The LEVA-EU member has described its partnership in helping fellow member Cleantron develop the new CLP XL swappable battery to meet the high demands of off-highway mobility and construction applications.
The light electric vehicle engineering design company is proud to have worked on the development of Cleantron’s new swappable battery.
It explained that the vibrations and harsh environments of off-highway mobility and construction environments meant that there were strict locking and docking mechanism requirements to consider for the CLP XL’s design.
VROEGH’s role in developing CLP XL
For this project, VROEGH engineered a concept that was based on eliminating vertical play while ensuring stability under heavy vibration, which also struck a balance between an ergonomic handle and compact form factor.
By producing various functional prototypes, the VROEGH team was able to iterate and verify the design quickly, to ensure ease of use and robustness, bringing peace of mind for Cleantron and its customers.
Like in the market of electric mobility, electrifying construction machinery requires more than adapting existing battery technology. Machines operate in different harsh outdoor environments, face higher extreme power requirements, and are often produced in limited volumes. For OEMs, this makes battery selection and integration one of the most complex aspects of electrification.
With the introduction of CLP XL, Cleantron addresses challenges that are relevant for electric mobility as well. The modular lithium-ion battery combines rugged mechanical design with the flexibility required to support a wide range of machine architectures.
The CLP XL is built to withstand impact, vibration, dust, and temperature fluctuations typical of construction sites. Its housing protects single-sided fused laser-welded cells, delivering both safety and efficient thermal management. This robustness allows the battery to perform reliably in demanding outdoor conditions in on-road EV’s as well as in off-road applications, from compact loaders to excavators.
Like in last mile delivery and city logistics, ease and intuitive handling is important when it comes to handling and connecting the battery in a single movement. A glove-compatible handle enables one-handed docking and removal, simplifying on-board and off-board handling. Multiple 40V battery packs can be connected in parallel to increase capacity or in series to raise voltage to 96V, allowing OEMs to scale power without redesigning the system. A dedicated portable station enables quick on site docking and charging.
The battery’s multi-directional mounting capability supports integration into vehicles and machines with unconventional geometries, where space constraints and weight distribution are critical design parameters. This flexibility allows the same battery architecture to be deployed across different machine types, reducing engineering effort and component variation. While the CLP XL simplifies electrification from a technical perspective, project execution and system integration remain key challenges for many OEMs. To support faster and more manageable electrification projects, Cleantron works in close partnership with TVH, a global supplier of parts and accessories for construction equipment.
Through this partnership, OEMs gain access not only to the CLP XL battery, but to a broader, fully supported electrification ecosystem. TVH acts as systems integrator and distribution partner, enabling machine builders, especially those operating in high-mix, low-volume environments, to move from concept to prototype with reduced complexity.
TVH further supports OEMs with consultancy, global stock availability, CAN Bus communication support, and telematics solutions for monitoring and optimizing prototypes in real time. This integrated approach allows machine builders to focus on machine design and performance, rather than managing multiple suppliers and long development cycles.
For OEMs transitioning to electric mobility and construction machinery, the CLP XL offers a practical foundation for scalable electrification. Supported by TVH’s integration expertise, the battery system enables faster development, lower integration risk, and a more streamlined path from prototype to production.
The LEVA-EU member has provided a comprehensive overview of its validated Accurate State of Charge (SoC), an estimate for anticipating the performance, safety, and longevity of lithium-ion batteries. With this feature already being embedded in Cleantron’s BMS platforms, it details the challenges, validation and benefits it offers for OEMs.
For light mobility, industrial batteries, and construction machinery electrified platforms, the SoC has a direct influence on signalling range, peak power delivery, and the risk of misuse.
Cleantron emphasises that a strong SoC reading is a system-level requirement for indicating reliability, safety compliance and commercial viability.
An accurate State of Charge (SoC) estimation is obtained from voltage, current, temperature, and time using model-based algorithms. The SoC indicates how much usable energy remains, when power should be limited and when to proceed with protective actions. An accurate SoC is a quantity that’s not directly measurable.
The implications of an inaccurate SoC for OEMs and end-users
If the SoC is inaccurate for these stakeholders, it could pose risks, including:
Unexpected shutdown
Reduction of available power by conservative derating
Acceleration degradation due to suboptimal charging strategies
Suboptimal thermal management
Why extreme conditions pose challenges
Cleantron explains that limitations can arise from extreme operating conditions.
With low temperatures, internal resistance is increased, diffusion dynamics slow down, and open-circuit voltage curves are flattened. These effects decrease observability and amplify errors in estimations.
At high temperatures, side reactions and nonlinear degradation effects modify cell characteristics in various ways, which static models fail to capture.
Additionally, real-world operating conditions create highly dynamic current patterns. Fast transients, regenerative pulses, and high C-rate discharges lead to voltage polarization and hysteresis, which can distort the perceived State of Charge (SoC). Depth of Discharge (DoD) adds further complexity, as partial cycling differs from full cycling, and degradation mechanisms change depending on the operating range.
Cleantron states that with nonlinear, temperature-dependent, and cycle-dependent factors making SoC estimation challenging, it is important that algorithms stay stable and precise across the whole operational envelope, not just under nominal laboratory conditions.
The significance of validation and how Cleantron ensures it
Due to SoC not being able to be measured directly, its validation is conducted through experimental characterisation.
