Customized 24V Lithium Battery Guide

With the intelligent upgrade of industrial equipment and the advancement of the "lead-to-lithium" policy, demand for lithium batteries in specialized fields continues to surge. According to data from the Global Industrial Lithium Battery Market Report 2024 by GGII (High-End Industry Research Institute), the global penetration rate of lithium batteries in industrial equipment is projected to reach 45% by 2025. Among these, 24V batteries, as the mainstream medium-voltage specification, are seeing annual demand growth exceeding 30% in scenarios like special equipment, robotics, and medical devices. Currently, the development of 24V lithium batteries exhibits three major trends: First, customized demands are becoming prominent, requiring adaptation to different equipment's power, space, and environmental requirements. Second, the lithium iron phosphate (LFP) system has become dominant, capturing over 60% of the industrial market due to its high safety and long lifespan. Third, integrated smart battery management systems (BMS) supporting remote monitoring and fault warnings have become standard features.

To help equipment manufacturers efficiently address technical compatibility, cost control, and compliance challenges in 24V lithium battery customization, JU-Da Lithium Battery leverages 23 years of customized lithium battery expertise. By analyzing industry data and real-world case studies, we have compiled this procurement white paper. It focuses on key customization aspects (such as parameter definition, BMS design, and scenario adaptation) to provide practical guidance for technical teams in selection and procurement teams in cost calculation.

1. Basic knowledge of 24V lithium battery

(1) Classification of mainstream chemical systems

Currently, 24V lithium batteries primarily utilize lithium iron phosphate (LiFePO₄) and ternary lithium (NCM/NCA) systems.

l Lithium iron phosphate (LFP): High safety (thermal runaway temperature>800℃) and long cycle life (2000-6500 cycles), but low energy density (100-160Wh/kg), suitable for industrial equipment and special equipment with high stability requirements.

l NCM (Nissan Cobalt-Manganese-Nickel): Featuring high energy density (200-300Wh/kg) and excellent low-temperature performance (discharge efficiency>70% at-20℃), though costly and requiring strict temperature control, it is suitable for mobile devices sensitive to size and weight, such as robots and surveying equipment. LCO (Lithium Cobalt Oxide) is not recommended for industrial applications due to its short cycle life (<500 cycles) and poor safety.

(2) Core advantages of 24V lithium battery

Compared with traditional lead-acid batteries, 24V lithium batteries have three core advantages:

1. Lightweight and high energy density: With the same capacity, the volume is 50% less than that of lead-acid batteries and the weight is 60% less, which is more suitable for compact space equipment.

2. Long life and low cost: the cycle life is 3-5 times that of lead-acid batteries, and the use cost of the whole life cycle (5-8 years) is reduced by more than 40%.

3. Intelligent Management and Safety: The built-in BMS (Battery Management System) provides protection against overcharging, overdischarging, and overheating, supports remote status monitoring, and reduces equipment failure rate by 70%.

2. Custom 24V lithium battery core technology

(1) Custom core parameters

Voltage parameters:

Lithium iron phosphate: 8 series cells in series, nominal voltage 25.6V, upper limit of charging 29.2V, lower limit of discharging 20V (below this value is easy to damage the cells).

Ternary lithium battery: 7 series cells in series, nominal voltage 25.9V, upper limit of charging 29.4V, lower limit of discharging 21V.

Capacity parameters:

Actual usable capacity = nominal capacity × 80% (reserving 20% safety redundancy to avoid deep discharge). For example, a 100Ah battery should be used with a capacity of 80Ah or less.

Lifespan parameters:

Cycle life: 2000 cycles for lithium iron phosphate (LFP) when capacity drops to 80%, and 800 cycles for ternary lithium (NMC).

Calendar life: up to 5-8 years at room temperature (25℃), requiring regular charging and discharging maintenance.

(2) Structural design

Cell combination method:

Series configurations determine voltage (8 series of lithium iron phosphate / 7 series of ternary cathode), while parallel configurations boost capacity (e.g., 2 parallel 100Ah cells achieve 200Ah total capacity).

size and shape ：

Small devices (5-50Ah): Use 18650/21700 cylindrical cells or soft pack cells, suitable for handheld devices and small sensors.

Medium and large equipment (100-500Ah): Square aluminum shell cells with modular customization support.

Shell material and protective design:

Material: Aluminum alloy (high heat dissipation, suitable for high-power equipment) or ABS engineering plastic (lightweight, suitable for ambient temperature scenarios).

