In the fast-evolving world of agricultural technology, power solutions are becoming just as critical as robotics and AI themselves. Farmers demand energy systems that are safe, durable, and capable of withstanding harsh outdoor conditions. Himax, a leading innovator in custom lithium battery pack solutions, has introduced a breakthrough product — a 36V 100Ah PVC pack battery tailored specifically for agricultural robots. Designed to function reliably between -20℃ and 60℃, the battery demonstrates how the right combination of engineering, materials, and smart communication features can redefine outdoor farming applications.

How Agricultural Robots Depend on Reliable Energy

Agricultural robots are no longer a futuristic concept; they are working in fields worldwide, handling tasks such as weeding, spraying, planting, and harvesting. However, the efficiency of these machines depends heavily on the performance of their batteries. Standard power packs are often challenged by demanding field conditions: dust, moisture, fluctuating temperatures, and physical impact.

This is where the 36V 100Ah PVC pack battery stands out. Not only does it provide the large energy capacity needed for extended field operations, but it also integrates protective features that ensure safe and consistent performance. In agricultural settings, reliability is not optional; it is the very foundation of productivity. Himax understood this reality and engineered a product to match.

Why the 36V 100Ah Battery Is a Game-Changer

The new Himax PVC battery introduces several innovations that directly address challenges faced by agricultural robots:

Temperature Tolerance:
Farmers work in diverse climates, from frosty winters to scorching summers. The battery’s operational range of -20℃ to 60℃ ensures that robots never face downtime due to weather. This wide range also extends the battery’s appeal to global markets, from Northern Europe to Middle Eastern deserts.

LED Display for Real-Time Monitoring:
A built-in LED display gives operators instant insight into the state of charge and performance. For farmers working long hours, this removes the guesswork, providing confidence that the machine will finish its task before recharge.

CAN BUS Communication:
In modern robotics, data communication is vital. The battery supports CAN BUS protocol, allowing seamless integration with robot control systems. This enables features such as predictive maintenance, accurate battery health reporting, and performance optimization during heavy workloads.

Thermistor Protection:
Overheating is a frequent risk in outdoor environments, especially under heavy mechanical loads. The battery includes thermistors to continuously monitor internal temperature, ensuring that the system can prevent damage before it happens.

Epoxy Board Reinforcement:
Perhaps one of the most innovative design choices is the inclusion of an epoxy board around the battery cells. This extra layer acts as structural armor, preventing cell damage if the outer PVC layer cracks. Given the rugged terrain where agricultural robots operate, this protective barrier is essential for long service life.

How Himax Balanced Safety and Practicality

Designing a battery for agricultural robotics is about striking the right balance between energy density, safety, and durability. Himax engineers applied their extensive experience in lithium battery pack customization to solve real-world issues:

The 36V nominal voltage offers a sweet spot for powering motors and robotic actuators while keeping energy efficiency high.

The 100Ah capacity ensures that machines can run for extended periods without frequent recharging, a vital feature for productivity in large farmlands.

The use of PVC housing provides lightweight protection, while the epoxy reinforcement ensures additional robustness against mechanical shock.

By embedding smart communication protocols and monitoring sensors, Himax positioned the battery not only as an energy storage unit but also as a smart energy management system.

This approach is a direct reflection of Himax’s philosophy: batteries should not simply store energy; they should actively contribute to the safety, intelligence, and efficiency of the systems they power.

Why Farmers and Robotics Companies Should Care

The agricultural industry is undergoing a profound transformation. Labor shortages, rising operational costs, and climate change are pushing farms to adopt smarter technologies. Robotic systems are leading the way, but without reliable power, these machines risk underperforming or failing in the field.

By offering robust outdoor usability, intelligent monitoring, and integrated communication, Himax’s 36V 100Ah PVC pack battery solves one of the most pressing challenges: how to ensure robots work continuously in unpredictable environments. This makes the battery an attractive solution not only for agricultural robots but also for outdoor drones, autonomous vehicles, and mobile industrial systems.

