How We Build a Battery Pack for Cleaning Equipment: From RFQ to Delivery

How We Build a Battery Pack for Cleaning Equipment: From RFQ to Delivery

A battery pack for cleaning equipment looks simple from the outside. In many machines, it is just a box installed under the seat, inside the battery tray, or behind a service panel. But for an OEM floor scrubber, sweeper, vacuum platform, or compact cleaning robot, the battery pack is not a commodity part. It directly affects runtime, motor performance, charging behavior, operator safety, serviceability, and logistics.

This is why we do not treat a cleaning equipment battery inquiry as a simple voltage-and-capacity quotation. A request such as “24V lithium battery pack for floor scrubber” or “36V battery replacement for cleaning machine” is only the starting point. Before we design the pack, we need to understand how the equipment actually works.

Commercial cleaning machines have traditionally used flooded lead-acid, AGM, GEL, and increasingly lithium-ion batteries. For many floor scrubbers, sweepers, and industrial cleaning platforms, lithium batteries are selected because they can reduce maintenance, support repeated daily use, and provide more stable performance when the pack is designed correctly.

This article explains how we normally move from an initial RFQ to a finished custom battery pack for cleaning equipment.

1. The RFQ: What We Usually Receive First

Most cleaning equipment battery inquiries start with a short message:

“We need a lithium battery pack for a floor scrubber.”

“Can you make a 24V/36V/48V battery pack?”

“We want to replace lead-acid with lithium.”

“We need a custom battery for our new cleaning machine.”

Sometimes the customer provides a drawing, a photo of the original battery compartment, or a nameplate from the old battery. Sometimes they only provide voltage and capacity. That is not enough for engineering.

At the RFQ stage, we first separate the known information from the missing information.

The basic information usually includes:

  • Nominal voltage

  • Required capacity or target runtime

  • Battery chemistry preference, usually LiFePO4 or lithium-ion NMC

  • Available battery compartment size

  • Connector type

  • Charger information

  • Application type: walk-behind scrubber, ride-on scrubber, sweeper, robotic cleaner, vacuum system, or combined cleaning platform

  • Target market and shipping destination

However, voltage and capacity only tell us part of the story. They describe the energy direction, but not whether the pack can safely support the real load. A cleaning machine may include a brush motor, vacuum motor, traction motor, pump, actuator, display, controller, and sometimes communication electronics. These loads do not behave the same way. Some pull steady current. Some create startup peaks. Some create short current pulses when the brush head hits resistance or when the traction system starts on an incline.

That is why the first engineering task is not quotation. It is clarification.

2. The Engineering Questions We Ask Before Design

Before we select cells or draw the pack structure, we ask a series of practical questions. These questions are not formalities. They determine the cell type, BMS rating, wire size, connector selection, thermal margin, enclosure design, and test plan.

2.1 Electrical Load

We need to understand:

  • What is the continuous discharge current?

  • What is the peak discharge current?

  • How long does the peak last?

  • Is the peak caused by traction, brush motor startup, vacuum motor startup, or another load?

  • Does the machine have regenerative braking or reverse current behavior?

  • What is the low-voltage cutoff requirement of the controller?

  • Does the system need CAN, UART, RS485, SMBus, Bluetooth, or a simple LED/SOC indicator?

This is where many battery projects fail if the design is based only on Ah. A pack with enough capacity may still fail if the BMS trips during motor startup. A pack with a high-current BMS may still overheat if the cell selection and internal layout are not suitable. Elevated temperature and high current both affect lithium battery life, so load profile is one of the most important inputs for cycle-life design.

2.2 Runtime and Duty Cycle

“Long runtime” is not an engineering specification. We need to know:

  • Expected runtime per charge

  • Number of cleaning shifts per day

  • Whether the machine is fully charged overnight or opportunity-charged during breaks

  • Typical depth of discharge

  • Charging time target

  • Expected service life

  • Whether the machine is used daily, weekly, or seasonally

For example, a rental fleet, a warehouse cleaning machine, and a small retail store scrubber may all use similar voltage platforms, but their battery stress profiles can be completely different.

2.3 Mechanical Envelope

For cleaning equipment, mechanical fit is critical.

We ask for:

  • Battery tray dimensions

  • Height limit under cover or seat

  • Mounting method

  • Cable exit direction

  • Connector position

  • Weight limit

  • Ventilation condition

  • Service access requirements

  • Vibration and impact environment

  • Water, detergent, dust, and splash exposure

A cleaning machine is not a clean laboratory environment. It works around water, detergent, floor debris, vibration, and operator handling. The battery pack must be designed for that reality.

