Heavy equipment lithium battery system engineered for an off-highway machine
Application-Engineered Power

Heavy Equipment Lithium Battery Systems

Purpose-built LFP battery systems for demanding off-highway machines—engineered around voltage, power, duty cycle, packaging, controls, and environmental requirements.

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  • 48V–700VSystem range
  • High-Power OutputFor traction and hydraulics
  • CAN / RS485 BMSMachine-level communication
  • IP65 / IP67 OptionsFor harsh-duty integration
System Fit

Built for machines that do real work

A strong battery specification begins with how the machine actually operates—not a catalog voltage and capacity alone.

01

Traction + Hydraulics

Coordinate propulsion, pumps, auxiliaries, and peak loads within one power architecture.

02

High Utilization

Support multi-shift duty, opportunity charging, and predictable service windows.

03

Severe Environments

Engineer for dust, water, vibration, temperature, shock, and industrial handling.

04

Machine Integration

Align enclosure, mounting, connectors, controls, and thermal interfaces.

Applications

One engineering approach, six demanding machine categories

Platform thinking creates consistency while application-specific engineering protects performance.

Battery-electric mining machine operating at an industrial site

Mining Equipment

Load-haul-dump machines and underground utility equipment.

High torque · constrained ventilation

Electric construction loader working on a rugged jobsite

Construction Equipment

Loaders, excavators, compactors, and material handlers.

Peak power · rugged packaging

Electric agricultural tractor working in a field

Agricultural Machinery

Tractors, sprayers, harvest-support, and autonomous field platforms.

Long shifts · seasonal uptime

04

Port & Terminal Equipment

Yard tractors, terminal tractors, and container-handling auxiliaries.

Opportunity charging · fleet duty

05

Municipal & Utility Vehicles

Sweepers, service units, refuse-support, and specialized utility machines.

Auxiliary loads · urban cycles

06

Special-Purpose Equipment

Custom industrial platforms with unusual packaging or power profiles.

Custom geometry · system controls

Engineers reviewing machine load data for battery system sizing
Right-Sized Engineering

Sized from the machine backward

A reliable solution begins with measured operating demands. Bonnen engineers translate six core inputs into a battery and controls architecture.

Nominal and operating voltage
Continuous and peak power
Duty cycle and shift profile
Charge strategy and downtime
Available envelope and mass limits
Ambient and cooling conditions
Share Your Machine Requirements
Engineering Challenges

The hard parts are connected

Energy capacity is only one variable. The system must manage electrical, thermal, mechanical, and control constraints together.

01

Peak Power Delivery

Handle traction launch, hydraulic surges, and simultaneous loads without destabilizing voltage.

02

Thermal Balance

Maintain cell consistency during high-rate discharge, fast charging, and uneven ambient exposure.

03

Mechanical Protection

Design the enclosure and mounting system for vibration, shock, dust, water, and service handling.

04

Controls Integration

Coordinate BMS, vehicle control unit, charger, inverter, contactors, and operator diagnostics.

05

Charging Workflow

Match connector, charger power, charge curve, operating window, and fleet availability targets.

06

Lifecycle Serviceability

Plan access, isolation, diagnostics, replaceable assemblies, and documentation for field support.

Cutaway visualization of a liquid-cooled heavy equipment battery enclosure
System Architecture

Designed as a complete machine subsystem

Component selection and packaging are developed as one coordinated safety and performance system.

LFP cell modulesModule framesBattery management systemCurrent sensorsMain contactorsPre-charge circuitService disconnectHigh-voltage junctionFuses and protectionLiquid cooling platesThermal sensorsLow-voltage harnessPressure equalizationStructural enclosure

Representative architecture only. Final component layout, redundancy, protection strategy, and interfaces are determined by the machine requirements.

Reference Platform

A modular path from 72kWh to 432.7kWh

A common high-voltage module concept can be arranged around power, range, packaging, and redundancy goals.

Modular high-voltage battery platform shown in scalable configurations
Configuration
Voltage
Capacity
Energy
Single pack
313.6V
230Ah
72kWh
Four packs
627.2V
460Ah
288.5kWh
Six packs
627.2V
690Ah
432.7kWh
  • 150A recommended continuous discharge
  • 230A maximum continuous discharge
  • 600A peak discharge for 3 seconds
  • CAN communication and liquid cooling
  • IP67 enclosure target
  • More than 4,000 cycles under defined conditions
  • Charge temperature: 0–45°C
  • Discharge temperature: -20–60°C

Engineering reference: This is a reference configuration used to illustrate scalability. It is not a standard stock product. Ratings and life depend on final cell selection, system limits, operating profile, and validation.

Engineering Examples

Different machines require different answers

These examples show how packaging and system architecture can change with machine type.

Compact orange battery enclosure concept for mining equipment

Compact Mining Pack

Low-profile packaging for confined machine spaces with ruggedized service access.

Irregular battery pack concept integrated around a wheel loader chassis

Wheel Loader Integration

Machine-shaped enclosure strategy designed around structure, articulation, and counterweight needs.

