system: air cooling and liquid cooling, and liquid cooling can be divided into cold plate liquid cooling and immersion liquid cooling. The thermal management system is equivalent to installing an air conditioner for the battery pack. The battery generates heat during discharge mode. To ensure that the battery operates at a reasonable ambient temperature and improve its cycling life, the system temperature difference is generally required to be ≤ 5 ℃.
▶ Box: mainly composed of box, box cover, metal bracket, panel and fixing screws, it can be regarded as the "skeleton" of battery PACK, playing the role of support, resistance to mechanical shock, mechanical vibration and environmental protection.
CTS 48V 5kwh lifepo4 battery module
3. Characteristics of battery pack
▶ PACK lithium battery packs require high consistency in battery capacity, internal resistance, voltage, discharge curve, and lifespan.
▶ The cycle life of the battery pack PACK is lower than that of a single battery.
▶ Used under limited conditions (including charging, discharging current, charging method, temperature, etc.)
▶ After the lithium battery pack is formed, the battery voltage and capacity have greatly increased, and it must be protected by charging balance, temperature, voltage, and overcurrent monitoring.
▶ The battery pack must meet the voltage and capacity requirements required by the design.
4. PACK method
▶ Series parallel composition: The battery module is composed of individual cells connected in series. Parallel connection increases capacity, voltage remains unchanged, and after series connection, voltage doubles, capacity remains unchanged. For example, if 16 cells with a voltage of 3.2V are connected in series, it is 51.2V, which is called series boosting. For example, if two cells with a capacity of 50Ah are connected in parallel, there will be 100Ah, which is called parallel expansion.
▶ Battery requirements: Select the corresponding battery cells according to your own design requirements. The types and models of batteries in parallel and series should be consistent, and the differences in capacity, internal resistance, and voltage values should not exceed 2%.
▶ PACK process: The battery can be PACKed in two ways. One is laser welding, ultrasonic welding or pulse welding. This is a common welding method, which has the advantage of good reliability but is not easy to replace. The second is through contact with elastic metal sheets, which has the advantage of no welding and easy battery replacement. The disadvantage is that it may lead to poor contact. Considering the production yield, efficiency, and internal resistance of the connection point, laser welding is currently the preferred choice for many battery manufacturers.
5. How to understand the technical parameters of battery PACK
Items
parameters
marks
Combination method
1P16S
Rated capacity
100Ah
Rated voltage
51.2V
total energy
5.12kWh
Discharge rate
1C
weight
45±0.5kg
▶ Combination method: 1P16S
Interpretation: S represents series cells, P represents parallel cells, and 1P51.2S represents 16 series and 1 parallel cells. After series connection, the voltage is doubled, and the rated voltage is 3.2 * 16=51.2V.
▶ Rated capacity: 100Ah
Interpretation: The rated capacity of a battery refers to the capacity of a battery to operate continuously for a long time under rated operating conditions. The rated capacity C of a battery, in ampere hours (Ah), is the product of the discharge current in amperes (A) and the discharge time in hours (h). So 100Ah represents discharge at a maximum current rate of 0.5C, which can last for 2 hours.
▶ Rated energy: 5.12kWh
Interpretation: Rated energy (Wh)=nominal capacity
(Ah) * nominal voltage (V), so the total energy that a battery can release is related to both capacity and voltage.
If you have any questions of energy storage lithium battery , feel free to contact us , thank you
China's Power Battery Installation Volume Ranks First Globally
According to data released by South Korean SNE Research recently, in the first quarter of 2023, CATL (300750) ranked first with a global market share of 35% for power batteries, BYD (002594) ranked second with a global market share of 16.2%, and Chinese battery manufacturers had a global market share of over 50% for power batteries.
Industry experts say that new energy vehicle sales bottomed out in the first quarter , but for the second quarter,With the decline in raw material prices and a rebound in demand, power batteries are expected to enter the peak season.
The market share keep increasing
According to SNE Research data, in the first quarter of this year, the total number of newly registered electric vehicle battery installations worldwide increased by 38.6% year-on-year, to 133 GWh. According to data released by the China Automobile Association, from January to March, the cumulative installed capacity of power batteries in China was 65.9 GWh, a year-on-year increase of 28.4%.
In the first quarter,CATL ranked first in the global power battery installation volume with a global market share of 35%; BYD ranks second with a global market share of 16.2%. Data shows that in the first quarter of this year, the loading volume of CATL and BYD increased by 35.9% and 115.5% year-on-year, respectively, reaching 46.6GWh and 21.5GWh.
