Design and Fabrication of LiFePO4 BESS for E2O EV

The client approached us to design and develop a new battery energy storage system for their existing electric vehicles (EVs). The vehicles were approximately five to six years old, and the original battery packs had reached the end of their service life due to degradation and limitations associated with the existing battery design. Following a detailed inspection and assessment of the vehicles and their existing electrical systems, a replacement battery system with increased energy capacity was engineered to improve both performance and driving range. The proposed battery configuration was developed through detailed electrical calculations, 3D modelling, and simulation to validate the design parameters, physical configuration, capacity, and expected performance before fabrication. Based on the simulation and design analysis, a customized battery pack was successfully fabricated and integrated with the vehicles. The upgraded battery system increased the driving range by approximately 60 km compared with the previous battery configuration, providing a significant improvement in vehicle usability and performance. Following installation and commissioning, the system demonstrated reliable operation with no reported issues over the subsequent three years. This project represents one of the key battery energy storage and EV engineering projects successfully undertaken by our team during the past three years.