2.4 Charger and System Compatibility

A lead-acid charger should not automatically be assumed compatible with a lithium battery pack. Lithium batteries require the correct charging voltage, current limit, termination logic, and protection coordination. For LiFePO4 systems, charging behavior is different from lead-acid systems, and prolonged or incorrect charging can reduce battery life.

We normally confirm:

  • Existing charger output voltage

  • Maximum charge current

  • Charging algorithm

  • Connector pinout

  • Whether charger replacement is acceptable

  • Whether the machine controller reads battery voltage only or communicates with the BMS

  • Whether the customer needs a charger supplied together with the pack

2.5 Compliance and Logistics

Battery compliance is not something to check at the end. It must be considered from the beginning.

For lithium battery transportation, lithium-ion batteries are commonly classified as Class 9 dangerous goods under UN3480 when shipped alone, and UN3481 when packed with or contained in equipment. Lithium cells and batteries also need to meet applicable UN38.3 transportation testing requirements before they can be shipped through many international logistics routes.

Depending on the project, we may need to prepare or coordinate:

  • UN38.3 test summary

  • MSDS/SDS

  • Battery specification sheet

  • Dangerous goods packaging

  • Transport labels

  • Carton/pallet packing details

  • CE/UKCA/RoHS-related documentation where applicable

  • IEC/UL-related testing requirements if required by product scope or customer market

For export shipments, the logistics route matters. Air, sea, express, DAP, and DDP solutions can lead to different packaging and documentation requirements.

3. Chemistry Selection: Why LiFePO4 Is Often Considered

For cleaning equipment, LiFePO4 is often considered because the application values safety, stable discharge, cycle life, and low maintenance more than maximum energy density.

This does not mean LiFePO4 is always the only answer. The right chemistry depends on:

  • Available space

  • Weight target

  • Discharge current

  • Runtime requirement

  • Cost target

  • Charging strategy

  • Market certification requirements

  • Safety margin

  • Service environment

For many floor scrubbers, sweepers, and industrial cleaning platforms, the design priority is not making the battery as small as possible. The priority is usually predictable operation, stable output, safe charging, long service life, and easy maintenance.

That is why the chemistry decision is made after we understand the machine.

4. Cell Selection: We Do Not Start with the Cheapest Cell

Once the electrical and mechanical requirements are clear, we move to cell selection.

For a cleaning equipment pack, we evaluate:

  • Cell chemistry

  • Nominal capacity

  • Continuous discharge capability

  • Pulse discharge capability

  • Internal resistance

  • Cycle-life expectation under the target load

  • Temperature behavior

  • Cell dimensions

  • Supplier consistency

  • Long-term availability

  • Certification status

  • Cost and lead time

A low-cost cell may look attractive in a spreadsheet, but it can create problems later if it has weak current capability, inconsistent internal resistance, unstable supply, or insufficient certification documents.

For OEM projects, we prefer to select cells that match the real load profile. If the application has high motor startup current, we do not design only around nominal capacity. If the machine is used in long daily shifts, cycle-life and thermal behavior become more important. If the battery compartment is tightly enclosed, heat dissipation becomes part of the design.

5. Pack Architecture: Series, Parallel, and Real Operating Voltage

After chemistry and cell direction are confirmed, we define the electrical architecture.

The pack design must match:

  • Nominal system voltage

  • Maximum charge voltage

  • Minimum discharge voltage

  • Controller voltage window

  • Charger output

  • BMS protection thresholds

  • SOC display behavior

  • Required capacity

  • Current requirement

For example, a “24V system” can mean different things depending on whether the original machine used lead-acid, LiFePO4, or another lithium chemistry. We do not simply copy the label. We check the actual controller range, charger voltage, and equipment behavior.

The BMS settings must coordinate with the machine. If the BMS cutoff is too aggressive, the machine may shut down early. If the cutoff is too low, the cells may be over-discharged. If the overcurrent protection is too sensitive, the pack may trip during normal motor startup. If it is too loose, the protection margin may be insufficient.

This is why the BMS is selected together with the cell and system load, not as an afterthought.

6. BMS Design: Protection, Communication, and Field Behavior

The BMS is the control and protection layer of the battery pack. For cleaning equipment, a suitable BMS normally needs to manage:

  • Cell over-voltage protection

  • Cell under-voltage protection

  • Charge over-current protection

  • Discharge over-current protection

  • Short-circuit protection

  • Temperature protection

  • Cell balancing

  • Charge/discharge MOS control

  • SOC estimation

  • Communication, if required

For simple machines, a non-communication BMS may be enough. For more advanced OEM equipment, the battery may need CAN, UART, RS485, or another protocol to communicate with the machine controller, display, or charger.

