How to Choose the Suitable Lithium Battery Pack for the Electrification Conversion of Wuling Rongguang Mini Bus? (339.2V 230Ah, CCS2 Solution with EVCC and CAN)
Electrifying the Wuling Rongguang mini bus requires a carefully selected lithium battery pack that matches the performance, safety, and integration demands of the vehicle. A 339.2V 230Ah battery system with CCS2 charging solution, EVCC (Electric Vehicle Communication Controller), and CAN communication is a robust configuration for reliable and efficient operation. Here’s a comprehensive guide to selecting the right battery pack.
1. Voltage and Capacity Compatibility
The battery pack must align with the 385V DC nominal voltage platform of the 120kW 3-in-1 powertrain. A 339.2V nominal voltage (likely based on a 94S or 96S lithium-ion configuration) is within the acceptable range and compatible with the 290–480V DC operating window. Ensure the battery can deliver 230Ah continuous discharge current to support the motor’s peak power of 120kW and peak current of 450A. Verify that the battery’s C-rate (e.g., 1C continuous, 2C peak) meets or exceeds the powertrain’s demands.
2. Battery Chemistry and Cell Quality
Opt for high-quality NMC (Nickel Manganese Cobalt) or LFP (Lithium Iron Phosphate) cells based on your priorities. NMC offers higher energy density and performance, ideal for maximizing range. LFP provides superior thermal stability, longer cycle life, and enhanced safety—critical for commercial fleets. Choose automotive-grade cells from reputable manufacturers (e.g., CATL, EVE, or Sunwoda) with proven longevity and consistency.
3. CCS2 Charging Solution Integration
The CCS2 (Combined Charging System 2) interface supports both AC and DC fast charging, making it ideal for versatile charging scenarios. Ensure the battery pack includes:
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A CCS2-compliant inlet with proper high-voltage interlock (HVIL)
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DC fast charging capability (e.g., up to 80kW) to enable rapid top-ups
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Thermal management during charging to prevent degradation
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Compatibility with GB/T or ISO 15118 communication protocols for plug-and-charge functionality
4. EVCC and CAN Communication
The EVCC (Electric Vehicle Communication Controller) acts as the gateway between the battery, charger, and vehicle network. It must:
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Support ISO 15118 for smart charging and bidirectional communication (if applicable)
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Enable PLC (Power Line Communication) over the CCS2 cable
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Translate charging commands and monitor charging progress
The battery pack must also feature CAN 2.0B communication to interface with the BMS (Battery Management System), motor controller, and dashboard. Key data to exchange includes:
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State of Charge (SOC), State of Health (SOH)
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Voltage, current, and temperature readings
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Charging status and fault codes
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Insulation resistance
Ensure the CAN baud rate (e.g., 250 kbps or 500 kbps) matches the vehicle network.
5. BMS (Battery Management System) Capabilities
A robust BMS is essential for safety and longevity. It should provide:
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Cell voltage monitoring (per-cell or per-module)
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Temperature monitoring (with PT1000 or thermistor sensors)
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Current sensing (shunt or Hall-effect sensor)
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SOC and SOH estimation using advanced algorithms (e.g., Coulomb counting + Kalman filtering)
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Active or passive cell balancing to maintain pack consistency
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Overvoltage, undervoltage, overcurrent, and overtemperature protection
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Crash and insulation monitoring for high-voltage safety
6. Thermal Management and Protection
Given the liquid-cooled 3-in-1 powertrain, the battery pack should also feature liquid cooling/heating to maintain optimal temperature (15–35°C). This prevents degradation in extreme climates and supports fast charging. The pack must meet IP67 protection level and use fire-resistant materials and arc quenching designs. Include pressure relief valves and thermal runaway propagation prevention.
7. Mechanical and Installation Design
Design the battery pack to fit the mini bus chassis, considering:
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Weight distribution to maintain vehicle stability
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Vibration resistance with proper mounting and damping
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Serviceability for maintenance and replacement
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High-voltage isolation and EMC compliance
8. Safety and Certification
Ensure the battery system complies with:
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GB/T 38031 (safety requirements for EV power batteries)
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UN 38.3 (transport safety)
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ISO 6469 (electrical safety)
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EMC standards to avoid interference
9. Lifecycle and Maintenance
Target a design life of 20 years or 300,000 km, with ≥3,000 cycles at 80% depth of discharge (DoD). Provide remote diagnostics, over-the-air (OTA) updates, and maintenance alerts via CAN or telematics.
Conclusion
A 339.2V 230Ah lithium battery pack with CCS2, EVCC, and CAN is ideal for the Wuling Rongguang mini bus electrification. By prioritizing voltage compatibility, safe charging, robust communication, and thermal management, you ensure a reliable, efficient, and future-ready electric powertrain.
