Solution for Electric Snow Blowers in Canada

Project Background

The development of electric snow blowers began in the late 20th century as a response to the growing demand for environmentally-friendly and quiet snow removal solutions. Over the years, electric snow blowers have gained popularity, especially in residential areas and urban environments where noise and exhaust pollution from gas-powered models are a concern. By the early 2000s, the electric snow blower market saw significant improvements, with more powerful motors and longer-lasting batteries enabling efficient snow clearing in smaller to medium-sized areas.

Simultaneously, the evolution of lithium-ion battery technology in the 1990s provided a breakthrough for electric vehicles and power tools, including snow blowers. With their superior energy density, longer life cycle, and quicker charging times compared to previous battery types like lead-acid, lithium-ion batteries became the go-to choice for modern electric snow blowers.

In Canada, a company that manufactures electric snow blowers faced significant challenges when their battery systems failed to perform adequately in the region’s extremely cold winters, particularly when temperatures dipped to -20°C or lower. Their existing batteries could not function effectively in these freezing conditions, resulting in reduced runtime, premature failure, and ultimately customer complaints. With the demand for reliable snow-clearing equipment during long Canadian winters, the company needed a robust solution to ensure their machines could operate efficiently in extreme cold weather conditions.

Key Challenges

• Extreme Cold Temperatures: The batteries were unable to maintain proper performance in temperatures as low as -20°C, leading to reduced power and short operation times.
• Charging Difficulties: Charging the battery at sub-zero temperatures was problematic, with batteries failing to charge properly or experiencing significant performance degradation.
• Space Constraints: The backup power unit had to fit within the compact housing of the snow blower without altering the overall design, weight, or balance.
• Durability and Safety  :The battery system needed to withstand the impact and vibration that is typical of snow blower operations, as well as exposure to moisture and snow.

Our Solution

Cell Selection

We recommended a wide-temperature lithium-ion battery capable of operating reliably at -20°C, maintaining 70% of its rated capacity under such conditions. This was crucial for the performance of the snow blowers during long periods of exposure to cold. The chosen cells had:

• High energy densityfor long-lasting operation.
• Long cycle life, ensuring durability through multiple winters.
• Excellent low-temperature performance, delivering reliable power even in sub-zero temperatures.

BMS Design

• Temperature Protection:The Battery Management System (BMS)was specifically designed to manage the battery’s operation in both high and low temperatures, ensuring optimal performance during charging and discharging in extreme cold.
  • Safety Features: The BMS incorporated protection against overcharge, overdischarge, short-circuits, and overcurrent to safeguard the battery during harsh winter conditions.
  • Charging Algorithm: A smart charging protocol was included to allow efficient charging even in low temperatures, avoiding battery damage and ensuring the snow blower could operate as needed.

Structural & Thermal Design

• The battery housingwas custom-designed to ensure impact resistanceand effective heat dissipation in harsh winter environments. This housing also protected the battery from snow, moisture, and physical damage.
  • Vibration Resistance: Given that snow blowers are subject to constant vibrations during use, we made sure the housing was robust and able to withstand typical operational stresses.
  • Space Optimization: To meet the compact requirements of the snow blower design, the battery was carefully sized to fit seamlessly without compromising the snow blower’s balance or performance.

Production & Testing

• The battery underwent extensive cold-weather testing, including simulations at temperatures as low as -20°Cto ensure it met performance standards in extreme cold.
  • The batteries were also subjected to vibration and impact teststo simulate real-world conditions.
  • Aging tests were conducted for 48 hours to ensure that the battery maintained long-term reliability and performance.

Results & Value

• Improved Performance in Extreme Cold: The battery maintained 70% capacity at -20°C, ensuring reliable operation of the snow blowers even during the coldest winter months.
• Customer Satisfaction Restored: Customer complaints about battery failures dropped significantly, and customer satisfaction increased due to the snow blowers’ enhanced reliability and consistent performance.
• Optimized Space Utilization: The compact design allowed for easy integration into the snow blower, without affecting the machine’s balance or overall design.
• Enhanced Durability: The battery successfully passed high-temperature and impact resistance tests, meeting industrial-grade standards necessary for outdoor equipment.

 

Next Steps

The solution has now entered mass production, and the customer is rolling it out across their entire electric snow blower range. Additionally, they are planning to incorporate this lithium-ion battery solution into other cold-weather equipment. The customer is also exploring a partnership to co-develop high-power battery systems for future industrial machinery designed for cold environments, further expanding the scope of this technology.

This case underscores the importance of adapting technology to the specific environmental challenges faced by products like electric snow blowers in cold climates. By providing a tailored lithium-ion battery solution, we were able to help our client deliver reliable, high-performance snow blowers that can operate even in Canada’s harsh winter conditions.