Battery solutions for mechanical engineering applications
Custom battery system development for the SycoTec Speeder 60
High-speed battery spindle with 100% autonomy
Why does an autonomous high-frequency spindle need a dedicated power supply?
Anyone who needs higher speeds on an existing CNC machine does not want to modify that machine to get them. A retrofittable spindle therefore has to run in the tool magazine and bring its own drive power.
SycoTec developed the Speeder 60 ER11 as a fully autonomous high-frequency spindle that enables high-speed machining on conventional CNC machines – without external controllers or complex retrofitting. The spindle integrates all required components and is compatible with automatic tool changers.
This created specific requirements for the power supply:
- Compact, integrable design compatible with tool holders
- Reliable performance at high rotational speeds
- Fast charging and high energy density
- Certifiability according to IEC 62133 and UL 62133 standards
BMS integration and heat dissipation in a confined space
Integration of all BMS functions in a confined space
In addition to basic protection and monitoring features, the system also had to incorporate a state-of-charge indicator and 1-wire (HDQ) communication within a compact housing. Combining these functions in such a limited space placed high demands on PCB design as well as mechanical and electrical integration.
Thermal challenge due to high current load
The application requires consistently high discharge currents, leading to thermal hotspots that had to be reliably managed within the compact design – without active cooling.
How is a battery system integrated into a cylindrical spindle housing?
Radial 9S2P cell configuration with copper connectors
The layout comprises 18 cylindrical lithium-ion cells in 18650 format, nine in series and two in parallel. To make optimal use of the cylindrical housing in the Speeder 60 ER11, the cells were arranged in a radial 9S2P layout. The cells are connected using custom-developed copper links:
- Radial 9S2P cell configuration for maximum energy density
- Copper connectors for low-loss current handling
- Compact integration of all electrical connections
BMS adapted to the housing geometry
The battery management system (BMS) was mechanically and electrically tailored to the housing geometry. All safety-relevant functions were implemented in accordance with IEC 62133:
- Monitoring of all cell voltages and temperatures
- NTC sensors for precise temperature measurement
- Energy-efficient operating modes: sleep and power-down
A dedicated charging station was also developed specifically for the battery system.
We develop custom battery systems – tailored to your application, your standards, and your available installation space.
Steffen Weller
Vertriebsleiter / Sales Director