The challenge: Traditional battery testing uses favorable lab conditions that don't reflect real-world usage. We decided to change that by testing our batteries exactly how they're used in the field.
Need for a Real-World Approach
The traditional way of providing battery warranty lies in defining a factor of safety around the lifecycle numbers provided by the Li-ion cell manufacturer. But why? No point in guessing that it saves tons of cost and manpower.
This results in inflated cycle life numbers due to favorable temperatures — a far cry from reality.
We at TEC embarked on a quest to redefine the standards of product testing by simulating actual usage conditions rather than idealized lab scenarios.
Custom Durability Cycle
Initially, we engaged with real users, specifically those involved in last-mile logistics, such as the diligent individuals delivering your favorite Zomato or Swiggy orders, or handling packages from e-commerce giants like Flipkart & Amazon.
Through customer interviews, we formulated an ideal usage cycle that realistically aligns with their daily routines. The usage cycle covers different times of day, multiple charging sessions, and a much more aggressive use case compared to a retail consumer.
Creating a realistic usage cycle based on customer interviews
Real-world test cycle simulation
Custom Durability Setup
Next, our Engineering Team stepped in, opting to innovate with a custom durability setup, eschewing expensive Pack Cyclers for a more cost-effective and practical solution.
Our Custom Setup Includes:
- Readily available 3kW charger — Standard commercial charging equipment
- Proprietary in-house battery — Built with our advanced cooling stack
- Integrated telematics — Real-time monitoring and data collection
- Variable loads — Simulating actual delivery route conditions
Results
The results validated our approach and exceeded our expectations. Our batteries demonstrated superior performance under real-world stress conditions compared to traditional lab-tested alternatives.
Cycle life comparison: Real-world testing vs. traditional lab conditions
Performance Comparison
cycles (lab conditions)
cycles (field validated)
Comprehensive test results showing durability across various conditions
Conclusion
Ultimately, our approach not only met but exceeded our durability and reliability objectives, affirming the robustness of our product under even the most challenging conditions.
By challenging the status quo and embracing the intricacies of real-world usage, we strive to set a new benchmark in product testing, paving the way for more reliable and consumer-centric innovations.