Protection level: Outdoor or humid environments require IP65 or higher (e.g., IP67 for short-term water immersion), and dust-proof mesh is required in dusty environments.

thermal design ：

High-power equipment (discharge current> 50A) requires built-in heat-conducting silicone or aluminum heat sink to ensure that the temperature difference of the cell is less than 5℃ during operation to avoid local overheating.

(3) BMS Customization

Basic protection features:

Overcharge protection (voltage accuracy ±0.02V), overdischarge protection (voltage accuracy ±0.1V), overcurrent protection (response time <5ms), short circuit protection (automatic power off after triggering).

Advanced management features:

Active balancing: dynamically balances the voltage of each cell (voltage difference <50mV), extending the battery life by more than 15% (recommended for industrial equipment).

Communication protocol: Supports SMBUS/I2C/CAN bus for power monitoring and fault warning. Some scenarios support OTA remote parameter upgrade (e.g., security devices, rail transit monitoring devices).

(4) Safety design and compliance certification

safety design ：

Hardware: Insulating partitions (with voltage resistance>500V) are installed between battery cells, and the housing is equipped with an explosion-proof valve that automatically releases pressure when internal pressure exceeds 1.2MPa.

Software: BMS features dual redundancy design (with independent monitoring of primary and backup chips) to prevent protection failure caused by single-point failure.

Compliance certification:

Basic Certification: Domestic sales require CQC certification (complying with GB 31241-2014), while exports require UL 1642 (US) and IEC 62619 (International Energy Storage/Industrial Standard).

Industry-specific certifications: Medical devices must meet CE-MDD and ISO 13485 (biocompatibility); rail transit equipment must comply with EN 50155 (wide temperature and vibration requirements).

3. 24V Lithium Battery Application Scenarios and Customized Solutions

(1) Special equipment and industrial robots

Key pain points: high vibration (e.g., mining detection equipment), wide temperature range (-40℃ to 60℃), and high-rate discharge (instant power over 3C).

JU Da Custom Solution:

l Battery: Choose lithium iron phosphate (LFP) for vibration resistance or lithium titanate (LTO) for ultra-low temperature applications, with normal operation at-40°C.

l Structure: Reinforced aluminum alloy casing (impact resistance IK08), IP67 waterproof, with built-in heating film (automatically activates in low-temperature environments, heats up to 5℃ before discharging).

b. BMS: Supports CAN bus communication, uploading voltage and temperature data to the central control unit in real time, and triggering equipment shutdown protection in case of abnormal conditions.

(2) Medical equipment and security system

Key pain points: low ripple interference (e.g., ultrasound diagnostic equipment), long battery life (7×24 hours), and high safety (anti-leakage, anti-electromagnetic interference).

JU Da Custom Solution:

l Battery: Features high-consistency ternary lithium (compact design for portable medical devices) with ceramic separators to minimize short-circuit risks.

l Electrical Design: The output terminal is equipped with an EMI filter, ensuring ripple voltage <50mV, compliant with the electromagnetic compatibility standard for medical devices (EN 61000-6-3).

(3) Surveying and mapping and power detection

Key pain points: harsh environments (dust, salt spray), long standby (5-7 days in the field), and high reliability (failure-free operation).

JU Da Custom Solution:

Protection: IP68 waterproof rating (resistant to 24 hours of submersion at 1 meter depth), with a triple-protection coating (moisture-resistant, mildew-resistant, and salt spray-resistant).

l Capacity: Equipped with 200-300Ah lithium iron phosphate batteries and a low-power BMS (static power consumption <10mA), it extends standby time.

4. 24V Lithium Battery Selection Guide: Technical Pitfalls and Certification Requirements

(1) Capacity calculation method (to avoid "false labeling" and "excess")

Basic calculation formula:

Required capacity (Ah) = Device power (W) × Working hours (h) ÷ Battery nominal voltage (V) × 1.2

Note: 1.2 is the safety factor, reserving 20% redundancy (to deal with power fluctuations and low temperature battery life decay).

Example reference:

A power testing device with 50W capacity operates for 8 hours daily, requiring a battery capacity of (50×8)÷24×1.2≈20Ah. It is recommended to use a 25Ah battery to avoid undercapacity.

Anti-fraud measures:

The supplier must provide third-party test reports (e.g., SGS, CTI) to verify the actual capacity under 25℃/0.5C discharge conditions, with a deviation of ≤5%.

