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Electric Vehicles Research
Posted on August 12, 2014 by  & 

Project reduces EV battery weight by 41%

UK-based Cenex is part of a consortium which has just completed a two-year project to reduce both the weight and cost of EV batteries, succeeding by shaving 99 pounds, or about 41% of the weight off a standard EV battery.
The EV-Lite project co-funded by the UK's innovation agency, The Technology Strategy Board also achieved 63% reduction in cost of the non-cell components.
The consortium realised significant cost reductions and weight savings without sacrificing functionality. The new battery design has no wire or screws, significantly improving 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.
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 project consortium includes the Manufacturing Technology Centre, Unipart Manufacturing, Electrovaya, RDVS, CRR, Bluebird Innovation Group, 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 Cenex-LCV 2014 at Millbrook Proving Ground in September. For further information on the event please visit
Source and top image: Cenex
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