hen it comes to robot development, consistent performance and reliable operation are the result of design
decisions made early, based on how the robot will actually operate on a day to day basis. Despite not being the first thing designers
think about, the battery pack often determines whether the machine performs as it should. When it’s designed around the real duty cycle and tested properly, it works quietly in the background, keeping operations running as planned. When it isn’t, problems appear quickly, including shorter run times, heat build-up or premature wear that can halt operations.
So the first step is to define how the robot will
work in service: how long it runs for, how often it charges, and the environment it operates in. For example, a unit working in a clean warehouse faces very different demands to one that spends its days on a loading dock or outdoors. Those early decisions shape everything that follows – from electrical design to how the pack is assembled and validated. To avoid drift and late redesigns, development
needs to follow defined stages. The first, Scope Freeze, is where the technical requirements, compliance planning and project timelines are agreed so that everyone is working to the same expectations. The second is working towards Design Freeze, when the detailed design has
been reviewed and validated – drawings, test plans and documentation are finalised, so the pack is ready for a prototype build. The final stage is to validate costs, including the bill of materials, 3rd party supplier quotes, tooling and commercial plan in order to reach Cost Freeze beforemoving to production. Taking this step-by- step approach keeps teams aligned, prevents scope creep and gives customers confidence that progress is controlled and measurable.
Once the application of the end-product is fully understood, chemistry choice becomes the next key decision. Lithium-iron-phosphate (LFP) cells are stable and long-lasting, making them a reliable option for robots that operate continuously. Nickel-manganese-cobalt (NMC) offers higher energy density where space is limited, which suits compact autonomous mobile robots (AMRs) and drones. Lithium-titanate (LTO) performs well for fleets that need very fast charging or work in colder environments. The right chemistry is the one that balances
energy, cost and weight in line with the duty cycle. An experienced battery design and manufacturing partner can help an OEM’s project team to weigh up the pros and cons for different chemistries and will guide the right decision based on each product’s specific requirements. It’s also worth deciding early how much usable
capacity the pack should retain after a shift. Too little and the robot may fail to complete its route; too much adds cost and weight. A good rule of thumb is to design for around 80% of original capacity at end-of-life, as this aligns with
26
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52
