A robotics startup needed an IP68, 86V high-C-rate battery. See how Surlon Power's custom lithium battery service delivered prototypes in just 21 days.
Case Details
The Client: DeepScan Robotics (California, USA)
- Profile: Startup developing a small remotely operated underwater vehicle (ROV) for pipeline inspection.
- Requirement: 86V nominal, 40Ah capacity, 200A continuous discharge, fully IP68 submersible (to 3m depth).
- Constraint: Maximum dimensions of 280mm × 180mm × 90mm – requiring an unconventional, flat “pizza box” shape.
The Challenge: Nothing on the Market Worked
DeepScan spent four months searching for an existing battery solution without success. The engineering roadblocks were significant:
- Standard 72V packs were too low, and 96V packs would damage their motor controller.
- While IP67 batteries are common, finding an IP68 (continuously submersible) pack was nearly impossible.
- The high 200A discharge requirement necessitated thick nickel strips and heavy-gauge wiring, far exceeding the 100A maximum of most off-the-shelf options.
- The physical dimensions were unyielding; the flat shape was unavailable in standard rectangular brick formats.
“We were ready to give up and design our own BMS – which would have taken 6 months. Then we found Surlon Power's custom lithium battery service.” — Sarah K., Lead Engineer
The Surlon Power Solution: Full-Stack Custom Engineering
Our engineering team designed and built a custom 86V 40Ah lithium battery pack entirely from scratch to meet the exact specifications.
Technical Specifications
- Cell Configuration: 24S2P utilizing high-discharge 21700 cells (Samsung 40T).
- Output Details: 24 series = 86.4V nominal; 2 parallel = 40Ah capacity; Max continuous discharge = 220A.
- Smart BMS: Custom 24S 250A system integrated with CAN bus communication to interface directly with the ROV’s flight controller.
- Enclosure & Hardware: 3D-printed glass-filled nylon, IP68 rated with fully gasketed seals. Fitted with a customer-specified SubConn® circular underwater connector.
- Compliance: Passed UN38.3 certification, critical for air freight to global testing sites.
The Custom Process Timeline: Delivery in 21 Days
Speed to market is crucial for startups. Here is how Surlon Power delivered:
- Day 1: Initial spec discussion (video call + CAD file sharing).
- Day 3: Engineering drawing and cell selection proposal delivered.
- Day 14: Prototype build completed (2 units for internal testing).
- Day 18: Customer testing phase (discharge curve, thermal analysis, vibration).
- Day 19: Final tweak (connector orientation adjustment based on feedback).
- Day 21: Final production of 10 units shipped.
The Results: ROV Passes Pressure Tests
Upon installing the Surlon custom battery pack in the ROV prototype, DeepScan achieved the following results:
- Extended Runtime: Achieved 75 minutes at full thrust (against a 60 min target) – exceeding spec by 25%.
- Thermal Management: Battery temperature remained under 55°C inside the sealed enclosure after a 1-hour dive simulation.
- Data Integration: CAN bus data successfully relayed real-time state of charge and cell voltages to the pilot’s tablet.
- Global Logistics: The UN38.3 report enabled air shipping to a crucial client demo in Norway.
Outcome: Armed with a reliable power source, DeepScan Robotics secured a $2M pilot contract with an offshore energy company.
What the Lead Engineer Says
“I didn’t think anyone could build a custom lithium battery pack that fast, especially with IP68 and CAN bus. Your team sent me daily photos of the assembly. No guesswork, no delays. We’ll use Surlon Power for all future ROV batteries.”
— Sarah K., Lead Engineer, DeepScan Robotics
Key Takeaway for Hardware Developers
Off-the-shelf batteries only work for standard applications. For specialized needs – unconventional voltages, unique shapes, extreme environments – a custom lithium battery pack is often faster and more cost-effective than redesigning your entire device. We handle the battery engineering so you can focus on building your core product.
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