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Customer Case: 18.5V High-Discharge Battery Pack for Cordless Chainsaw in Low-Temperature Outdoor Use

Customer Case Study
INR18650 · High Discharge
Power Tools
Pack: INR18650 · 18.5V · 6000mAh · 15A

18.5V High-Discharge Battery Pack for Cordless Chainsaw in Low-Temperature Outdoor Use

A cordless outdoor power tool manufacturer needed a battery pack that could handle high startup current and
continuous cutting load—while staying reliable in cold outdoor environments. PKNERGY engineered a compact
INR18650-based pack delivering 18.5V 6000mAh with 15A continuous discharge and controlled internal resistance
to reduce voltage sag and improve real-world cutting performance.

Nominal Voltage
18.5V
Capacity
6000mAh
Max Continuous Discharge
15A
Internal Resistance
≤ 120mΩ
Project highlight: The key challenge was preventing voltage sag during chainsaw startup and heavy cutting,
especially in colder outdoor conditions. We focused on high-discharge capability, low IR, and production-ready consistency.

Application Photo
Battery Photo
At a glance
15A continuous output
Low voltage sag
Outdoor-ready
Production-consistent

Introducing the Customer (Anonymous) & Their Journey

The customer is an outdoor power equipment manufacturer focusing on cordless tools for forestry, farm maintenance, and DIY users.
Due to confidentiality, we do not disclose the company name. For this case study, the project representative is described as a
realistic anonymous profile.

Project Contact
Michael Turner
Product Manager, Cordless Tools Division
Country / Region
Canada (British Columbia)
Outdoor operations in cold seasons
Typical Use Case
Cordless chainsaw cutting wood logs, pruning, and farm maintenance in off-grid environments.
Operating Temperature (Field)
Discharge: -20°C to 60°C (best performance -10°C to 35°C)
Charge: 10°C to 35°C (recommended indoor/vehicle charging)
Customer’s goal: launch a reliable battery platform for a cordless chainsaw product line that can handle high load cutting tasks
and remain dependable in colder outdoor environments.
Customer environment / device context (optional)

Challenges (What was going wrong)

1) High startup current & voltage sag
Chainsaw motors draw significant surge current at startup and under heavy cutting load. If the pack cannot sustain the current,
voltage sag may trigger protection or reduce cutting performance.
2) Outdoor cold temperature impact
In cold environments, internal resistance increases and available power drops. The customer needed reliable output
for winter forestry and farm maintenance use.
3) Mechanical robustness for handheld tools
Handheld power tools experience vibration and impact. The pack required a robust structure and stable connector interface
to avoid intermittent contact and field failures.
Engineering note
For high-load tools, the real differentiator is how the pack behaves under load:
internal resistance distribution, connector integrity, and threshold stability matter as much as rated capacity.

Solution (How PKNERGY engineered it)

PKNERGY delivered an INR18650-based battery pack platform optimized for cordless chainsaw power demand.
The pack was designed to support high continuous discharge and reduce voltage sag, enabling stable cutting performance
and improving reliability in outdoor conditions.

High Load Capability
15A continuous discharge supports startup and heavy cutting, helping reduce sudden power drops.
Low Internal Resistance
Controlled pack IR (≤ 120mΩ) improves voltage stability and performance consistency.
Defined Voltage Window
Charging cut-off 21.0V and discharge cut-off 12.5V for predictable control behavior.
Production Support
QC checkpoints and integration notes improved repeatability for future batch supply.

Technical Specifications

Parameter Value
Model INR18650
Nominal Voltage 18.5V
Nominal Capacity 6000mAh
Size 48.5 × 80.5 × 108.5 mm
Internal Resistance ≤ 120mΩ
Charging Cut-off Voltage 21.0V
Discharge Cut-off Voltage 12.5V
Maximum Constant Charging Current 2A
Maximum Continuous Discharging Current 15A
Cycle Life ≥ 300 cycles (80% DOD)
Weight 680g
Temperature Guidance (Project Reference)
Charge Temperature: 0–10°C (0.2C) · 10–35°C (2A) · 35–45°C (0.2C)
Discharge Temperature: -20–0°C (0.2C) · 0–10°C (0.5C) · 10–35°C (15A) · 35–60°C (0.5C)

Results & Customer Feedback

  • Stable cutting performance: reduced voltage sag during startup and heavy load cutting.
  • Improved cold-weather reliability: dependable output for outdoor operations in colder seasons.
  • More consistent user experience: fewer sudden slow-downs or protection triggers during use.
  • Production-ready platform: defined QC criteria supported future batch supply.
“Our chainsaw requires a battery that can handle high startup current and continuous load, especially in colder outdoor environments.
PKNERGY’s battery pack delivered stable power even during heavy cutting tasks, and the form factor fits perfectly into our handheld tool design.”
— Michael Turner, Product Manager (Canada) (Anonymous profile

Photo Gallery (Optional)

Replace each image URL with your WordPress Media Library link. Duplicate or remove cards freely.

Caption: battery pack overview.
Caption: tool battery interface / docking fit.
Caption: outdoor cutting application.

FAQ — Common Questions

Q1: Why do cordless chainsaws require high discharge capability?
Chainsaw motors draw high current during startup and heavy cutting. If the pack cannot sustain the current, voltage sag can reduce torque,
cause speed drop, or trigger protection. A high-discharge design improves cutting performance and reliability.
Q2: What happens to batteries in cold outdoor environments?
Cold temperatures increase internal resistance and reduce available power. Designing for low IR and validating load behavior helps maintain
usable output in winter conditions. Charging is recommended in warmer indoor/vehicle environments.
Q3: What information do you need for a power tool battery project?
Provide voltage, peak/continuous current, duty cycle (startup + cutting load), size constraints, connector/interface, charging method,
and tool installation photos. If you have motor specs or current waveform data, validation becomes faster and more accurate.
Q4: Can you supply stable batches for mass production?
Yes. We align QC criteria to application risks—commonly IR control, capacity verification, threshold stability, and mechanical checks—so
your production batches deliver consistent real-world performance.

Need a custom battery for power tools?
Share your voltage, peak/continuous current, size limits, tool interface photos, and operating temperature range.
Our engineers will propose a production-ready solution.
Post time: Jan-05-2026

Customize samples immediately

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