Inside a Storage Factory's Engineering Team: 2D Design to Hot Load Testing
Seven engineers own the full product lifecycle: 2D/3D and industrial design, small-batch prototyping, thermal and cycle testing, SOP work instructions, hot load testing with waveform checks on inverters, custom development, and after-sales repair.
Visitors touring a factory usually watch the production line. What actually decides whether a product can be built is the engineering team. This video shows our engineering department, seven people who own the product from design through after-sales.
How the team is organised
Engineering handles the full path: design, prototype testing, volume shipment, and after-sales repair. The space is tight, stacked with products and test equipment, but this is where drawings become hardware.
Development flow: drawing to prototype
Development starts with 2D and 3D design, then industrial design, where appearance, structure, and user interaction get fixed.
After design comes small-batch prototyping. Returned prototypes go through a full round of testing. Powering on and lighting up is not a pass.
What gets tested
Environmental testing is the baseline: high-temperature and thermal cycle tests. A battery behaves very differently when charged at low temperature, and high temperature stresses whether the BMS protection thresholds are set correctly.
Stability testing and various cycle tests follow. Cycle testing runs repeated charge and discharge to a set count and watches the degradation curve.
For inverters, hot load testing is the one that matters
New product testing happens in engineering. For inverters, the most important test is hot load: running the unit at full output in a set high-temperature environment while observing the output waveform.
Why this one? An inverter generates heat at full power, and high ambient temperature combined with load is the limiting case for its components. Room-temperature no-load tests miss the problems. Under hot load, inadequate thermal design and waveform distortion both show up immediately.
SOP is what makes volume production repeatable
The core of process work is the SOP, the standard work instruction. It fixes the steps, parameters, and acceptance criteria for every station.
What happens without one? The same model assembled by different workers varies a lot. One unit gets insufficient screw torque, another has wrong harness routing. Both may pass outgoing tests, and then the field failure rate climbs.
We are currently writing work instructions for a portable product. Custom products especially need an SOP written fresh, because no standard exists to reference.
Commissioning and after-sales
Some equipment needs software commissioning, such as protocol matching between the BMS and the inverter. That also sits with engineering.
After-sales repair is handled here too. When something fails, whether the cause is a design flaw or an assembly error, the people who designed it can tell fastest.
Custom development is what we are known for
Custom development is a defining capability here, and turnaround is quick. A customer raises a requirement, engineering assesses feasibility, produces a proposal, and builds a prototype. That chain is short, which is why response is fast.
Where the limit is
Strong engineering does not mean everything is possible. Non-standard certification, unusual chip selection, and very small minimum order quantities are constrained by supply chain and certification cycles. Engineering cannot override those.
FAQ
- Why do inverters need hot load testing?
An inverter at full output generates heat, and high ambient temperature combined with load is the limiting case for its components. Room-temperature no-load testing will not reveal whether thermal design is adequate or whether the output waveform distorts. Hot load testing observes waveform and temperature rise, and it is the single most important inverter test. - What role does an SOP play in battery manufacturing?
An SOP is a standard work instruction that fixes the steps, parameters, and acceptance criteria for each station. Without one, the same model assembled by different workers varies widely, and both rework and failure rates climb. Custom products especially need an SOP written for them.
Want the factory walkthrough video or a quote? Contact us with your application and our engineers will spec a system.