BMS selection also affects the user experience. A cleaning machine operator does not want random shutdowns in the middle of a shift. The pack must be protected, but the protection thresholds must be aligned with the equipment’s real operating behavior.

7. Mechanical Design: The Battery Has to Survive the Machine

The mechanical design is where many custom battery packs become truly application-specific.

For cleaning equipment, we usually consider:

  • Battery tray fit

  • Enclosure material

  • Internal cell fixing method

  • Insulation structure

  • Busbar or nickel strip design

  • Wire routing

  • Connector strain relief

  • Fuse location

  • BMS mounting

  • Thermal path

  • Foam, bracket, or holder structure

  • Anti-vibration design

  • Service label and warning label position

  • Water and dust exposure

Floor scrubbers and sweepers can experience vibration, sudden stops, uneven surfaces, impact from operator handling, and moisture exposure. The internal structure must prevent cell movement, cable abrasion, insulation damage, and connector stress.

If the customer requires a certain ingress protection level, the enclosure, cable gland, connector, and sealing method must be designed together. An enclosure alone does not make a battery waterproof. Cable exits and service openings are usually the weak points.

8. Thermal Review: Heat Is a Design Input, Not a Test Surprise

Battery heat comes from current, internal resistance, ambient temperature, enclosure conditions, and duty cycle. For cleaning machines, the battery may be installed inside a compact tray with limited airflow. If the customer wants fast charging or high discharge current, thermal review becomes even more important.

In practice, this means we check whether the selected cells, busbar structure, BMS, wires, and enclosure can operate within a safe temperature range under the expected duty cycle.

For many cleaning equipment packs, active cooling is not necessary. But passive thermal design still matters. We may adjust cell spacing, layout, conductor size, BMS position, insulation material, or enclosure structure to improve thermal margin.

9. Prototype Build: From Drawing to First Sample

Once the electrical and mechanical design is approved, we move to sample production.

A typical prototype process includes:

  1. Confirming the battery specification

  2. Finalizing the cell model and BMS model

  3. Preparing the pack layout

  4. Confirming connector, wire gauge, fuse, and communication cable

  5. Creating mechanical drawings or 3D structure files

  6. Preparing the bill of materials

  7. Building the first sample

  8. Testing the sample internally

  9. Sending the sample for customer validation

During sample production, the focus is not speed alone. The goal is to verify whether the design works as intended before moving to batch production.

10. Cell Matching and Assembly

Before assembly, cells should be checked and grouped. The exact criteria depend on the project, but the purpose is consistent: reduce imbalance and improve pack consistency.

Typical incoming and pre-assembly checks may include:

  • Cell model verification

  • Visual inspection

  • Voltage check

  • Internal resistance check

  • Batch traceability

  • Cell grouping

  • Polarity confirmation

Then the pack moves into assembly.

The assembly process may include:

  • Cell holder or fixture preparation

  • Cell grouping

  • Spot welding or laser welding, depending on the structure

  • Busbar or nickel strip connection

  • Insulation placement

  • BMS installation

  • Temperature sensor placement

  • Fuse and protection component installation

  • Wire harness routing

  • Connector crimping or soldering where applicable

  • Enclosure assembly

  • Labeling and serial number recording

Every step must avoid hidden risks: reversed polarity, weak welds, sharp metal edges, poor insulation, loose wires, wrong connector pinout, or insufficient clearance.

For cleaning equipment, we pay special attention to vibration resistance and cable routing. A battery may pass a bench test but fail in the field if internal cables rub against metal edges or if the connector is stressed during installation.

11. Electrical Testing Before Customer Shipment

A finished sample or production pack should not leave the factory only because it “turns on.” It needs structured testing.

Depending on the project, testing may include:

  • Open-circuit voltage check

  • Internal resistance check

  • Charge test

  • Discharge test

  • Capacity verification

  • BMS protection function check

  • Over-current protection check

  • Short-circuit protection verification under controlled conditions

  • Temperature sensor check

  • Communication test, if applicable

  • SOC display test

  • Charger compatibility test

  • Connector polarity and pinout verification

  • Insulation and safety check

  • Aging or cycling test according to project requirement

For OEM projects, we also recommend machine-level validation. Bench testing is necessary, but the real question is whether the battery works correctly inside the customer’s equipment.

A cleaning machine validation may check:

  • Startup behavior

  • Brush motor operation

  • Vacuum motor operation

  • Traction behavior

  • Peak load behavior

  • Runtime estimate

  • Charger behavior

  • SOC display accuracy

  • Error codes

  • Physical fit

  • Cable installation

  • Service access

  • Heat after operation

This stage is where small adjustments are often made. The connector angle may need to change. The cable may need to be longer. The BMS current threshold may need to be reviewed. The enclosure may need a mounting detail adjustment. These are normal engineering refinements before batch production.

