84V 48Ah Custom Lithium Battery Solution for Survey and Mapping Unmanned Boats

Challenges in Scenario Adaptation Due to Lack of Customization for Survey and Mapping Unmanned Boats:

The core pain point for equipment manufacturers stems from the mismatch between generic batteries and the specific characteristics of survey and mapping unmanned boats, directly impacting product competitiveness:

1.Discrepancy between endurance and operational requirements: Shallow-draft mapping UAVs have weight constraints due to their shallow draft. Generic batteries with only 40Ah capacity provide just 4 hours of endurance per charge, enabling a maximum of 20km of river mapping per day. This falls far short of clients' “30km/day” requirements, resulting in a 35% project delay rate.

2. Lack of status monitoring poses safety risks: When operating in complex waterways like reed beds and shoals, unmanned vessels with non-communicative primary batteries cannot remotely assess power levels. In 2023, two incidents resulted in vessel groundings due to over-discharge, with rescue costs exceeding ¥20,000 per occurrence.

3.Insufficient Environmental Tolerance: During southern China's rainy season, high humidity causes oxidation at battery interfaces, accounting for 27% of malfunctions due to poor contact. Interfaces also loosen during wind and wave turbulence, compromising sensor power supply stability.

4. Short lifespan drives up customer costs: Primary batteries have a cycle life of 500 cycles, requiring replacement every 18 months on average. In 2023, battery lifespan-related complaints accounted for 30% of total after-sales issues.

 

 

Based on equipment manufacturers' hull parameters and operational scenarios, we deliver tailored solutions centered on “customized design + standardized parameters.” All specifications strictly adhere to the 84V 49Ah standard:

 

Core Customization Parameters and Application Scenario Compatibility Table

Nominal Voltage: 84V

Nominal Capacity: 49Ah

Rated Capacity: 42Ah/3.50KWh

Charging Temperature: 0°C to +45°C

Discharging Temperature: -20°C to +55°C

Product Dimensions: 523*494*120mm

Product Weight: ≤26kg

 

Customized Solution Details

1. Precise Size and Weight Matching, No Hull Modification Required

Based on the battery compartment dimensions (530×500×125mm) provided by the equipment manufacturer, Zhongke strictly controlled the battery dimensions to 523×494×120mm, reserving a 7mm installation clearance. Weight was optimized to ≤26kg, below the hull's 28kg load limit, preventing vessel sinking. Pre-shipment 1:1 compartment testing ensures plug-and-play functionality, reducing per-vessel production time from 3 hours to 1.5 hours—a 50% capacity increase.

 

2. Energy configuration optimized for operational power consumption, extending endurance to 6 hours

Tailored 84V/49Ah energy combination for the shallow-water unmanned vessel's propulsion system (approx. 580W), rated at 3.50KWh. A single full charge enables continuous operation exceeding 6 hours, meeting the requirement for “30km river surveying per day.” The discharge cutoff voltage is synchronized with the unmanned vessel's control system to prevent sudden power loss from over-discharge, resolving the issue of “insufficient endurance slowing down projects.”

 

3. Customized Communication Functionality for Real-Time Status Monitoring

Based on the central control system protocol of equipment manufacturers, a customized CAN bus communication module (baud rate 250K) employs optocoupler isolation design (interference resistance ≥1000V) to transmit real-time data—including battery state of charge (SOC), temperature, and cycle count—to shore terminals with an error margin ≤2%. Automatic alerts trigger when power drops below 20%, prompting return route planning to eliminate the risk of “loss of contact in remote waters.”

 

4.Structural Protection Adapted for Aquatic Environments, Enhancing Durability

Housing constructed from aluminum alloy, withstanding 500 hours of salt spray testing without corrosion, suitable for humid southern climates; surface undergoes insulation treatment to prevent conductive interference from the hull;

Custom aviation connectors at the output end ensure ≥1000 insertion/removal cycles with ≥60N insertion force, maintaining stable contact even during Level 4 wind and wave turbulence, eliminating “loose connection power loss” issues;

Battery cycle life reaches 1500 cycles (1C charge/discharge), three times that of original batteries. Customers typically require no replacement for 5 years, significantly reducing operational and maintenance costs.

 

 

Implementation Results

Since the customized solution was implemented in June 2024, over six months of field validation across diverse water bodies (rivers, lakes, reservoirs) has yielded significant outcomes:

1. Operational efficiency increased by 50%: Daily surveying mileage per unmanned vessel rose from 20 km to 30 km. A county-level river survey project duration was reduced from 20 days to 12 days, with customer repurchase rate increasing by 30%.

2. 100% vessel compatibility: No battery compartment modifications required, installation time reduced by 50%, annual production capacity increased from 180 to 240 vessels, with a 33% boost in manufacturing efficiency;

3. Zero safety incidents: No groundings or interface failures occurred over six months; BMS early warning system prevented five potential risks, reducing customer complaints to zero.

4. 40% reduction in overall costs: Due to extended equipment lifespan and fewer malfunctions, after-sales service expenses for equipment manufacturers decreased by 40% year-over-year in Q4 2024, saving over 200,000 yuan.

5.  Accelerated market expansion: Leveraging customized solutions, four new provincial hydrological station clients were added, with order volume increasing by 45% year-over-year.