In recent years, the global market share of Chinese power battery companies has been continuously increasing, while as an established battery manufacturer, the global market share of South Korean power battery giants LG , SK , and Samsung SDI has shown an overall downward trend.
In 2022, LG New Energy, SK , and Samsung SDI jointly accounted for 23.7% of the global electric vehicle battery market, a decrease of 6.5 percentage points compared to 2021. On the other hand, as the largest power battery manufacturer in China, CATL achieved a global market share of 37% in 2022, an increase of 4 percentage points from 33% in 2021. Together with six other top ten Chinese power battery manufacturers, its global market share reached 60.4%, a significant increase from 48.2% in 2021.
CITIC Securities Research Report pointed out that looking forward to 2023, battery manufacturers remain optimistic about revenue and profit margin growth, and are optimistic about the growth of the global power battery market and the driving force of tax subsidies on profit margins. The recently held China Automotive Power Battery Industry Innovation Alliance Conference mentioned that by 2023, the demand for power battery installation in China will reach 409.9GWh, a year-on-year increase of 39.3%.
SNE Research predicts that by 2035, global sales of electric vehicles will be approximately 80 million units, with a penetration rate expected to reach around 90%. The demand for electric vehicle secondary batteries will also increase from 687GWh in 2023 to 5.3TWh in 2035.
Strong market demand
With the rapid development of China's new energy vehicle industry, the market penetration rate has been rising, which has brought strong demand to power battery enterprises. Our CTS established in 2011, which is a manufacturer specializing in the R & D, production, sales and service of power battery packs, focusing on one-stop customized lithium battery products, such as electric vehicle batteries,electric motorcycle batteries, OEM battery pack etc...
With Twenty-people R& D team who has rich experience, CTS focuses on power battery customization for middle and high end markets by selecting first grade lithium cells with high energy density and assembling cells into packs with different shapes and sizes. All batteries are produced by following safety testing standards.
We always followed Strict quality control ensures the higher quality of products. With the concept of "customers the first, quality the life", we strictly follow ISO 9001 and TS16949 management system through the production of every detail, each battery must be strictly tested before its delivery.
If you have any inquiry of power batteries, feel free to contact us ,thank you
Application of Liquid Cooling system in Power Battery System
With the requirement of IP67 for passenger cars becoming a necessity, liquid cooling systems have been widely used in power batteries.
Definition of liquid cooled plate: In a power battery system, excess heat is generated by the operation of the battery. The heat is transferred through the contact between the battery or module and the surface of the plate type aluminum device, and ultimately carried away by the cooling liquid passing through the internal flow channel of the device.
General requirements for liquid cooling plates
High heat dissipation power, able to timely export excess heat generated during the operation of the power battery, avoiding excessive temperature rise;
High reliability, working in road vehicle environments, vibration, impact, high and low temperature alternating environments, is a relatively harsh working condition for most products. However, the voltage of power batteries is often several hundred volts, and coolant leakage is a serious problem. Even if you use a coolant with good insulation performance, the insulation performance will immediately decrease when encountering external impurities. Therefore, the reliability of cooling plate sealing is very important;
The precise heat dissipation design avoids excessive temperature difference within the system, which is due to the performance requirements of lithium batteries themselves. The performance and aging of batteries are closely related to the working temperature;
The strict requirements for the weight of the cooling plate, which comes from the pursuit of energy density in the power battery system. Cooling systems that seriously lower the energy density of the system are simply unacceptable to both customers and designers.
What kind of liquid cooling plate CTS use ? please check below pictures , we normally put the cooling plate in the botton of the battery pack , it can adjust the battery temperature to maintain it within the temperature range suitable for battery operation; Reduce the difference between the highest and lowest temperatures inside the battery pack. except cooling system , we also can Integrated battery heating system . if you want know more about the Battery thermal management system ， feel free to contact us , thank you !
Welcome to visit CTS battery factory
Customer visit
CTS lithium battery manufacturer-focus on customization service
1, For EV, e-scooter, home storage, electric boat/truck etc..
2, With 13 years battery customization experience
3, Professional technical team to provide services for you
4, Complete after-sales service system
5, Independent factory, fast delivery
With the disappearance of the COVID-19, more and more customers from all over the world come to visit our factory, We are so happy to share with you the memorable moments from recent meetings with customers.
