Custom Lithium Battery Solutions for Cycling GPS Computers: Reliable Power for Smarter Navigation

The Evolution of Smart Cycling Electronics

Cycling has transformed into a connected, data‑driven experience. From competitive athletes to weekend enthusiasts, today’s riders rely on cycling GPS computers and navigation devices to record performance metrics, plan routes, and stay connected through Bluetooth and ANT+ sensors.

These compact devices integrate satellite positioning (GPS, GLONASS, Galileo), touch displays, real‑time analytics, and wireless communication—demanding stable and long‑lasting power. The riding experience depends on the battery’s ability to sustain performance through heat, vibration, rain, and long hours outdoors.

Market Trend: Growing Demand for Intelligent Power Systems

The global cycling electronics market continues to rise as smart, energy‑efficient mobility becomes mainstream. High‑end bike computers have evolved into miniature computers with data sync, voice guidance, and AI‑assisted routing—pushing batteries to deliver more energy in smaller spaces while remaining safe and cost‑effective.

Higher energy density for extended battery life without increasing volume.
Wider operating temperature range for mountain or winter rides.
Enhanced waterproofing to withstand rain, mud, and sweat.
Smart integration for USB‑C charging and digital communication with main boards.

Technical Requirements & Power Challenges

A cycling GPS computer typically draws 100–500 mA of continuous current depending on screen brightness, GPS mode, and connectivity, with peak loads up to 1 A. The pack must maintain stable 3.0–4.2 V output under intermittent spikes while minimizing internal resistance.

Requirement	Target / Notes
Energy Density	180–250 Wh/kg (Li‑ion NMC/LCO)
Capacity Range	1S: 1500–3000 mAh; 2S: 2200–4000 mAh
Cycle Life	≥ 500–800 cycles, >80% capacity retention
Temperature	Operation −10 ℃ ~ +60 ℃; charge 0 ℃ ~ +45 ℃
Ingress Protection	IP67–IP68 via encapsulated packs & sealed routing
BMS / Protection	OVP, UVP, SCP, OTP; optional fuel gauge (I²C)

Chemistry options: Li‑ion (NMC) for mainstream high capacity; LiFePO₄ for longer lifespan and safety; Li‑Po pouch for ultra‑slim form factors. For special shapes and harnesses, see our Custom Pack service.

Typical Battery Configurations

Device Class	Voltage	Capacity	Battery Type	Key Features
Compact GPS Tracker	3.7 V	1500 mAh	Li‑Po	Slim design, 10–20 h runtime
Standard Bike Computer	3.7 V	2200–2600 mAh	Li‑ion (NMC)	Balanced size & capacity, 20–30 h runtime
Advanced Navigation Unit	7.4 V	3000–4000 mAh	Li‑Po or Li‑ion	Dual‑cell, up to 40 h runtime
Rugged Industrial Cycling Device	7.4 V	4000–5000 mAh	LiFePO₄	Thermal & mechanical stability

All configurations include miniaturized BMS for electrical protection and optional communication with the device MCU (CAN / I²C). USB‑C charging and 5 V fast‑charge compatibility are available on request.

PKNERGY’s Engineering Expertise: Built for Outdoor Endurance

🧩 Tailored Form Factor: Custom Li‑Po packs matched to internal cavities for seamless assembly.
⚙️ Precision BMS Design: PCM/BMS with NTC sensors, advanced MOSFET protection, optional fuel gauge.
💧 Environmental Protection: Sealed laminates, silicone encapsulation, nickel‑tab welding for IP67+ performance.
🔋 High Reliability: Cell matching within ±5 mV for voltage consistency and extended lifespan.
🧠 System Integration: Support for USB‑C PD, ESD and surge protection.
🧪 Testing & Validation: Vibration, drop, overcharge, and 70 ℃ thermal endurance tests.
🌍 Compliance: UN38.3, IEC 62133, CE, UL; ISO 13485 available for medical‑grade models.

Case Study: Compact Power for High‑End Cycling Navigation

A European cycling computer brand required >30 h continuous operation with full connectivity (GPS + Bluetooth + ANT+). PKNERGY engineered a 3.7 V 2600 mAh Li‑Po (7 × 30 × 48 mm) with smart BMS, delivering:

+28% runtime vs. previous cylindrical solution
97% voltage stability under variable GPS load
Verified operation down to −10 ℃ in mountain testing
Full compliance: UN38.3, IEC 62133, CE

Result: electrical precision + mechanical adaptability for outdoor‑grade electronics.

FAQ

Which chemistry should I choose for a slim cycling computer?

For thin housings, Li‑Po pouch provides the best packability. If maximum cycle life and safety are priorities, consider LiFePO₄ with a slightly larger volume budget.

How do I estimate runtime?

Divide usable capacity (mAh × 3.7 V × efficiency) by average power draw (V × A). Validate with worst‑case profiles (max backlight, continuous GPS, live sync) and temperature derating.

Can you support fuel gauge and percentage display?

Yes. We integrate fuel‑gauge ICs over I²C for accurate SoC reporting and optional learning algorithms for aging compensation.

Do you offer waterproof packs?

We provide encapsulated packs and sealed harness designs targeting IP67–IP68, validated by immersion and spray testing.