Furthermore, by extending service life and preventing costly failures, the battery directly supports farmers’ bottom lines. Reduced maintenance costs and improved reliability translate into higher return on investment for robotic deployments.

 

How Safety Innovations Drive Market Confidence

The addition of epoxy boards to guard against PVC damage is more than a technical improvement — it represents Himax’s commitment to proactive safety. While many batteries rely solely on casing materials for protection, Himax anticipated real-world scenarios: robots hitting rocks, machines tipping over, or external impacts in the field. By anticipating failure points, the company provided a solution that builds trust among robotics manufacturers and end users alike.

Equally important, the CAN BUS integration ensures compliance with advanced robotics standards, where interoperability and data-driven insights are increasingly valued. This future-proofs the battery, allowing it to integrate seamlessly with evolving agricultural technologies.

Looking Toward the Future of Agricultural Robotics

The launch of the 36V 100Ah PVC battery signals more than just a new product release. It highlights how specialized energy solutions can directly drive innovation in agriculture. As farms around the world adopt autonomous robots to increase efficiency and reduce dependence on human labor, the demand for durable, intelligent, and safe batteries will only grow.

Himax is positioning itself at the forefront of this shift. By continuously investing in custom pack design, advanced protection systems, and integrated communication technologies, the company is not just supplying batteries — it is powering the future of farming.

Conclusion: Why Himax Leads the Way

The agricultural sector is at a crossroads, where innovation determines competitiveness and sustainability. Reliable energy storage sits at the heart of this transformation. Himax’s 36V 100Ah battery pack, with its ability to withstand extreme temperatures, communicate with robotic systems, and offer robust protection against external damage, provides a benchmark for the industry.

From LED monitoring displays to CAN BUS communication and epoxy reinforcement, every element reflects Himax’s commitment to delivering more than just energy — it delivers confidence, safety, and long-term performance. For robotics developers and farmers alike, this product is a clear answer to the question: Why do the right batteries matter in agriculture?

The answer is simple: because with Himax powering the field, farming’s future looks smarter, safer, and more sustainable.

 

In the real-world application of lithium-ion battery packs, performance issues like overcharged-low discharge and undercharged-high discharge are common causes of customer complaints. These phenomena can severely impact the performance evaluation, safety, and overall user experience of battery systems.

This article aims to break down these two issues in simple, professional terms — explaining their symptoms, root causes, potential risks, and possible solutions. Whether you’re a battery designer, manufacturer, or end-user, this guide can help you better understand and manage these challenges.

1. The Overcharged-Low Discharge Issue: Hidden Capacity Loss and Safety Risks

What Is Overcharged-Low Discharge?

The term overcharged-low discharge refers to a mismatch between the battery pack’s charging and discharging capacity. For example, a pack rated at 100Ah may appear to charge up to 105Ah, but during discharge, it only delivers 95Ah. This leads to confusion about the battery’s actual capacity and performance.

What Causes It?

There are several technical reasons behind this issue:

Inconsistent Cell Aging: In a multi-cell battery pack, not all cells age at the same rate. Some cells degrade faster due to manufacturing differences or usage conditions. During charging, weaker cells reach their maximum voltage sooner, causing the Battery Management System (BMS) to halt charging to prevent overcharging — even though other cells are not fully charged. During discharge, these weaker cells also drop voltage faster, again prompting the BMS to stop discharging early.

Internal Resistance Differences: Cells with higher internal resistance show a faster voltage rise during charging and a quicker drop during discharging. This leads to misleading voltage readings that cause early cutoffs by the BMS.

Uneven Temperature Distribution: Cells operating in cooler areas of the pack show reduced electrochemical activity, which limits their ability to charge or discharge fully. These cells become bottlenecks, reducing the usable capacity of the entire pack.

What Are the Risks?

Misleading Capacity Indications: Users may believe the battery has more capacity than it can safely deliver.

Accelerated Aging: Cells that are frequently undercharged or prematurely stopped during charge/discharge cycles age more quickly.

