Battery Swapping Network Solution for Two- and Three-Wheeler Fleets
Swap-based energy delivery removes charging downtime from two- and three-wheeler fleets entirely. Origin Drive Future supplies the full hardware stack behind a swapping network: standardised 48V to 72V LiFePO4 swap packs, rack-mounted charger…
Battery Swapping Network Solution for Two- and Three-Wheeler Fleets
What a swapping network looks like in the field
A swapping network is a distribution business with a depot attached. Packs move between stations and vehicles all day, are charged in racks between shifts, and are handled by riders rather than technicians.
- Two- and three-wheeler vehicles on 48 V, 60 V or 72 V platforms, often a mixed population across models and years
- Stations in shops, roadside kiosks or depots, usually with a limited incoming supply
- One or more swaps per vehicle per shift, with the pack lifted and seated by hand
- Charging windows set by the local tariff and by how many spare packs are in rotation
What the design has to respect
- Two or more cycles per pack per day, so cycle life and mechanical durability come before energy density
- A single pack interface across vehicles and stations, so spares stay interchangeable as the network spreads
- Connectors that survive daily manual mating and keep contact resistance stable over thousands of cycles
- Charging inside the depot’s existing supply, with staggered charging where the local transformer is weak
- Pack-level data an operator can act on without opening the pack, and a theft or tamper signal
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.
Station Integration and Charging Infrastructure
A swapping 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.
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.
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.
Reference specification
| Pack voltage and capacity | 48V 24Ah / 60V 40Ah / 72V 45Ah |
|---|---|
| Chemistry | LiFePO4 (prismatic or cylindrical) |
| Cycle life at 80% DoD | More than 6,000 cycles at 80% DoD |
| 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 |
How an order runs
These are the terms we quote on for packs and station hardware in this solution. Voltage, capacity, quantity and destination are fixed on the quotation, and every figure below is confirmed in writing before production starts.
| Minimum order | 20 units per model for a production order. Single units are available as paid evaluation samples, credited against your first production order. |
| Lead time | 25 days after the deposit is received for a standard batch. Tooling, custom BMS or project-specific capacity is scheduled separately and confirmed on the quotation. |
| Payment | T/T: 30% deposit with the order, balance against the bill of lading copy. |
| Shipment | Tell us the destination port or door. The quotation states the Incoterm and the freight option we are quoting, so the delivered cost is comparable across suppliers. |
| Packing | Packed to the packing instruction applying to UN3480 or UN3481, terminals protected, lithium battery mark and hazard label applied, pallets strapped and shrink-wrapped. |
| Documents with the goods | Packing list, commercial invoice, MSDS, UN38.3 test summary and report, shipper’s declaration for dangerous goods, and the bill of lading or air waybill. |
| Per unit | Datasheet for your model and the end-of-line test record for that serial number. |
| Warranty | 3–5 years, depending on model, written into the contract. |
| HS classification | Lithium-ion accumulators, heading 8507.60. The national tariff line and duty rate are confirmed against your destination before the order is placed. |
Documents: Packing and shipping document checklist · provided with your quotation · BMS protocol mapping note · provided with your quotation
How to verify before you commit
Verification is done on samples before the volume order, not after it lands.
- Paid evaluation samples shipped with the end-of-line test record for those serial numbers
- Capacity, internal resistance and balance data from the factory sorting record
- An incoming-inspection protocol, so your team can re-check new stock against the same criteria
- UN38.3 test summary and report for transport, plus the datasheet for the model quoted
- A quotation that states voltage, capacity, enclosure, connector, BMS protocol and warranty period
Models that fit this scenario
Every figure in these tables is published on the matching product page. Voltage, capacity, enclosure and connector can be re-rated for your project.
Battery Swapping Packs
| Application / load | Voltage platform & capacity | Current & thermal design | BMS & communication |
|---|---|---|---|
| Delivery three-wheelers and light cargo carts on battery-exchange networks | 48 V 24 Ah swappable pack · 51.2 V (48 V class), 24 Ah, 1.23 kWh | Maximum continuous charge current 25 A; IP67; -20 °C to +60 °C | Cell-level monitoring with active balancing; CAN / RS485 / UART, Bluetooth optional |
| Electric motorcycles and ride-hailing fleets that swap packs mid-shift | 60 V 40 Ah swap pack · 64 V (60 V class), 40 Ah, 2.56 kWh | Charge current 40 A, full charge in about 2 hours; IP67 aluminium case | Active balancing and current limiting; CAN / RS485 / UART, Bluetooth optional |
| Heavy-duty and long-route fleets that need the largest pack in the line | 72 V 45 Ah heavy-duty pack · 76.8 V (72 V class), 45 Ah, 3.46 kWh | Charge current 45 A, full charge in about 2.5 hours; IP67, shock-absorbing mounts | Active balancing and current limiting; CAN / RS485 / UART, Bluetooth optional |
E-Motorcycle & E-Scooter Batteries
| Application / load | Voltage platform & capacity | Current & thermal design | BMS & communication |
|---|---|---|---|
| City commuter e-scooters and delivery mopeds | 60 V 20 Ah scooter pack · 64 V (60 V class), 20 Ah, 1.28 kWh | Charge current 20 A, full charge in about 1.5 hours; IP67 ABS/PC shell on aluminium frame | Over-current and short-circuit protection; UART / RS485, CAN optional |
| High-speed electric motorcycles | 72 V 20 Ah motorcycle pack · 76.8 V (72 V class), 20 Ah, 1.54 kWh | Charge current 20 A, full charge in about 1.5 hours; IP67, anti-vibration mounts | Over-current and short-circuit protection; CAN / RS485 / UART |
| Three-wheelers, e-rickshaws and passenger trikes | 60 V 32 Ah three-wheeler pack · 64 V (60 V class), 32 Ah, 2.05 kWh | Charge current 32 A, full charge in about 2 hours; IP67 powder-coated steel tray | Over-current and short-circuit protection; UART / RS485, CAN optional |
Recommended products
Configuration is confirmed against your duty cycle before quotation.
48V 24Ah Swappable LiFePO4 Battery Pack
48V 24Ah swappable LiFePO4 pack with smart BMS, IP67 enclosure and over 6,000 cycles for battery swapping stations.
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60V 40Ah Swap Battery for Electric Motorcycles
60V 40Ah swappable LiFePO4 battery for e-motorcycles, with 2.56 kWh energy, smart BMS and IP67 case.
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72V 45Ah Heavy-Duty Battery Swap Pack
72V 45Ah heavy-duty swappable LiFePO4 pack with 3.46 kWh, 150A continuous discharge and IP67 enclosure.
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60V 20Ah E-Scooter Battery Pack
60V 20Ah LiFePO4 e-scooter battery pack with 1.28 kWh, smart BMS, IP67 case and vehicle-matched mounting.
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24V 200Ah Parking Air-Conditioner Battery for Trucks
24V 200Ah LiFePO4 parking battery, 5.12 kWh, runs truck air-conditioners overnight without idling the engine.
View productSend us your fleet size, vehicle voltage class and target station count, and we will return a pack specification and BOM proposal.