After two years of intensive collaboration, the EV-Lite project is drawing to a close. The consortium, formed of the Manufacturing Technology Centre, Unipart Manufacturing, Electrovaya, RDVS, CRR, Bluebird Innovation Group, Loughborough University and Cenex, has been immensely successful with the design of a new electric vehicle battery. The project targets have been surpassed with a 41% reduction in weight and a 63% reduction in cost of the non-cell components realised. This translates to a saving of 45kg at the battery pack level. The ultimate aim of this ambitious and exciting project is to enable volume manufacturing for electric vehicle battery packs in the UK through innovative design and, in doing so, help bring electrical vehicles to the mass market. Innovative design and manufacturing ideas have helped the consortium to achieve significant cost reductions and weight savings without sacrificing functionality. The new battery design has no wire or screws; this step change in design has translated into significant improvements in battery pack assembly. When compared to a benchmarked battery the EV-Lite design has a parts count of 196 vs 807 for a 4KwHr sized module. The key achievements of the project include:
  • No wires or screws used in design
  • Novel safety feature to isolate cells in an accident
  • Design for low cost, automated assembly
  • Novel battery interface system
  • 5 patent applications
  • Novel battery management board design
The lead partner, the Manufacturing Technology Centre, has manufactured two prototype battery packs, utilising a new Battery Management System designed by RDVS. One of the battery packs has been tested by Loughborough University using real life test cycles developed by Cenex. The other prototype battery has been used by the Manufacturing Technology Centre for automated assembly trials. Electrovaya provided the project with its latest generation SuperPolymer®2.0 lithium polymer cells. The project consortium has a broad spectrum of capabilities, ranging from manufacturing and assembly to reuse and recycling. The consortium is led by the Manufacturing Technology Centre and is formed of Unipart Manufacturing, RDVS, Electrovaya, Bluebird Innovation Group, the Centre for Remanufacturing and Reuse, Loughborough University and Cenex. The prototype battery pack and the mobile robotic assembly cell used for automated assembly will be presented to the public at LCV 2014 at Millbrook Proving Ground in September. For further information on the event please visit For additional information about the project please contact: The Manufacturing Technology Centre, Pilot Way, Ansty Business Park, Coventry, CV7 9JU Tel: +44 (0)2476701600 Email: Website: