HaxonWorks Battery Module

The Challenge

Many students, like myself, Power users, and colleagues in the industry have voiced their difficulties in using battery banks with a limited capacity, ability to supply high amounts of current, portability and ease of use. So I challenged myself to create a base product that solves all of those problems. Develop a solution that solves all the common difficulties whilst also incorporating several innovative features: • Choose an appropriate battery technology • Determine a voltage for the pack • Source and implement an appropriate Battery Management System (BMS) • Develop a touch screen User Interface (UI) • Engineer a modular friction-fit battery-module interface • Design all parts of the system to operate within a -20 ~ 55°C range.

Solution

• Battery Technology: Lithium Ion 18650 Batteries for their energy dense property • Battery Voltage: 24 volt battery pack for optimal performance • BMS Spec: 6S3P battery pack configuration with advanced management • User Interface: ESP32-based touchscreen with smartphone connectivity • Battery Interconnect: Low profile solution with minimal moving parts • Temperature Range: Tested for wide environmental conditions • Added 100W 2-way USB-C port for versatile charging

Outcome

The battery pack delivered significant improvements during testing. Though still in early development stages, future improvements will include: • Aluminum enclosure for better durability and thermal management • More compact internal layout • Development of additional compatible modules The project sets a foundation for a versatile power solution system.

Technologies Used

• Arduino IDE used to program the ESP32 for display inputs/outputs/app connectivity
• SolidWorks for mechanical design, 3D modeling, and assembly
• Swift used to code and design the IOS app
• Microsoft Visual Studio for integration of code
• 3D printing for rapid prototyping
• Integrated safety systems

Project Gallery