How to design and assemble a Drone/UAV battery pack?
In the fast-evolving world of drone/UAV industry, power efficiency and battery technology play a crucial role in delivering top-tier performance. In this article, we will take a deep dive into the details of a commercial off-the-shelf (COTS) drone battery (Model#: DJI BWX170-2000-22.2), explore the engineering behind this high-performance battery, unpack its intelligent design, and reveal how to build a robust drone battery pack for demanding applications.
This battery is designed mainly for high speed Drones, where the discharging power capability (C rating) is a key. Here’s a breakdown of its core specs:
- Capacity & Voltage: 2,000 mAh capacity with 6S1P configuration. It has a 22.2V nominal voltage (25.2 V max charging voltage), delivering 44.4 Wh of energy.
- Weight & size: At 295 grams, it balances power and portability, featuring rubberized feet for stability and a robust attachment system for secure mounting.
- Charging Efficiency: Supports 90W fast charging, reaching full capacity in ~50 minutes within a 5–40°C temperature range.
Mechanic Design: Engineered for Extreme Conditions
The rugged construction of the battery ensures reliability under high-stress environments and conditions:
- Robust Construction: Reinforced plastic casing and rubberized flaps protect internal components from crashes and vibrations.
- User-Friendly Features: Four LED indicators display charge status with an on/off switch simplifies power management.
- Thermal Management: Efficient heat dissipation ensures stable performance during aggressive maneuvers.
Teardown of this battery shows that this battery has 6 Li-po battery cells connected in series (6S1P configuration) and was laser soldered on a BMS board.
Intelligent BMS Technology: Smarter, Safer, Stronger
A sophisticated intelligent BMS (Battery Management System) is critical to drone batteries to ensure reliability and longevity. It acts as the brain of a battery pack. With an advanced BMS, the battery delivers reliable power, contributing to a seamless flying experience. Pilots can monitor battery health, gaining insights into charge levels, estimated flight time, and maintenance needs.
Key Components in this BMS include:
- ST Microcontroller (MCU): Acts as the central hub, coordinating communication between the battery and drone.
- TI BQ90xx Battery Control Chip: Monitors cell health, voltage, and temperature while enabling precise protection.
- MOSFETs: Serve as electronic switches to regulate charging/discharging cycles.
- NTC Temperature Sensors: Prevent thermal runaway by monitoring real-time heat levels.
- Balancing Circuitry: Ensures uniform cell voltage with discharge resistors.
Smart features enabled by BMS:
- Auto-Discharging Function: To prevent swelling and extend lifespan, the battery automatically discharges to 96% after 3 days of inactivity and further down to 60% after 9 days. This controlled self-discharge mimics natural battery behavior while prioritizing safety and longevity.
- Real-Time Monitoring: Users can track critical metrics of the battery, including: Battery Cell Status, Voltage & Temperature, Cycle Count and more.
- Safety Protections: Built-in safeguards include overcharge/over-discharge prevention, short-circuit detection, and hibernation mode for long-term storage.
Conclusion: How to Build a High-Performance Drone Battery Pack
Designing a custom drone/UAV battery requires precision engineering and industry expertise. Here’s a summary of some critical steps:
- Chemistry and Cell Selection: Choose proper high C-rate and energy density Li-ion/Li-Po cells.
- BMS Integration: Implement a robust BMS with protection, cell balancing, temperature sensing, and communication control.
- Mechanical Design: Utilize advanced welding technology for secure connections and rugged materials like reinforced ABS.
- Testing & Validation: Ensure compliance with safety standards (UN38.3, UL2054) and simulate real-world stress tests.
PHD Energy: Your Partner in Custom Drone Battery Solutions
At PHD Energy, we specialize in premium custom battery solutions tailored to your unique demands. Founded by battery experts and professionals in Texas, we serve a wide range of products from Fortune 500 and industrial leading companies to startups and emerging businesses.
Why PHD Energy?
- Expertise in premium battery chemistry selections and cell & pack customizations.
- One-stop support: engineering & design, testing, compliance, mass production, warehousing and logistics.
- Cutting-edge solutions for medical devices, drone/UAV, mobility power, and more.
Feel free to contact us at info@phdenergy.com
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