High-voltage orange battery pack concept for large industrial equipment

High-Voltage Platform

Scalable pack arrangement for higher-power drivetrains and larger usable-energy targets.

Configurations shown are engineering references for discussion, not certified production specifications or evidence of deployment in a named customer machine. Final performance, dimensions, interfaces, compliance, and warranty terms require project-specific engineering and validation.

Heavy equipment working in a dusty harsh-duty industrial environment
Harsh-Duty Readiness

Protection begins before the machine reaches the field

Environmental resilience comes from enclosure engineering, component selection, interface design, and validation as a system.

Dust and water ingress strategy
Vibration and mechanical shock
Hot and cold operating windows
Corrosion-resistant materials
Pressure equalization
High-voltage interlock
Isolation monitoring
Service-safe disconnects
Cell Chemistry

Why LFP for heavy equipment?

Thermal stability
Long cycle-life potential
High power capability
Cobalt-free chemistry
Why Bonnen Battery

From requirement definition to production support

A practical partner for OEM teams that need battery engineering, integration coordination, and scalable manufacturing under one roof.

Application Engineering

Requirements translated into electrical, thermal, and mechanical targets.

Custom Pack Design

Voltage, capacity, enclosure, connectors, and mounting adapted to the machine.

BMS Integration

CAN / RS485 communication, control logic, diagnostics, and protection coordination.

Thermal Engineering

Passive, air, or liquid-cooling concepts selected for the duty profile.

Prototype Validation

Engineering samples and agreed verification plans before production release.

Manufacturing Support

Design-for-manufacture review, controlled assembly, and traceability planning.

Compliance Planning

Project-specific support for transport, safety, and market requirements.

Charger Coordination

Battery, charging hardware, connectors, and operating strategy aligned.

Lifecycle Collaboration

Technical documentation, change control, and service considerations.

Project Roadmap

A disciplined path to the right system

Six connected steps keep performance, packaging, controls, and validation aligned.

Requirements

Machine data, use case, constraints, targets.

Concept

Architecture, chemistry, voltage, and capacity.

Integration

Envelope, cooling, interfaces, and controls.

Prototype

Engineering sample and system bring-up.

Validation

Agreed electrical, thermal, and mechanical checks.

Production

Release, quality controls, and lifecycle support.

FAQs About Heavy Equipment Lithium Battery Systems

Answers to common questions about custom battery design, system integration, harsh-environment operation and project development.

Yes. We develop custom lithium battery systems for construction equipment, mining machinery, agricultural vehicles, industrial vehicles, material handling equipment and other off-highway applications. The battery voltage, capacity, enclosure, BMS, cooling system and communication interface can be designed around your machine and operating requirements.

You can start with any information you already have, such as system voltage, motor power, required operating time, available installation space, charging method, operating temperature, communication requirements and expected quantity. Complete specifications are not required at the beginning. Our engineering team can help identify the remaining parameters during technical evaluation.

We can develop battery systems across a wide voltage and energy range, from low-voltage auxiliary or compact equipment batteries to high-voltage battery packs for large electric machinery. The final voltage, capacity and power capability are selected according to the motor, controller, operating duty cycle and available installation space.

Yes. Custom mechanical integration is one of the key parts of our development process. If you provide the maximum installation dimensions, CAD drawings, STEP files or photos of the battery compartment, our engineers can evaluate cell arrangement, enclosure structure, connector position and service access to develop a battery that fits the available space.

Yes. Communication can be customized according to the equipment architecture. Depending on the project, the battery can support interfaces such as CAN, CANopen, J1939 or RS485. We can also work with your controller, charger, VCU or other system suppliers to confirm the required communication protocol and control logic.

The thermal management system is selected according to battery power, operating environment, duty cycle and installation conditions. Depending on the application, the design may use passive cooling, forced-air cooling, liquid cooling or battery heating to maintain suitable cell temperatures and support reliable operation under demanding workloads.

Yes. Heavy-equipment battery systems can be designed for harsh operating environments using sealed enclosures, reinforced mechanical structures, suitable IP protection, vibration-resistant mounting and appropriate thermal management. The final protection level and environmental requirements are confirmed according to the actual machine and working conditions.

Yes. Custom projects can begin with engineering evaluation and prototype development before moving into production. We normally review the system requirements, develop the battery design, confirm mechanical and electrical integration, build and test the prototype, and then optimize the design for repeat production if required.

Depending on the project and destination market, we can provide documents and testing support such as UN38.3 and MSDS, together with battery electrical, safety and environmental testing. Additional certification or validation requirements can be reviewed during the project according to the equipment type, shipping method and applicable market requirements.

The development schedule depends on battery complexity, enclosure design, communication requirements, thermal management and certification needs. Projects with complete technical information can normally move faster. Providing installation drawings, system voltage, power requirements, expected quantity and target schedule at the beginning helps us evaluate the project more efficiently.

Start With the Machine

Bring us your voltage, power, duty cycle, and packaging constraints

Our engineering team can help turn those inputs into a practical heavy equipment battery-system concept.

Discuss Your Project
Discuss Your Battery Project