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Power battery accounts for a major part of the development of Lithium ion battery market
Power battery accounts for a major part of the development of Lithium ion battery market
Power battery accounts for a large proportion in the application of lithium ion battery at present, with its market share in lithium battery sector reaching 56.10% in 2020 alone. Power battery is widely used on electric vehicles for different scenario, electric boats and ships, two wheel autos like electric bicycles, scooters, and electric tools, etc. Among them, EV sector is the fastest growing one and it’s the biggest in its scale, concerning downstream applications of power batteries. Power battery is considered to be the key component to promote the development of new energy vehicle industry.
In recent years, countries in Europe, North America, East Asia and other regions are making efforts to develop clean energy by adjusting their energy mix to achieve the goal of peak carbon emissions and carbon neutrality.In the
meantime, there has been continuous progress in EV related technology and infrastructure. The new energy vehicle industry is developing rapidly.
According to the statistics provided by EV Sale, the global sales volume of new energy vehicles in 2020 was 3.24 million, 43.36% more than that of last year. In 2021, the sales volume of new energy vehicles worldwide increased rapidly, reaching 6.75 million, 108% more than that of last year. This figure continues rocketing in 2022. In recent years, under the policy of vigorously promoting "carbon neutrality" and "electrification, intelligence and interconnection" of the automobile industry, major economies in the world have increased the market share of new energy vehicles. It is expected that the global new energy vehicle market will continuously and significantly develop in the next few years.
China boasts one of the largest market for new energy vehicle in the world. Propelled by policies and market force, this market has experiencing rapid development in recent years. According to the data of China Association of Automobile Manufacturers, the annual sales of new energy vehicles have rapidly increased from 18000 in 2013 to 1.206 million in 2019, with a compound annual growth rate of 101.53%, since central and local preferential policies coming into force in 2013. In 2020, the sales volume of new energy vehicles is 1.367 million. In the face of COVID-19, the sales volume of new energy vehicles grows by 10.9% than previous year.
In 2021, the overall volume of production and sales of new energy vehicles is 3.545 million and 3.521 million respectively, with a record high growth of 159.5% and 157.5% than previous year. And the market share will also rise to 13.4%. In the first half of 2022, new energy vehicles will still maintain a high growth trend. The production and sales of new energy vehicles will be 2.661 million and 2.6 million, respectively, with a year-on-year growth of 118.2% and 115.0%.
In recent years, with the gradual decline of the subsidy policy to its abolition, the marketization of new energy vehicles has taken a solid step forward. More and more new energy vehicle enterprises, without relying on financial subsidies, have achieved substantial growth in sales by improving product performance and technical level. The new energy vehicle market has gradually shifted from policy driven to market driven.
The rapid development of new energy vehicles has driven a strong demand for power batteries. According to the data of GGII, in the face of COVID-19 in 2020, the sales volume of power battery in China was 80.0GWh, maintaining a yearly growth of 12.67%. In 2021, China's power battery shipments will be about 226.0 GWh, driven by the rapid development of the upstream new energy vehicle market, with a yearly growth of 182.5%. In the first half of 2022, China's power battery sales volume exceeded 200GWh, with a yearly growth rate of more than 150%.
With the implementation of long-term policies such as the new energy vehicle credit system, the technology of the new energy vehicle industry is constantly improving, and the supporting infrastructure is also increasingly improved. More new energy vehicles and brands that meet the market demand will be launched in succession. The demand of China's power battery market will also maintain a trend of rapid growth, while driving further growth of the upstream market of anode material.
What's the difference between lead acid battery and lithium battery?
What's the difference between lead acid battery and lithium battery?
At present, there are lead-acid batteries and lithium batteries on the market. What's the difference between lead-acid batteries and lithium batteries?
① In terms of price, due to the better heat dissipation function and endurance function of lithium battery, the production process from packaging to sealing is also very strict; Therefore, the production cost is much higher than that of lead-acid battery.
② The main component of positive electrode is lead dioxide, and the main component of negative electrode is lead; When the battery is charged, the main component of both positive and negative electrodes is lead sulfate.
（Structure diagram of lead acid battery）
In the working state of lithium battery, the main component of the positive electrode is manganese dioxide, and the main component of the negative electrode is lithium metal or its synthetic metal, which uses non-aqueous electrolyte solution; In the state of charge, lithium alloy metal oxide is usually used as cathode material, graphite is used as anode material, and non-aqueous electrolyte is used as battery.