12. Pilot Run: Before Mass Production

After the sample is approved, we normally recommend a pilot run before full production.

The pilot run confirms:

  • BOM stability

  • Production process repeatability

  • Welding parameters

  • Fixture suitability

  • Assembly time

  • QC checkpoints

  • Packaging method

  • Labeling

  • Traceability records

  • Batch test data format

Pilot production is especially important for custom battery packs because a design that works once must also be manufacturable repeatedly. The goal is not only to build one good sample. The goal is to build the same quality consistently.

13. Production Quality Control

For production batches, quality control needs to happen throughout the process, not only at the end.

We usually control quality in four layers.

13.1 Incoming Quality Control

This covers cells, BMS, wires, connectors, metal parts, enclosure parts, insulation materials, labels, and packaging materials.

13.2 In-Process Quality Control

This covers welding quality, polarity, insulation, wire routing, connector assembly, BMS installation, temperature sensor placement, and enclosure assembly.

13.3 End-of-Line Testing

Each finished pack should pass defined electrical and functional tests before shipment. The exact test items depend on project requirements, but voltage, capacity direction, protection behavior, connector polarity, and charging behavior are usually core checks.

13.4 Traceability

For OEM projects, traceability matters. A battery pack should be linked to its cell batch, production date, test record, BMS version, and serial number. If a field issue happens later, traceability allows the engineering team to identify whether the problem is isolated, batch-related, installation-related, or application-related.

14. Packaging and Delivery

A lithium battery is not packed like an ordinary electronic accessory. Before shipment, we classify the battery and prepare the correct documents and packaging according to the shipping method.

For lithium-ion batteries, common transport classifications include UN3480 for lithium-ion batteries shipped alone and UN3481 for lithium-ion batteries packed with or contained in equipment. In many export situations, the shipper also needs to provide a UN38.3 test summary, MSDS/SDS, product specification sheet, and dangerous goods packaging information.

A typical shipment preparation may include:

  • Battery inspection before packing

  • Correct state-of-charge handling according to transport route and regulation

  • Individual pack protection

  • Short-circuit prevention

  • Shock-resistant carton or wooden pallet packaging

  • Dangerous goods labeling where required

  • UN38.3 test summary

  • MSDS/SDS

  • Commercial invoice

  • Packing list

  • Product specification sheet

  • Operating and charging instructions

  • Tracking information

For OEM customers, we can also support packaging customization, carton labels, batch labels, and project-specific documentation.

15. What the Customer Receives

A well-delivered cleaning equipment battery project should provide more than a physical battery pack.

The customer should receive:

  • A battery pack that fits the equipment

  • A specification sheet

  • Charging requirements

  • Connector and wiring information

  • Safety instructions

  • Transport documents

  • Batch traceability

  • Test records where agreed

  • Technical support for installation and validation

For OEM customers, we also support design updates after field testing. If the first batch reveals a better cable direction, improved mounting method, clearer label, or revised BMS communication setting, we treat that feedback as part of product optimization.

16. Why This Process Matters

A cleaning equipment battery pack is a working power system. It has to support motors, survive vibration, fit inside a limited compartment, handle charging safely, meet transport requirements, and remain serviceable in the field.

That is why we do not quote only from voltage and capacity. We first understand the equipment, define the load profile, select the right cell and BMS, design the structure, build a sample, test it, validate it with the customer, and then move into controlled production.

For PackForge Energy, a good custom battery pack is not simply assembled. It is specified, engineered, verified, documented, and delivered as part of the customer’s equipment platform.

Engineering Checklist for a Cleaning Equipment Battery RFQ

Before starting a custom battery project, it helps to prepare the following information:

  • Equipment type and model

  • Original battery voltage and capacity

  • Target runtime

  • Continuous current

  • Peak current and duration

  • Motor power information

  • Charger output voltage and current

  • Battery compartment dimensions

  • Connector photos or drawings

  • Cable length and exit direction

  • Target chemistry, if already selected

  • Operating temperature range

  • Water, dust, vibration, and cleaning chemical exposure

  • Required certification or market access documents

  • Target shipping country

  • Expected sample quantity and batch quantity

The more complete the RFQ information is, the faster the engineering team can move from concept to a reliable battery pack design.

Need a Custom Battery Pack for Cleaning Equipment?

If you are developing or upgrading a floor scrubber, sweeper, vacuum system, cleaning robot, or other battery-powered cleaning equipment, PackForge Energy can help you define a practical custom battery pack solution.

Send us your battery voltage, capacity target, machine photos, battery compartment size, charger information, and load current requirements. Our engineering team will review the application and help define the right battery pack direction before quotation.