(2) Mandatory verification requirements (compliance check first)

(3) Key points for model selection

Myth 1: Only look at capacity, ignore discharge rate

Risk: Some batteries are rated at 100Ah, but the continuous discharge current is only 1C (100A), which cannot drive the industrial mechanical arm that requires 2C (200A) instantaneous power, resulting in the failure of equipment startup.

Solution: Specify the maximum discharge current of the equipment and require the supplier to provide the discharge rate curve (e.g., 2C discharge capacity should be ≥ 90% of the nominal capacity).

Misconception 2: Focusing solely on price while overlooking BMS configuration

Risk: Low-cost batteries predominantly use passive BMS for balancing. When the voltage difference between cells exceeds 200mV, imbalance occurs, potentially causing individual cell over-discharge and reducing the battery's overall lifespan by 50%.

Solution: Industrial equipment should prioritize active balancing BMS (costs approximately 30% higher but extends service life by 20%), with a BMS functional test report required.

Myth 3: Neglecting environmental adaptation leads to failure

Case: A security device uses ordinary ternary lithium battery in the environment of-15℃ in the north, and the battery life drops from 8 hours to 3 hours, requiring frequent battery replacement in winter.

Solution: For low-temperature environments (<-20℃), use lithium iron phosphate (LFP) batteries with a heating module; for high-temperature environments (>50℃), implement forced air cooling; and for humid environments, ensure waterproofing with IP67 or higher protection.

5. Custom 24V lithium battery price

The price variation of customized 24V lithium batteries fundamentally stems from the combined costs of "base cost + functional cost + customization cost + compliance cost". This breakdown reveals five core factors, each with its specific pricing impact and quantifiable reference as outlined below:

(1) Cell type & brand

1. Differences in chemical systems

Lithium iron phosphate: the raw material cost is low (lithium and iron prices are stable), and the overall cost is 20%-30% lower than that of ternary lithium.

Lithium-ion batteries: They rely on precious metals like nickel and cobalt, with raw material prices being highly volatile. Production costs increase with higher nickel content (e.g., NCM811 is 15% more expensive than NCM523).

2. Battery brand & grade

Brand differences of battery cells:

l International brands such as Samsung, Panasonic, and LG are favored for their high consistency and extended service life (10%-20% longer than domestic counterparts), though priced 30%-50% higher than top-tier domestic brands.

Top-tier domestic brands such as Bick, Lishen, and Eve Energy offer balanced value with prices 30%-50% lower than international brands and 10%-20% higher than second-and third-tier domestic brands.

Cell grade difference:

l A-grade battery cells (fully certified): deliver stable performance (with capacity deviation ≤2%) and the most competitive pricing, making them the top choice for industrial equipment.

B-grade battery cells (with minor defects): slightly inferior in capacity-to-voltage consistency (3%-5% deviation), priced 20%-30% lower than A-grade, suitable only for low-demand applications.

l Disassembled or partially replaced cells (used/retired): The most affordable option (50% cheaper than Grade A), but with limited lifespan (≤500 cycles) and high safety risks. Not recommended for industrial-grade equipment.

(2) BMS functional complexity

1. Protection board type

l Hardware protection board: Only supports basic overcharge, overdischarge, and overcurrent protection. The parameters are fixed and cannot be adjusted, and the cost is low.

l Software protection board: supports parameter programming adjustment and can be linked to device communication monitoring (such as power display and fault warning). The cost is 50%-120% higher than that of hardware protection board because of the need to develop software logic and communication protocol.

l Hardware + software board: Combines the reliability of hardware-based protection with the flexibility of software for parameter adjustment and communication functions. The combined development cost is 80%-180% higher than that of hardware protection board.

2. Balanced Function Types

Passive equalization (discharge-only): No extra charge, ideal for small batteries with capacity ≤50Ah.

Active balancing (bidirectional charge-discharge balancing): Cost increases by 30%+ and battery life extends by 15%. Recommended for batteries with a capacity of ≥100Ah or high consistency requirements (e.g., medical devices).

3. Advanced Expansion Features

Special communication protocols (e.g., CAN bus, SMBUS): 20-50 yuan per set, with central control linkage support;

Battery level display (LED/number display): 10-30 yuan per set, for on-site maintenance.