（Structure diagram of lithium battery）
③ The memory effect is different. After a period of time, the battery goes into sleep state, and the capacity is lower than the normal value; Lead acid battery will have memory effect, so special methods and equipment are needed to activate the battery and restore its normal capacity; Lithium battery has its own characteristics, without memory effect. It only needs 3-5 normal charge discharge cycles to activate the battery and restore its normal capacity.
④ The service life of lead-acid batteries is generally only two years, and the number of complete charge discharge cycles is generally less than 300. The service life of lithium battery is four to five years. It is durable and can be fully charged and discharged for more than 500 times.
⑤ Environmental protection efforts are different. Under the environmental protection policies, in order to protect the environment and reduce pollution, there is pollution caused by improper treatment in the production, use and recycling of lead-acid batteries. However, lithium batteries are relatively environmentally friendly due to their perfect packaging and sealing.
CTS48100 Lifepo4 Solar Battery
CTS 48V 100Ah lithium iron phosphate battery is perfect for many solar powered applications, including home solar storage system , off-grid system and monitoring systems. It has the most safe LFP battery technology and built-in battery management system (BMS). , the capacity can be expandable with space saving , its our hotselling 48V BESS products , we have exported these battery systems in many countries .
Now lithium battery is a new trend to replace lead acid battery for solar storage , it has many advantages than lead acid battery :
Light on Weight; Heavy on Power
lithium batteries typically weigh one-third less and provide up to 50% more energy than traditional AGM, or GEL lead-acid batteries, and they provide more power.
LONGER LIFE CYCELS:
Lifepo4 lithium batteries provide up to 6 times longer life than lead-acid batteries, and they still provide 80% of rated capacity after 3000 cycles. Spend more time powering your applications and less time replacing your batteries.
MORE HOURS OF POWER:
LIfepo4 Lithium batteries provide 100% of their rated capacity, regardless of the rate of discharge. Lead-acid batteries typically provide less usable energy with higher rates of discharge. They are usually limited to 50% of the rated capacity to prevent diminished life.
Cash In On Performance
While lithium-ion batteries may cost more up front, the long-term savings are tremendous. Lithium batteries deliver greater performance and longer life than lead-acid batteries. This means fewer replacement and labor costs, and less down-time.
When you’re powering your home or business,, you need energy that you can depend on around-the-clock, no matter if you’re on or off the grid. CTS48V100 offers a safe, clean and high power energy solution for all types of solar power systems.
How to charge lithium iron phosphate batteries? The correct way to use lithium iron phosphate batteries
How to charge lithium iron phosphate batteries?
The correct way to use lithium iron phosphate batteries
The full name of the Lifepo4 batteries is lithium iron phosphate attery. Because its performance is particularly suitable for power application, the word "power" is added to the name, namely lithium iron phosphate power battery.
At present, the mainstream market of lithium iron phosphate batteries is used in the electric bus market and electric passenger car market, respectively. The related issues related to the charging of lithium iron phosphate have also been enlarged.
For example, can lithium iron phosphate batteries be charged every day, is the lithium iron phosphate battery charging at any time and so on.
So, let's take a look at the correct charging method of lithium iron phosphate batteries today.
Combined with the working principle of the lithium battery pack, the correct usage method mainly includes three aspects: charging, discharge, and maintenance.
1. The correct charging method of lithium battery packs
First, the principle of shallow charging and shallow discharge
Secondly, full charging can prevent overcharging. For lithium-ion batteries in the industrial industry, charging is relatively slow when using batteries in the past. It may take 8-12 hours for a single charge, while lithium battery packs can achieve fast charging. A lithium battery with the same capacity as the storage battery only takes about 4 hours to fully charge at a time, so pay attention when charging, and do not charge the lithium battery pack according to the charging time of the storage battery.
In the end, it's best not to use two things at once.
In layman's terms, don't let the lithium battery work while charging. The main reason why this cannot be done is also very simple. This approach will reduce the service life of the lithium battery pack.
Improper use will lead to battery attenuation, which will affect battery life. The following points must be paid attention to:
1. Long-term parking at low temperature.
The new energy vehicle batteries currently on the market are mainly divided into two types: ternary lithium batteries and lithium iron phosphate batteries. attenuation phenomenon.
