Selection Guide for Power Supply Boards in Power Swap Cabinets: Is “Maximum Power” Really Important? The Core of Stability Is “adaptation”

  With the rapid global expansion of shared two-wheelers and the instant delivery sector (including food delivery and courier services), urban battery swap networks have emerged as critical new infrastructure. As the "core component" of battery swap stations, the performance, safety, and reliability of their built-in power management systems directly determine the operational efficiency and user experience of the entire network. This article analyzes the key technologies and selection criteria for battery swap station power boards, providing guidance for product design, selection, and maintenance.
1. Industry status quo and core challenges
Battery swap network operators are well aware that the real headache isn't battery shortages, but power board failures. These issues stem from extreme conditions like high humidity in building corridors, voltage spikes in remote areas, and operators accidentally reversing batteries during quick swaps. Such unreliable power boards force maintenance teams to make frequent on-site trips, driving up operational costs.

Grid adaptability: Voltage fluctuations vary significantly in different regions and time periods, and the power supply needs to have wide voltage input capabilities.

Battery compatibility: It needs to be safely and efficiently adapted to multiple types of batteries such as lead-acid, ternary lithium, lithium iron phosphate, etc. The charging curves of various types of batteries are different.

Environmental reliability: It needs to operate continuously and stably 24/7 in high temperature, high humidity, and dusty environments, so heat dissipation design is crucial.

Safety and compliance: It must meet dual standards of electrical safety and battery safety, must pass strict certification and have multiple built-in hardware protection mechanisms.

Operating costs: Power consumption, cooling efficiency, and failure frequency will directly affect long-term operating costs.
In fact, to deal with these challenges, choosing the right “adaptive” charger is crucial. For example, the Lilon charger not only has comprehensive specifications and can match the needs of power swap cabinets with different voltages and different types of batteries, but also has targeted optimization in safety protection and heat dissipation design, which can minimize the risk of failure in complex environments and help operators save a lot of operation and maintenance troubles.
2. In-depth interpretation of the core performance indicators of the power board

1.When selecting or evaluating a power strip, you need to focus on the following technical dimensions:
Intelligent charging management algorithm This is the "core control module" of the power supply. A good algorithm should have: Automatic identification and adaptation: Implement customized multi-stage charging strategies (constant current/constant voltage/trickle charging) for different types of batteries through communication protocols or battery characteristics determination.

Temperature compensation: Dynamically adjusts charging voltage and current based on ambient and cell temperature to ensure safety and prolong battery life.
Policy configurability: Algorithm parameters should support flexible adjustments to accommodate future battery technology iterations

2. Heat dissipation and structural design
Heat dissipation capability determines power density and long-term reliability. The mainstream designs are divided into: Natural cooling (passive cooling): relies on cabinet shell and heat dissipation fins for heat dissipation, no fan, no noise, maintenance-free, long life, but high requirements for structure and space design.
Forced air cooling: This method achieves higher power density through fan cooling, but carries risks of fan failure, dust accumulation and noise interference.
In terms of heat dissipation design, Lilon has chosen a natural air cooling solution that is more suitable for the long-term operational needs of battery swap cabinets. The absence of a fan means one less potential point of failure, eliminating concerns about dust accumulation and blockage or fan damage. Additionally, it operates completely silently and requires no additional maintenance. The optimized heat dissipation structure can quickly conduct heat away, ensuring stable support for 7×24 hours of continuous operation even in high-temperature, dusty outdoor or warehouse environments.


Hardware protection circuit is the last line of defense for security and must adopt "redundant design":

Input side: Lightning protection, overvoltage and undervoltage protection.

     Output side: overcurrent, short circuit, overvoltage, and overpower protection.

           Battery side: Anti-reverse connection (very important), anti-current backflow protection.

                                 System level: over-temperature hierarchical protection (derating operation → alarm → forced shutdown).
4. Certification and Compliance Requirements

Certification is not merely a procedural formality, but a tangible validation of product design capabilities. For instance, FCC certification guarantees that a power supply will not interfere with adjacent devices, while RoHS is a mandatory requirement for entering European and American markets. Beyond the basic CCC/CE certifications, global market expansion requires proactive planning for regional certifications such as FCC (Electromagnetic Compatibility), KC (Korea), and PSE (Japan). These certifications ensure compliance with electromagnetic interference, safety standards, and environmental requirements, serving as essential prerequisites for market entry.
For companies engaged in the global battery swap cabinet market, the most troublesome issue is the inconsistent compliance standards across different regions. However, Lilon chargers have already addressed these aspects in advance, with all international certifications such as CE, FCC, RoHS, KC, and PSE in place. Whether entering the European, North American, Japanese, or South Korean markets, they can directly meet the local access requirements without the need to spend additional time and costs on supplementary certifications. Moreover, in terms of quality control, Lilon has always adhered to high-standard production and testing to ensure that every product can operate stably and reliably.

3. Common misunderstandings in selection and design
In practice, the following misunderstandings can easily lead to subsequent problems:

Power-centric design: blindly pursuing high power per board while neglecting the importance of multi-module redundancy design for system availability.

Neglecting the input voltage range: In regions with unstable power grids, wide voltage input (e.g., AC90-264V) is essential for stable operation.

The heat dissipation design of the power board must be optimized in coordination with the overall air duct and structure of the cabinet, rather than being designed independently.

Neglecting communication interfaces: The absence of standardized communication protocols (e.g., RS485/CAN) will hinder intelligent operation and data acquisition in later stages.

4. Outlook on future development trends
From the perspective of technological evolution, the power supply system of the power replacement cabinet is showing the following trends:

Higher power density: Through the application of new materials, smaller size and higher energy efficiency can be achieved.

Intelligent and connected: The power supply becomes an IoT node, supporting remote monitoring, fault warning, and algorithm OTA upgrades.

Energy interactive management: intelligent charging during low periods of the power grid, and even participating in the energy regulation of local microgrids to reduce electricity costs.

Full life cycle maintainability: Modular design supports hot-swappable replacement, greatly reducing the difficulty and time-consuming on-site maintenance.

Conclusion

A high-quality and reliable power supply solution is a solid foundation for the stable and efficient operation of a battery swap network. For battery swap cabinet enterprises, "compatibility" is far more important than "maximum power", and Lilon chargers have precisely grasped this point: they are fully certified to be compatible with global markets, come in various specifications to suit different scenarios, offer comprehensive protection against complex risks, ensure long-term stability through natural air cooling, and are backed by a three-year warranty service commitment. These features exactly address the core pain points of operators in product selection and operation and maintenance.

If your battery swap network is facing issues such as frequent power board failures, incompatibility in charging batteries of different brands, or high operating costs, or if you want to know how to choose a "compatible" power supply solution, you can contact us. By providing your deployment scenarios (such as outdoor/warehouse), battery types (lead-acid/ternary lithium), and power grid conditions, you can obtain free customized selection recommendations, allowing Lilon chargers to safeguard your battery swap network.