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
What does international field use demand of a battery system?
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 UL 2054.
BMS integration, thermal management and certifiability
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 at least 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.
Battery system for mobile optics at temperature limits
To ensure reliable power for a portable thermal imaging system, VRI developed a custom 2S1P battery system.
Cell configuration and mechanical integration
The system comprises two cylindrical lithium-ion cells in 18650 format connected in series. The Panasonic NCR18650BF cell was integrated into a mechanically constrained housing. At under 110 g, the battery system is designed for handheld devices.
Battery management system functions
The integrated battery management system (BMS) handles monitoring and communication. All safety-related functions were implemented to IEC 62133 and UL 2054:
- Communication via I²C (SDA, SCL)
- Temperature monitoring via NTC sensors with defined cut-off thresholds
- Protection against overvoltage and undervoltage, overcurrent and short circuit
Operating limits and charging behaviour
The system delivers continuous discharge of up to 4.88 A without active cooling and operates from –20 °C to +60 °C. The charging interface was matched to a CV/CC characteristic, with charging enabled from 0 °C ambient temperature.
We develop custom battery systems – tailored to your application, your standards, and your available installation space.
Steffen Weller
Vertriebsleiter / Sales Director