Safety Hazards: In extreme cases, deep discharge of weak cells can lead to lithium plating or thermal runaway — a dangerous safety concern.

2. The Undercharged-High Discharge Issue: Algorithm Errors and Temperature Effects

What Is Undercharged-High Discharge?

This is a phenomenon where a battery appears to charge less than its rated capacity but releases more during discharge. For instance, it might charge to 95Ah but discharge 98Ah. This seems counterintuitive but is observed in many battery pack applications.

What Causes It?

BMS Calibration Errors: The BMS may inaccurately estimate the battery’s state of charge (SOC), leading to an early stop during charging or extended discharging.

Low-Temperature Charging: In cold environments, lithium-ion mobility is reduced, decreasing charge acceptance. However, when the temperature rises during discharging, the cells can perform normally, appearing to release more energy than they received.

Balancing Circuit Interference: During charging, passive balancing circuits may drain energy from higher-voltage cells to equalize the pack, lowering the total reported charge.

What Are the Risks?

Unnecessary Service Complaints: Users may believe the battery did not charge properly and request service or replacement.

Over-Discharge Risk: The battery may discharge below safe limits due to inaccurate SOC readings.

Structural Damage to Electrodes: Repeated over-discharge or undercharge can degrade the internal structure of the battery cells, shortening lifespan.

3. The Root Cause: Inconsistency Among Cells

At the core of both problems is one major factor: cell inconsistency. Variations between individual cells lead to imbalances during both charging and discharging. These inconsistencies stem from three main areas:

Manufacturing Variability: Even small differences in electrode coating thickness or electrolyte saturation can result in performance variation between cells.

Uneven Usage Conditions: Non-uniform heat distribution, differing current paths, and environmental conditions cause individual cells to age at different rates.

Diverging Aging Speeds: Some cells may deteriorate faster due to localized overheating, repeated overcharge/discharge cycles, or physical stress.

4. Effective Solutions: From Design to Intelligent Management

Addressing these problems requires a multi-pronged strategy from the initial cell selection to long-term system management.

Cell Grading and Grouping

Before assembling the pack, cells should be sorted based on their capacity, internal resistance, and self-discharge rate. Grouping closely matched cells reduces imbalance and improves the performance of the entire pack.

Advanced Balancing Technologies

Active Balancing: Transfers energy from higher-voltage cells to lower-voltage ones using inductors or capacitors. This improves pack efficiency but increases system complexity and cost.

Passive Balancing: Uses resistors to bleed excess energy from stronger cells. While simpler and cheaper, it wastes energy and is less efficient.

Smarter BMS Algorithms

Combine Coulomb Counting (Ah integration) with Open Circuit Voltage (OCV) methods for more accurate SOC estimations.

Monitor individual cell voltages and temperatures in real time, and trigger balancing actions if the voltage gap exceeds set thresholds (e.g., >0.3V).

Better Thermal Management

Use liquid cooling or forced air systems to maintain a uniform temperature across all cells.

Avoid localized hotspots or cold zones that can accelerate aging or reduce performance.

5. Conclusion: Focus on Consistency, Intelligence, and Control

The overcharged-low discharge scenario often indicates the presence of weak cells that limit the overall capacity and raise safety concerns. The undercharged-high discharge issue is usually linked to BMS miscalibration or environmental factors like low temperature.

Ultimately, both issues can be traced back to inconsistencies between individual cells. The best long-term solution lies in:

Careful matching of cells at the factory,

Applying dynamic balancing methods, and

Employing smart BMS algorithms with real-time monitoring.

As lithium-ion battery packs technologies evolve, advanced sorting equipment, AI-powered BMS systems, and efficient thermal designs will become key tools in minimizing these customer complaints and maximizing battery performance.

By implementing these strategies, manufacturers can build safer, longer-lasting, and more reliable lithium-ion battery packs — delivering real value to customers in today’s increasingly electrified world.

Reference: “Why Do Battery Packs Show Overcharged-Low Discharge and Undercharged-High Discharge?” by Buyan (Original article in Chinese).