Battery systems design
Energy storage systems development
BESS integration.

Stationary battery energy storage (BESS), mobility applications (drones, light and heavy EVs, marine), and industrial auxiliary and backup power. We work with common lithium-ion chemistries, including LFP and NMC, and evaluate other chemistries on request.

Off-the-shelf BMS boards suit standard packs and low volumes. A custom BMS pays off when you need a specific cell count or form factor, particular communications or safety architecture, lower cost at volume, or control of the firmware roadmap. We also integrate third-party BMS and add the EMS, telemetry and AI layers on top.

It starts with the analog front end. We select an AFE for the accuracy your chemistry needs, use Kelvin sense connections and careful filtering, and sample voltage and current together so we can estimate impedance. Between modules we use isolated daisy-chain links or wireless, depending on pack size and wiring constraints.

Passive balancing bleeds excess charge through resistors, which is simple, low cost and fine for well-matched cells. Active balancing moves charge between cells, recovering usable capacity in large, aging or second-life packs at higher cost and complexity. We model your pack’s expected imbalance and duty cycle before recommending one.

For the right application, yes. INTERCAL8 builds wireless communication into BMS architectures to reduce wiring complexity and reliance on connectors. We design the link for the RF realities of metal enclosures, with message integrity checks, timeouts and a defined safe behavior if a node goes quiet.

Isolated and non-isolated DC-DC converters, bidirectional converters, chargers, auxiliary supplies and motor and inverter stages, with gate drive for silicon, SiC and GaN devices. Thermal design, magnetics selection and EMC filtering are part of every design from the start.

We size pre-charge for your bus capacitance and fault cases, sequence contactors in firmware with weld detection and economizers, and coordinate fuses so faults clear in the right order. For larger contactor banks, the INTERCAL8 ICL8-GP515 provides isolated, algorithmic switching.

It depends on chemistry, sensors and usage, so we show you measured error bands for your pack. LFP’s flat voltage curve defeats voltage-only methods. We fuse Coulomb counting with model-based estimators, such as an extended Kalman filter on an equivalent-circuit model, recalibrate at rest points, and validate against reference cycling data.

The fastest, most critical protection (short circuit and gross over-current) runs in hardware so software cannot delay it. Firmware handles voltage and temperature limits, derating, contactor logic, balancing, estimation and fault logging, with independent secondary protection for critical faults.

CAN and CAN FD, SAE J1939, CANopen, MODBUS RTU/TCP, RS-485 and SMBus at the device level. Bluetooth, Wi-Fi, LoRa and NB-IoT for telemetry, MQTT to the cloud, and OCPP when integrating EV chargers.

It is an edge-connected, cloud-based energy management system with a multi-company, multi-site interface. It connects to sensors and controllers to monitor, automate and optimize energy generation, storage and use. It reports on power sources and storage with historical, real-time and predictive analytics.

Yes. INTERCAL8 offers MES software for battery manufacturing. We also build the end-of-line testers, cell-grading stations, BMS flashing and calibration fixtures, and serial-level traceability that connect cells to finished packs.

Models trained on voltage, current, temperature and impedance trends estimate capacity fade and remaining useful life. They detect outlier cells (rising resistance, abnormal self-discharge) long before a cell trips a limit, and they flag thermal anomalies. Depending on latency and data needs, they run at the edge (for example on the ICL8-TM116 or a gateway) or in the EMS cloud.

Yes. Load and generation forecasts drive charge and discharge schedules for peak shaving, demand-charge reduction and time-of-use shifting. LOMA load managers then execute the shedding priorities, and the INTERCAL8 AI Assistant lets operators adjust the rules in plain language.

AI improves early warning. It does not replace hard protection limits. Dense temperature sensing combined with models of normal heating under a given current lets us flag a cell or connection that is warming abnormally, often well before an absolute limit is reached. Hardware and firmware limits still trip independently.

Send us a message through our contact form with what you’re building, where it will operate and your timeline. We’ll schedule a technical discovery call, then send a scoped, phased proposal, so you can begin with an architecture study or prototype and commit to production later.

Yes. We can own the whole system as a Team-in-a-Box, or take a defined piece (the power stage, the firmware, the cloud pipeline, the AI model) and work inside your repositories, toolchains and design reviews.

Yes. We carry designs from prototype through DFM and DFT reviews, test-fixture and end-of-line test development, pilot builds and full-scale production support.

Yes. We design to the target standard from the start, whether that is UL 1973, UL 9540A, IEC 62619, UN 38.3 or another. We run pre-compliance testing and prepare documentation and samples for the accredited lab.