(3) Shell Material & Mold

The shell is the "physical carrier" of the battery adapter device. The material selection directly affects the cost, protection ability and adaptability. Combined with the standard size, the cost difference is as follows:

1. Ordinary PVC packaging (soft packaging)

Cost level: lowest (only material costs, no processing or mold-making costs)

Key features: lightweight, basic insulation only, no impact or waterproof capability

Size compatibility: No mold required, fits standard cylindrical cell packs

Applicable scenarios: Small devices with low power and no protection requirements (such as micro sensors)

2. ABS+PC Plastic Shell (Hard-shell Base Model)

l Cost level: medium (20%-30% higher than PVC, including materials and processing fees)

Key features: Lightweight (40% lighter than metal), impact-resistant (can withstand 1.5m drop), easy to process, supports basic waterproofing (IP54 grade), and surface can be processed with matte, spray oil and other processes.

l Size association:

Standard size of spot: use the supplier's inventory mold, no mold opening cost, only need to pay the material and processing fee;

Customized standard size: the mold cavity is customized based on the standard mold frame, the mold opening cost is low (about 3000-8000 yuan), and the average price increase is 5%-15%;

Customized dimensions (ultra-thin/curved): Full-process mold customization (including mold frame, cavity, core-pulling mechanism, etc.), mold opening fee 10,000-50,000 yuan, with 20%-40% price increase spread evenly

l Applicable scenarios: Basic protection, weight-sensitive equipment (such as portable medical detectors)

3. Gold-plated shell (hard shell advanced version)

l Cost level: medium-high (30%-50% higher than ABS+PC, including sheet metal cutting, bending, and painting process costs)

l Core features: robust construction, excellent heat dissipation, IP65 waterproof rating, and compatible with high-power equipment cooling requirements

l Size association:

Standard size (standard rectangle): processed with standard sheet metal parts, no additional cost;

Custom dimensions (non-standard mounting holes, irregular heat dissipation channels) require custom cutting molds and bending processes, resulting in a 25%-40% cost increase.

l Applicable scenarios: High-power, vibration-resistant equipment (e.g., AGV robots, robotic arms)

4. 304 stainless steel shell (hard shell high-end model)

l Cost level: highest (40%-60% higher than sheet metal, including stainless steel materials, laser cutting, welding, and anti-corrosion treatment costs)

Key features: corrosion-resistant, explosion-proof (Ex d IIB T4), with a service life exceeding 10 years outdoors

l Size association:

Conventional size (such as standard cylindrical, square explosion-proof housing): there are a small number of ready-made molds, the cost is increased by 15%-30%;

Customized dimensions (e.g., interface designs, explosion-proof enclosures with integrated sensors) require full-process mold and process customization, resulting in a 40%-50% cost increase.

l Applicable scenarios: Equipment for harsh environments (e.g., outdoor surveying, chemical testing, and coastal areas with high-salt fog)

(4) Battery certification

1. Basic General Certification

Certification: CCC, UL, CE, CB, UN38.3, etc. (select according to export region or equipment usage scenario)

Cost breakdown: Certification fees vary by test type and certification body (typically ranging from several thousand to tens of thousands of yuan per project). Clients may either handle the process themselves or have a supplier manage it on their behalf, with the latter incurring additional charges (including testing and service fees).

2. Industry-specific certification

Certification programs: Medical (e.g., ISO 13485, CE-MDR) and rail transit (e.g., EN 50155)

Cost Note: Additional 5%-15% markup applies for specialized tests (e.g., biocompatibility, wide-temperature vibration testing).

(5) Purchase batch

Batching is the "key to bargaining". Suppliers reduce costs by optimizing production scheduling and raw material purchase volume. Price fluctuations are as follows:

Small batch (10-50 sets): no scale effect, the highest unit price, no bargaining space (need to arrange production separately, the purchase amount of raw materials is small);

Medium batch (51-99 sets): Small negotiation space, unit price can be reduced by 2%-5% (can be combined with other orders for production);

Large quantity (more than 100 sets): the maximum bargaining space, unit price reduced by 5%-15% (raw materials can be purchased in bulk, continuous production process, labor cost diluted).

(6) 24V lithium battery price reference

Lithium iron phosphate battery: 24V 100Ah about 800-1200 yuan, 24V 200Ah about 1600-2200 yuan.

Ternary lithium battery: 24V 100Ah, about 1500-2000 yuan, suitable for equipment with high energy density requirements.

Lithium titanate battery: 24V 100Ah, about 2000-3000 yuan, mostly used in low-temperature industrial scenarios.

Note: The above price is only the market reference price of the basic configuration. The actual quotation shall be adjusted according to the specific requirements of the equipment. The final price shall be subject to the official quotation issued by the supplier according to the demand.

VI. 24V Lithium Battery Usage and Maintenance Specifications

(1) Charging specifications (core for extending battery life)

1. Charger Selection: Use original factory-approved chargers (±0.5% voltage accuracy, ±1% current accuracy). Lead-acid battery chargers are prohibited due to voltage mismatch and risk of overcharging.

