A portable industrial lighting manufacturer was developing a compact rechargeable lighting product for field service, maintenance, inspection, and equipment monitoring applications.
The product needed to provide dependable power in a small enclosure while remaining lightweight and easy to install. Because the lighting equipment would be used in different working environments, the battery also needed to support stable operation, safe charging, and flexible connector configuration.
The manufacturer contacted Surlon Power to develop a custom NCM lithium battery pack for the new product platform.
The customer faced several common challenges associated with compact industrial equipment:
Limited internal installation space
Strict weight requirements
Need for reliable rechargeable power
Compatibility with an existing charging system
Customized connector and cable requirements
Protection against overcharge and over-discharge
Stable supply for future OEM production
A standard battery could provide basic power, but it could not fully match the product’s mechanical dimensions, wiring layout, and electrical requirements. The customer therefore needed a battery pack designed around the equipment rather than a general-purpose replacement battery.
Surlon Power developed a compact NCM lithium battery pack based on an 18NC-2S2P configuration.
The selected battery solution featured:
Nominal voltage: 7.2V
Rated capacity: 5.2Ah
Rated energy: approximately 37.44Wh
Package: PVC
Dimensions: approximately 37.3 × 37.3 × 69 mm
Weight: approximately 191 ± 20 g
Standard charging current: 1A
Maximum charging current: 2A
Standard discharge current: 1A
Maximum continuous discharge current: up to 2A under the specified dual-wire configuration
The compact structure allowed the battery to fit into equipment with limited internal space while providing sufficient energy for portable lighting and related industrial applications. View the 7.2V 5.2Ah Custom NCM Battery Pack
For portable equipment, battery integration involves more than selecting voltage and capacity. The battery housing, connector, cable length, wire definition, and installation position must all be coordinated with the final device.
Surlon Power supported the customer with customized pack integration, including:
PVC packaging
Connector selection
Cable length configuration
Positive and negative wire layout
Voltage sensing connection
Protection circuit requirements
Mechanical installation compatibility
This approach helped the manufacturer simplify the internal design of the lighting product and prepare the battery system for repeatable OEM production.
The battery pack was designed with protection requirements for overcharge, over-discharge, and abnormal temperature conditions.
These protection functions help reduce the risk of battery damage during charging and operation. For portable industrial lighting, where equipment may be used by different operators and charged in different locations, integrated protection is an important part of the overall product design.
Surlon Power also provides BMS and battery protection solutions for custom lithium battery projects, allowing the protection system to be matched with the equipment’s charging and operating requirements. Explore Surlon Power BMS solutions
The custom NCM battery pack can support a variety of compact equipment applications, including:
Portable industrial lighting
Inspection lamps
Security and monitoring devices
Industrial control equipment
Portable instruments
Communication equipment
Medical and electronic devices
Small backup power systems
Customized OEM and ODM products
The product is especially suitable for equipment that requires a small rechargeable battery with defined voltage, capacity, dimensions, and connector specifications.
The customized battery design helped the customer address the main requirements of the portable lighting project:
Compact integration within a limited enclosure
Reduced battery weight
Defined electrical output
Flexible connector and cable configuration
Integrated protection functions
Easier product assembly
Better suitability for OEM production
Because the battery was developed according to the equipment’s actual requirements, the customer gained greater design flexibility compared with using a standard off-the-shelf battery.
Surlon Power provides customized lithium battery solutions from cell selection through complete pack assembly. Its product and service information highlights support for voltage and capacity design, cell matching, BMS integration, housing development, thermal management, and OEM and ODM production.
The company supplies cylindrical, prismatic, and pouch battery cells for different power requirements and application environments. Its custom battery services are intended to help equipment manufacturers develop more consistent and application-specific energy solutions. Learn more about Surlon Power custom lithium battery services
This case demonstrates how a custom NCM battery pack can improve the design flexibility of portable industrial lighting equipment.
By combining a compact 7.2V 5.2Ah configuration, lightweight PVC packaging, customized wiring, and integrated protection requirements, Surlon Power provided a battery solution aligned with the customer’s space, weight, and performance needs.
For manufacturers developing portable lighting, monitoring devices, industrial equipment, or other compact electronic products, Surlon Power offers customized NCM lithium battery packs and OEM battery assembly services.
Visit SurlonPower.com to discuss your next custom battery project.
