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Standardised LiFePO4 swap packs, station hardware and BMS telematics for battery-as-a-service network operators.

Battery Swapping Network Solution for Two- and Three-Wheeler Fleets

Overview

Battery Swapping Network Solution for Two- and Three-Wheeler Fleets

Swap-based energy delivery removes charging downtime from two- and three-wheeler fleets entirely. EcoDyny supplies the full hardware stack behind a swapping network: standardised 48V to 72V LiFePO4 swap packs, rack-mounted chargers, station controllers and the BMS telematics layer that reports every pack's state of charge, cycle count and location to a central fleet platform. Because swap packs are cycled hard, often twice per day, cell consistency, connector durability and pack-level data integrity determine whether the network is profitable. We build packs for that duty cycle, supply them in container-load volumes, and work with operators on pack standardisation so vehicles, stations and spares remain interchangeable across a growing footprint.

Part 01

Swap Pack Design for High-Cycle Duty

Swap packs are the highest-wear asset in the network, so we design around cycle life and mechanical abuse rather than peak energy density. Standard configurations cover 48V/24Ah, 60V/40Ah and 72V/45Ah using prismatic or cylindrical LiFePO4 cells selected for matched capacity and internal resistance.

Aluminium or steel enclosure with IP65 sealing and a reinforced handle geometry rated for daily manual handling
Locking, arc-resistant connectors rated for 10,000+ mating cycles
BMS with CAN or RS485 output, cell-level voltage logging and tamper or anti-theft detection
Barcode or RFID identification tied to the pack serial number for asset tracking
Optional internal heating film for cold-start operation in northern markets

Every pack is capacity-sorted and cycled at the factory, and we can supply an incoming-inspection protocol so operators can verify new stock against the same criteria.

Part 02

Station Integration and Charging Infrastructure

A swap station is a charging system first and a swapping mechanism second. We supply the DC charging and power-conversion layer that sits behind the swap rack, sized from small cabinet stations for a single shopfront up to containerised multi-rack sites.

Rack-mounted chargers with per-channel current control and temperature-compensated charge profiles
Charger-to-BMS handshake over CAN so each pack receives its own charge curve
Grid interface options: 220/380V AC single- or three-phase, or DC bus input for solar-assisted stations
Station controller aggregating pack status, charger faults and door or lock events
Fire-safety provisions: cell-level monitoring, thermal fuses, ventilation and optional aerosol suppression

Charging at 0.3C to 0.5C keeps pack temperature rise moderate and preserves cycle life; the platform can schedule staggered charging to flatten the station's peak demand.

Part 03

BMS Telematics and Battery-as-a-Service Economics

In a battery-as-a-service model the operator keeps ownership of the pack and sells kilometres or swap credits, which means the asset must be visible at all times. Our BMS boards support optional 4G and GPS modules so each pack reports state of charge, state of health, cycle count, cell voltage spread, temperature and position.

Data pushed over MQTT or HTTP to the operator's own platform, or to a hosted dashboard
Fleet views for pack distribution across stations, swap frequency per vehicle and rider-level usage
Anomaly alerts for over-temperature, cell imbalance, abnormal self-discharge and unauthorised pack movement
State-of-health trending to plan pack retirement and second-life redeployment
Optional immobilisation signal for packs reported stolen or out of contract

Reliable telemetry converts an opaque asset pool into a measurable one, which is what financiers and fleet customers need before committing to volume.

Benefits

What this design gives you

Standardised Pack Interchange

One pack specification across vehicles and stations keeps spare-part variety minimal, simplifies maintenance training, and allows the network to expand into new cities without redesigning the swap interface or qualifying a second pack format.

Duty-Cycle Matched Cells

Cells are selected and matched for high-frequency shallow cycling rather than maximum nameplate capacity. This is where swap fleet packs actually earn their service life, and it keeps replacement costs predictable across the fleet.

Container-Load Supply Capacity

Production lines can deliver swap packs in container quantities with consistent batch quality, supporting operators who need to roll out hundreds of packs per city across multiple deployment phases and financing rounds.

Full Asset Visibility

Pack-level telemetry covers state of charge, health, cycle count and location, giving operators the utilisation data required for internal reporting and for discussions with third-party financiers and asset owners.

Staggered Charging Control

Charge scheduling spreads station load across the day, reducing demand charges and easing pressure on weak local distribution networks where transformer capacity is already the binding operational constraint.

Spares and After-Sales Support

Documented BMS parameters, spare-parts lists and technical response support help operators maintain network uptime without shipping packs back to China for routine diagnostics, firmware checks or repair work.

Specification

Reference specification

Pack voltage and capacity	48V 24Ah / 60V 40Ah / 72V 45Ah
Chemistry	LiFePO4 (prismatic or cylindrical)
Cycle life at 80% DoD	2,000-3,500 cycles
Enclosure protection	IP65
Operating temperature	-20 to +55 C (charge 0 to +45 C)
BMS communication	CAN / RS485, optional 4G + GPS
Swap frequency	1-3 swaps per vehicle per day
Station charge rate	0.3C-0.5C per channel
Network size supported	10 to 500+ packs per site cluster