2. Charging conditions: Maintain temperature between 0℃ and 40℃, avoiding direct high-temperature exposure (e.g., on the roof of summer equipment) or low-temperature charging (<0℃ requires preheating the battery to above 5℃).

3. Charging logic: Charge on demand when the remaining power is 20%-30%, and fully charge at least once a month (calibrate the power meter to avoid false capacity measurement).

(2) Daily use precautions

1. Avoid overload: The device power must not exceed the battery's rated discharge power (e.g., for a 100Ah/1C battery, the maximum load should not exceed 2400W).

2. Installation requirements: The battery must be securely fastened to prevent cell displacement caused by vibration. The positive and negative terminals must be tightened with a torque of at least 5N·m to avoid poor contact and overheating.

3. Environmental precautions: Keep away from open flames and corrosive liquids (e.g., acids and alkalis). When used outdoors, avoid prolonged submersion (even with IP67 rating, continuous water immersion is not recommended).

(3) Daily maintenance points

1. Regular inspection: Clean the battery surface weekly (using anti-static brush to remove dust), and check the terminals for oxidation monthly (grind with sandpaper after oxidation and apply rust-proof grease).

2. Condition Monitoring: The BMS software monitors cell voltage (requires balancing charge when voltage difference exceeds 100mV) and internal resistance (new batteries should have <50mΩ; if resistance increases by>20%, troubleshoot).

3. Long-term storage: If the device is idle for more than 1 month, the battery should be charged to 50% and stored in an environment with humidity ≤60% and temperature 10℃-25℃. Recharge once every 3 months.

(4) Common faults and solutions

1. Capacity decline: may be caused by overcharge or high temperature aging. Partial capacity can be restored by balanced charging. Severe attenuation requires replacement of the cell.

2. Charging malfunction: Inspect the charger interface, fuse, and BMS communication to rule out poor contact or module damage.

3. Bulging deformation: Discontinue use immediately. It may be caused by internal short circuit or overcharge. Professional disassembly is required.

7. 24V lithium battery market trends

(1) Technology trends

Large cells and integration: According to data from the China Chemical and Physical Power Supply Industry Association (CCPSA), the market share of large-capacity lithium iron phosphate cells above 314Ah will exceed 65% in 2025, and modular design can reduce assembly costs by more than 20%.

Solid-state battery pilot: According to the "China Lithium Battery Industry Development White Paper (2024)", solid-state electrolyte batteries will be commercially available on a small scale in 2028, with energy density increased to 400Wh/kg, supporting ultra-low temperature startup at-50℃ (suitable for polar exploration and mapping scenarios).

(2) Application trends

The global industrial lithium battery transition is accelerating: By 2025, the adoption rate of lithium batteries in industrial equipment is projected to reach 45%, with annual demand for AGV robots and mining inspection equipment expected to grow by 30% (Source: GGII's Global Industrial Lithium Battery Market Report 2024).

Scenario-specific customization is advancing: Medical devices require ISO 10993 biocompatibility certification for batteries, while security systems are evolving toward integrated 'battery + IoT' solutions (enabling remote power-off and anti-theft alerts).

(3) Policy trends

Perfect recycling system: China's "Management Measures for the Recycling and Utilization of Power Batteries for New Energy Vehicles" requires that the secondary utilization rate of lithium batteries reaches 70% by 2025, and retired industrial batteries can be prioritized for low-power energy storage (such as backup power for security equipment).

Green certification is mandatory: The EU's New Battery Regulation (effective in 2024) requires full disclosure of battery life cycle carbon footprint, pushing companies to prioritize low-carbon systems such as lithium iron phosphate.

In the 24V lithium battery customization sector, JU-Da Lithium Battery – a 23-year veteran in custom lithium battery manufacturing – delivers safe and efficient solutions with decades of technical expertise and scenario-specific adaptations. Our products serve core industries including special equipment, robotics, and medical applications, offering end-to-end support from cell selection and BMS customization to structural design and compliance certification. All batteries meet fundamental certifications like CCC, UL, CE, and CB, with some models complying with specialized standards for medical and rail transit applications. JU-Da prioritizes customization flexibility, swiftly addressing irregular dimensions and special protection requirements (e.g., IP68). During collaboration, we provide detailed technical solutions and prototype testing, enabling equipment manufacturers to streamline procurement while technical teams efficiently advance projects, effectively mitigating selection and partnership risks.