Developing battery solutions for hunting and outdoor technology
Power supply for mobile high-end optical systems with highest demands on performance, precision and safety
Compact, rugged and certified battery systems for thermal imaging devices
Battery system for thermal imaging device
A manufacturer of high-end portable thermal imaging systems required a custom-developed battery system for international field use. The application demanded high continuous load capacity, temperature resistance and reliable system communication – all while meeting global safety and certification standards such as IEC 62133 and UL2054.
Integration of all BMS functions in a compact system design
In addition to cell protection and voltage monitoring, temperature sensing, state-of-charge indication and digital communication (I²C) had to be integrated into a space-optimized housing architecture. The combination of high functional density and limited PCB space placed stringent demands on circuit design, component selection and EMC-compliant signal routing.
Managing thermal performance under continuous high load
The manufacturer specified a continuous discharge current of 4 A across the full temperature range (-20 °C to +60 °C). With passive cooling, thermal hotspots in the compact design had to be reliably controlled. The system design required precise thermal management without active heat dissipation.
Qualification for global certification standards under demanding conditions
In addition to functional implementation, the system had to be certifiable according to IEC 62133 and UL2054. This included requirements for short-circuit protection, temperature monitoring and mechanical robustness (drop, vibration, shock). Compliance was achieved without compromising form factor or operating parameters.
Rugged battery solution for mobile optics in extreme temperature ranges
To ensure reliable power supply for a portable thermal imaging system, VRI developed a custom 2S1P battery system. The Panasonic NCR18650BF cell was integrated into a mechanically constrained housing - including monitoring, communication, and thermal management.
The system featured an integrated battery management system with the following specifications:
- Mechanical integration under strict space constraints
- Continuous discharge up to 4.88 A without active cooling
- Communication via I²C (SDA, SCL), NTC temperature monitoring
- Weight under 110 g for handheld systems
- Operating temperature range: -20 °C to +60 °C
All safety-relevant functions were implemented in accordance with IEC 62133 and UL2054:
- Protection against overvoltage, undervoltage, overcurrent and short circuit
- Temperature monitoring with defined shutdown thresholds
In addition, a charging interface with CV/CC characteristics was configured - including precise charge enable from an ambient temperature of 0 °C.
We develop custom battery systems – tailored to your application, your standards, and your available installation space.
Steffen Weller
Vertriebsleiter – Sales Director