Nilar batteries are very different from other advanced battery packs available in the market. Other suppliers use arrays of cylindrical cells which are tab welded together and then covered in shrink tube. These small tab welds increase the resistance of the pack. Additionally multiple cells in parallel, rather than one or two large format batteries in parallel further increases the resistance. High resistance and poor quality control of the Chinese made cells severely limits the current capability of the pack.
Nilar batteries are built using a patented construction which results in a dense battery with very low resistance and extremely high power. These batteries are produced in the United States and were designed for use in military applications. The battery is so safe that it has been qualified for use in commercial aircraft. The battery uses proven NiMH chemistry and includes integrated charge control.
Read more about techniques to use Nilar batteries in your applications:
We know that many small volume users do not get the attention they deserve from large scale battery companies. We also know that many users need a high performance and high reliability power pack but at an affordable price.
You can literally plug our battery solution into your application and get going right away. Here are some examples of possible applications along with some case studies of applications already using our NiMH batteries.
Robotic Projects
Small Electric Vehicles including wheelchairs, bikes and scooters
Remote RC recharging
Electric Lawn and Garden Tools
Electric Bike Conversion
Colorado Advanced Battery offers a 48V nickel metal hydride battery solution ideal for electric bike conversion projects. The Nilar 48V 10Ah battery can be used 10 power a standard 25A motor controller or two 48V 10Ah batteries can be used in parallel to provide 48V 20Ah and easily deliver 40A.
Front tire mounted hub motor
48V 25A motor controller
Thumb throttle
48V 10Ah Nilar Batteries mounting on frame
30 to 40 mile range on an assist
48V system
30mph w/o peddling
600W electric hub motor – wilderness energy using low rolling resistance tires
SAE Formula Hybrid
The Colorado State University SAE Formula Hybrid team finished second out of 30 teams in the 2009 SAE Formula Hybrid competition in Loudon, N.H., giving Colorado State its first formula car competition trophy. The CSU team scored fourth in the engineering design finals where the top four cars are judged best in engineering design, analysis, fabrication, assembly and testing. They were first in two events - the 75-meter electric acceleration event and the 75-meter hybrid acceleration event.
"I think the reason they did so well was based on their strong industry support, especially from a Colorado company, Nilar Inc. in Centennial," Advisor Professor Patrick Fitzhorn said. "Nilar engineers were generous not only with their patented battery technology, but they were equally as generous with their time and information. It is clear to me that this success is specifically due to the partnering between bright and committed CSU mechanical engineering students interested in new energy technologies, and a Colorado company working in state-of-the-art energy systems."
96V System
15kW Peak Power
150 Amps
2.6 kWh installed capacity
24 x 12V Nilar Power Modules
75m drag race under all electric propulsion in 6 sec
This ATV was originally made using lead acid batteries then converted to the Nilar battery. The Nilar battery is a nickel metal hydride (NiMH) battery that is only 60% the weight of lead acid batteries and will deliver 50% more energy and range under aggressive driving conditions. The cycle life of the Nilar battery versus lead acid is 2 times greater and up to 5 times greater with good battery management. What the end user gets is a electric ATV that goes twice the distance, weighs less, and has an eco-friendly NiMH battery that will last much longer.
This ATV is eco-friendly with no emissions. It's so quiet it can be used in areas where fossil fuels are not allowed. The electric power provided by this Nilar battery has better acceleration and is highly reliable. The electric motor is very simple and has fewer parts than a combustion engine.
Converting the ATV from the lead acid to Nilar nickel metal hydride (NiMH) batteries was simple. The size of the Nilar battery fits better into the ATV saving weight and volume while greatly improving vehicle performance. The Nilar battery was mounted with the terminals facing up but could also be mounted with the terminals laying flat. Extra free volume in the battery box allows for improved thermal management of the batteries. The battery installation did not require a custom battery box, and the final product looks like the factory design, this is due to the size and flexibility of design when fitting the Nilar battery into the battery box which was intended for a lead acid battery.
Charging should always be performed through the Deans charge plug and the JST thermistor plug should be connected to the charger as well. The Nilar battery includes an integrated charge control, accessed through the Deans connector. This charge control must be used because the Nilar resistance profile is different than other NiMH batteries which means the Nilar battery should not be charged to the point that voltage decreases. The integrated charge control will take over if the battery is entering an overcharge state and will cut off the connection to the charger. To the charger this will look like the battery has been removed from charge and the LEDs will signify that nothing is connected. If the battery is allowed to stay connected to the charger, it may reconnect after a period of time and start a new charge cycle. However, it is not advised to allow the battery to continue to cycle on charge in this manner as it can affect life. If you are using a 3 stage lead-acid charger and the charger enters float mode, then the battery can remain on the charger in this condition without adverse effects.
NiMH Chargers
Fundamentally, the Nilar battery is nickel metal hydride and can be charged with standard NiMH battery chargers.
NiMH chargers can be rated up to 3A
3 stage Lead Acid Chargers
The Nilar NiMH can be used on lead acid chargers
The charger should at least be a 3 stage charger (constant current, constant voltage, float)
Lead Acid chargers should be rated up to 2A
Charge capacity will depend on the voltage cut-off of the charger which can vary substantially, 28.8V is a good cut off
It is best to charge around 70 degrees F to maximize charge when using lead acid chargers
One of the major advantages of using the Nilar battery is that these batteries can be connected into much larger packs. In commercial applications, Nilar uses these batteries to build packs over 400V and 100Ah. We don't suggest going that big as Nilar designs in sophisticated battery control. WARNING: Voltage above 48V is very dangerous and should only be handled by qualified people. If you build these batteries into larger packs you are completely liable for the safety of the pack.
Building Higher Voltage Packs
Batteries can be connected in series to increase the voltage of the pack. For instance to build a pack for a Phoenix electric bike, which requires 48V and 40A, we suggest using two 24V 20Ah batteries in series. One battery can be mounted on each side of the tire, then connect the two batteries in series to obtain 48V. We do not suggest exceeding 120V because isolation becomes critical as the pack voltage increases and a ground fault is a serious issue.
Building Higher Capacity Packs
Batteries can be connected in parallel to increase the capacity (Ah) of a pack. The Phoenix electric bike in the previous example could be powered using two 48V 10Ah batteries connected in parallel to reach 48V 20Ah. However, we prefer the 24V solution as it is more versatile to charge. Three points to remember when building up capacity.
Connect batteries together in parallel at every 24V not just at the highest voltage and ground
Place batteries of the same voltage next to each other to keep them at the same temperature
Don't store batteries in parallel strings, disconnect them from each other for winter storage
It is important to keep the batteries balanced between strings. Therefore we recommend keeping parallel strings to 3 or fewer strings. Larger numbers of parallel strings should have balancing circuitry.
Good luck with your pack designs. We hope you use our forum to discuss your application where we can help you on your specific projects in more detail.