2. Often charge with low battery.
Since lithium-ion batteries do not have a battery memory effect, electric vehicles are like our smartphones, which can be charged as they are used, and try not to run out of power on charging.
3. Step on the accelerator heavily and brake in an emergency.
Because electric vehicles have a characteristic, that is, excellent acceleration performance, some car owners like to step on the accelerator heavily, which leads to emergency braking.
But it must be clear that the large current will increase the internal resistance of the battery sharply, and frequent driving in this way may even damage the battery.
All about electric car batteries
All about electric car batteries
Learn about electric car batteries, how they work and how they're recycled.
How do electric car batteries work?
Where internal combustion engined cars get energy from burning petrol or diesel, an electric vehicle gets its power directly from a big pack of batteries.
These are much like a scaled up version of the lithium-ion (Li-ion) battery in your mobile phone - EVs don't use a single battery like a phone, they use instead a pack which is comprised of thousands of individual Li-ion cells working together. When the car's charging up, electricity is used to make chemical changes inside its batteries. When it's on the road, these changes are reversed to produce electricity.
Electric car battery technology
EV batteries undergo cycles of 'discharge' that occur when driving and 'charge' when the car's plugged in. Repeating this process over time affects the amount of charge the battery can hold. This decreases the range and time needed between each journey to charge. Most manufacturers have a five to eight-year warranty on their battery. However, the current prediction is that an electric car battery will last from 10 – 20 years before they need to be replaced.
How a battery and the car's electric motor work together is surprisingly simple – the battery connects to one or more electric motors, which drive the wheels. When you press the accelerator the car instantly feeds power to the motor, which gradually consumes the energy stored in the batteries.
Electric motors also work as generators, so when you take your foot off the throttle the car begins to slow down by converting its forward motion back into electricity – this happens more strongly if you hit the brakes. This regenerative braking recovers energy that would otherwise be lost, storing it in the battery again and so improving the car's range.
Electric car battery lithium-ion
A Lithium-ion (Li-ion) battery is a type of rechargeable battery used in electric vehicles and a number of portable electronics. They have a higher energy density than typical lead-acid or nickel-cadmium rechargeable batteries. This means that battery manufacturers can save space, reducing the overall size of the battery pack.
Lithium is also the lightest of all metals. However, lithium-ion (Li-ion) batteries contain no lithium metal, they contain ions. For those wondering what an ion is, an ion is a an atom or molecule with an electric charge caused by the loss or gain of one or more electrons.
Lithium-ion batteries are also safer than many alternatives and battery manufacturers have to ensure that safety measures are in place to protect consumers in the unlikely event of a battery failure. For instance, manufacturers equip electric vehicles with charging safeguards to protect the batteries during repeated rapid charging sessions in a short period of time.
Battery capacity explained
Electric car battery life
Once an EV battery loses its capacity to power a vehicle, it can be used to power a home or building by contributing to a battery storage system. A battery energy storage system stores energy from batteries that can be used at a later time.
If you power your home with renewable energy such as wind or solar, you can also pair it with an EV battery. You can store it up to use throughout the night when wind and sunlight are reduced. Or even during the day alongside solar or wind energy. This method of generating energy can help you save on bills and reduce the amount of energy you use from the grid.
The battery on an electric car is a proven technology that will last for many years. In fact, EV manufacturers guarantee it. Nissan warrants that its electric car batteries will last eight years or 100,000 miles, for example and Tesla offers a similar guarantee.
This might seem remarkable when the battery in your mobile phone begins to wear out after only a couple of years, but during that time it might be fully charged and discharged hundreds of times. Each of these so-called charge cycles counts against the life of the battery: after perhaps 500 full cycles, a lithium-ion phone battery begins to lose a significant part of the capacity it had when new.
While that might be OK in a phone, it's not good enough for a car designed to last many thousands of miles, so EV manufacturers go to great lengths to make electric car batteries last longer. In an EV, batteries are 'buffered', meaning that drivers can't use the full amount of power they store, reducing the number of cycles the battery goes through. Together with other techniques such as clever cooling systems, this means that electric car batteries should give many years of trouble-free life.
In fact, in order to preserve the life of an electric vehicle battery, manufacturers ensure that there is additional spare capacity to compensate for degradation over time. So as an electric vehicle ages and the battery cycles, the additional spare capacity is used up. This allows the range of the vehicle to stay the same throughout the life of the battery. Once the battery capacity falls below 80%, drivers may start to notice a fall in the range and performance of the battery.
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