cosomicexpert of battery packs
cosomicexpert of battery packs
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E-Mobility Battery System Engineering — Custom E-Mobility Battery Pack OEM ODM | COSOMIC TECHNOLOGY COMPANY LIMITED Foshan China
E-Mobility

E-Mobility Battery
Systems

From 36V commuter e-bike packs to 72V high-performance scooter and golf cart batteries — engineered for range, safety, and regulatory compliance across European, North American, and Asian markets.

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Application Overview

Why E-Mobility Battery Design Is Different

E-mobility batteries operate in the most demanding consumer-facing environment: rain, vibration, temperature swings, and daily deep cycling. A great e-bike battery is not just a collection of cells — it is a thermal management system, a structural component of the frame, a compliance document (EN15194 / UL2271), and a user interface (fuel gauge, Bluetooth, charge port). We engineer every layer.

Key Engineering Challenges

1

Riders expect 50–100km range with 3–5kg battery weight — energy density and thermal management must be optimized together.

2

E-mobility batteries face daily vibration, road splash, and temperature cycling from -10°C winter commutes to +40°C summer delivery shifts.

3

Regulatory compliance varies by market: EN15194 (EU), UL2271 (US), GB/T (China) — each requiring different test protocols and documentation.

4

Fleet operators need remote monitoring (Bluetooth/GPS), anti-theft locking, and predictive maintenance data from every pack.

5

Shared-mobility fleets require fast-swap or integrated-charging architectures with minimum downtime.

Engineering Requirements

What Every E-Mobility Battery Must Deliver

Range Optimization

Cell selection, BMS efficiency, and discharge profile tuned to your motor controller and rider use case.

IP65 / IP67 Sealing

Full weatherproofing including charge port, connector, and housing seams — tested to IEC 60529.

Frame Integration

Down tube, rear rack, frame bag, or custom cavity — designed to your CAD geometry with FEA-validated mounts.

Smart BMS + App

Optional Bluetooth 5.0 BMS with mobile app for SOC, cycle count, fault history, and geofencing.

Typical Specifications

Engineered to Your Exact Requirements

These are the typical parameter ranges for e-mobility battery systems. Every project is custom-engineered to your specific application requirements.

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Typical Voltage36V / 48V / 52V / 60V / 72V
Capacity Range10Ah – 60Ah (360Wh – 4.3kWh)
Cell OptionsSamsung 35E/50E, LG M50LT, Panasonic NCR, CATL
Cell Format18650 / 21700 / prismatic (custom)
Continuous Discharge20A – 150A (motor matched)
Peak DischargeUp to 300A (≤ 5 sec)
IP RatingIP55 standard / IP65 / IP67 available
CommunicationUART / CAN / Bluetooth 5.0 (optional)
Charge Time3–6 hours (standard) / 1.5–2 hours (fast charge)
Cycle Life500–2,000+ cycles (chemistry dependent)
Operating Temp-20°C to +55°C (with BMS cutoff)
CertificationsCE, EN15194, UL2271, UN38.3, RoHS
Regulatory Compliance

Certifications for E-Mobility

EN15194

EU e-bike battery safety standard covering electrical, thermal, and mechanical abuse testing.

UL2271

US and Canadian e-mobility battery safety standard for light electric vehicles.

UN38.3

UN transport safety certification required for air and sea freight of lithium batteries.

CE / RoHS

European market access and hazardous substance restriction compliance.

IP65 / IP67

Ingress protection for dust and water — validated by third-party test labs.

Real Projects

E-Mobility Case Studies

🇩🇪 GermanyGerman E-Bike Fleet Operator

48V 17.5Ah Samsung 21700 Hailong Pack for Shared City E-Bike Fleet

40% order expansion Y2

Challenge

A German shared-mobility operator needed 12,000 battery packs for a city e-bike fleet upgrade. Requirements included 80km+ range, IP65 all-weather protection, EN15194 compliance, and Bluetooth BMS for fleet SOC monitoring via mobile app.

Our Solution

We designed a 48V 17.5Ah Hailong-style pack using Samsung 50E 21700 cells (Grade-A), 3A fast-charge support, IP65 sealed aluminum housing, and a Bluetooth 5.0 BMS transmitting real-time SOC, SOH, and fault data to the fleet management platform.

Voltage

48V (13S Li-ion)

Capacity

17.5Ah (840Wh)

Cells

Samsung 50E 21700

Charge Rate

3A (0.17C) fast charge

IP Rating

IP65

Communication

Bluetooth 5.0 + UART

CEEN15194UN38.3RoHSZero field failures in 18 months of operation across 12,000 units. Client expanded order by 40% in Year 2 and introduced a premium tier using the same platform.
Recommended Products

Battery Systems for E-Mobility

E-Bike Battery PackHailong E-Bike PackRear Rack E-Bike PackEV Scooter PackEV Golf Cart PackSodium-ion E-Bike Pack
Technical Deep Dives

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FAQ

Common Questions about E-Mobility Battery Systems

Can you design a custom e-bike battery to fit my specific frame?
Yes. We design batteries for down tube, rear rack, frame bag, and integrated frame mounting. Send us your frame CAD or cavity dimensions and we will engineer a pack that fits perfectly while maximizing capacity within your available space.
What certifications do I need to sell e-bikes in the EU and US?
For the EU, EN15194 certification is mandatory for e-bikes with pedal assistance up to 25km/h. For the US, UL2271 is required by most retailers and insurers. We design our packs to meet both standards and can coordinate third-party testing on your behalf.
Can you add Bluetooth monitoring to the battery?
Yes. We offer an optional Bluetooth 5.0 BMS that connects to a mobile app (iOS/Android) for real-time SOC, SOH, cell voltages, temperature, and fault alerts. This is especially popular for fleet operators and premium consumer brands.
What is the typical lead time for e-bike battery prototypes?
Sample lead time is 7–14 days for standard Hailong or rear rack configurations. Custom frame-integrated designs require 15–25 days for the first prototype. Mass production lead time is 20–35 days depending on order size.
Do you support white-label and OEM branding?
Yes. We supply white-label e-mobility batteries to manufacturers worldwide. Services include custom housing color, brand logo printing, retail packaging design, and full certification support. MOQ for OEM orders starts at 500 pieces.

Ready to Design Your E-Mobility Battery System?

Share your requirements and our engineering team will respond within 24 hours with a custom solution.

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cosomicexpert of battery packs

COSOMIC TECHNOLOGY COMPANY LIMITED is a battery system engineering company specializing in custom OEM and ODM power solutions for industrial, medical, mobility, and energy storage applications.

Building 8, New Energy Industrial Park, Foshan, China
+86 158 8990 0503

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