Electric Tool

Electric Tool Needs Analysis:

• Increase tool runtime by at least 35%
• Reduce battery pack weight by 20% without compromising torque output
• Improve rapid charging capabilities to reach 80% charge in under 40 minutes
• Enhance battery durability to withstand heavy-duty daily use and harsh environments
• Ensure safety compliance with IEC and transportation standards for global shipping

Electric Tool Battery Specifications:

The manufacturer required a custom battery solution with the following specifications:

• Dimension: Maximum 120mm × 80mm × 60mm to fit existing battery slot
• Weight: Not exceeding 650g for ergonomic balance
• Voltage: 18V nominal (5S configuration)
• Capacity: Minimum 4000mAh, with a target of 5000mAh for extended operation
• Discharge Rating: Continuous discharge of 20A, with burst capability of 35A for 5 seconds
• Chemistry: High-power Li-ion cells (21700 format preferred)
• BMS (Battery Management System):
• Intelligent cell balancing with ±0.015V accuracy
• Temperature monitoring with dual NTC sensors
• Overcurrent and short-circuit protection
• Cycle life optimization algorithms
• Certifications: UN38.3, IEC 62133, IP54 rating for dust and splash resistance

PKCELL Solution Design:

We developed a robust yet lightweight battery solution for the client’s cordless electric tools:

• Used premium high-discharge 21700 Li-ion cells to deliver both high capacity and strong current output
• Designed a glass fiber-reinforced polymer casing for high impact resistance and reduced weight
• Integrated a smart BMS with real-time current and temperature monitoring
• Created a proprietary fast-charge profile compatible with the client’s existing chargers

Implementation Process:

Worked closely with the client’s R&D team for mechanical fitting and electrical integration

Conducted torque and runtime testing across different tool types under simulated job site conditions

Performed environmental tests including vibration, dust ingress, and thermal cycling (-20°C to 60°C)

Provided training for service centers on battery maintenance and diagnostics

Performance Data:

• Runtime increased by 38%, from 45 minutes to 62 minutes of continuous drilling under load
• Battery weight reduced by 21%, from 650g to 513g
• Charging time decreased by 42%, achieving 80% charge in 35 minutes
• Maintained full torque delivery even at 20% remaining capacity
• Safety and Reliability:
• Exceeded UN38.3 and IEC 62133 safety standards
• Achieved IP54 rating for dust and splash protection
• Implemented safeguards against over-discharge, overcurrent, overheating, and thermal runaway

Conclusion

This case study demonstrates PKCELL’s ability to deliver high-performance, reliable, and durable battery solutions tailored for the power tool industry. By exceeding the client’s runtime, weight, and charging goals, PKCELL has helped them enhance user experience, productivity, and competitiveness in global markets.