Cleantron has extensively fine-tuned its battery models with extensive validation across the whole temperature spectrum, with testing carried out at both high and low temperature extremities to monitor resistance shifts, capacity variation, as well as kinetic effects that can impact estimation performance.
Validation also covers various cycling strategies, with real-world drive cycles being used to imitate practical application loads, such as dynamic current profiles that represent end-use environments. Simultaneously, controlled artificial cycles have been applied to pinpoint specific electrochemical behaviours and stress conditions. For these tests, multiple DoD windows were used to verify the accuracy of partial and full cycling regimes.
Cleantron explains that its multi-dimensional dataset has brought a continuous improvement of model parameters, observer tuning, and validation against measurements of ground-truth, resulting in framework which brings a SoC estimation which remains stable, precise, and robust under temperature stress, high dynamics, and long-term cycling.
SoC benefits for OEMs using Cleantron battery systems
With Cleantron’s systems, OEMs can receive validated Accurate State of Charge estimations for predictable performance and reduced integration risk, with reliable range predictions, stable power availability for varied temperatures, and a decreased risk of unexpected shutdown or accelerated degradation.
As its models have been validated and tuned using realistic and worst-case scenarios, its battery system’s behaviour closely equals engineering expectations to reduce calibration effort, decrease development timelines, and optimise confidence for certification and customer use.
Cleantron prides itself on providing SoC validation in helping to ensure its battery packs are dependable energy systems.
How Cleantron supplies the electric vehicle industry
The company is a leading European producer of advanced lithium-ion batteries, which are innovated to provide long-term reliability with captive BMS technology. Its battery technology provides flexibility and dependability to help various company types, including microcars and light electric vehicles, to scale successfully
Its battery portfolio includes a full range of modular batteries, including low and high voltage solutions. As well as standard batteries, Cleantron is specialised in creating tailored battery modules for OEM customers.
LEVA-EU member Cleantron, a specialist producer of li-ion battery modules based in the Netherlands, has installed cutting-edge Trumpf laser-welding technology into its production line, allowing for increased output with enhanced product quality and reduced environmental impact.
Cleantron’s product design features a fused welding technology, giving every welded cell its own fuse, and so offering intrinsic battery safety. Laser welding is the key to enabling this safety feature.
Precision laser welding for multiple battery pack types
The equipment is described by Cleantron as a key production enabler, performing laser welding with high accuracy, speed and reliability across a wide range of battery cells. From swappable lithium batteries for LEVs to li-ion battery packs for industrial equipment, the machine ensures consistent results.
The system allows for rapid production changeovers and minimal downtime, enabling Cleantron to quickly shift between lithium ion battery 48v, 36V e-bike battery, and lithium ion battery 48v modules, and from low voltage to high voltage battery configurations.
Durable welds and smart BMS integration
Cleantron is able to ensure reliable connections within its lithium-ion battery products thanks to the Trumpf technology. The production line enables smart welding and built-in vision systems for high-quality joins, minimal defects, and full traceability.
Combined with Cleantron’s proprietary battery management systems (BMS), the precision of laser welding directly supports safer, longer-lasting, and smarter battery solutions designed to perform in demanding environments.
Efficient, environmentally friendly production
Cleantron highlights that the Trumpf technology allows them to reduce waste and the need for reworking, and boost production capacity, enabling enhanced consistency of product quality at both small and large production quantities.
With a wide range of lithium-ion battery products including those suited to the e-bike and light electric vehicle sectors, they provide reliable power solutions to European brands with minimal shipping miles, further boosting the sustainability of Europe-made products.
LEVA-EU members Cleantron and VanRaam worked together to improve the reliability of VanRaam’s special needs bikes, with Cleantron supporting them with advanced lithium-ion battery packs, reliable battery management systems and improved battery procedures.
It has been reported that European demand for special needs bikes grows annually at a rate of 16.9%, leading to manufacturers requiring cutting edge battery systems to help them meet this demand while bringing trustworthy performance for customers.
Cleantron assessment of VanRaam’s battery situation
VanRaam is a Dutch e-bike brand that specializes in increasing cycling inclusivity with products including adaptive bicycle-tandems, tricycles and side-by-side models. It was concerned about its existing e-bike batteries being able to reliably support its bikes and satisfy increasing demand levels for its products in Europe and North America.
When Cleantron first started working with VanRaam, the team noted that the brand had a battery design in place but was experiencing significant workflow issues. VanRaam’s existing battery set-up had flaws, lacked an assembly-friendly design, and was unable to meet the durability standards required for daily use. VanRaam’s production schedule was also being repeatedly interrupted by an inconsistent battery supply.
After carefully examining VanRaam’s battery situation, Cleantron calculated that it could provide VanRaam with improved technical reliability and a more stable supply chain.
How Cleantron helped VanRaam
Cleantron used its customer centred approach in listening closely, designing with precision and delivering consistently. It came up with a solution that prevents field breakdowns and simplifies operations to help it keep up with growing demands for special needs bicycles. The Cleantron team worked together with VanRaam engineers in designing custom NMC lithium ion battery packs for its adaptive e-bikes. The team also developed a proprietary battery management system (BMS) tailored to VanRaam’s needs as a solution for persistent electronic reliability issues and proposed improvements in detail, including waterproof housing and a simplified startup interface.
Results of the partnership between Cleantron and VanRaam
VanRaam has sourced over 100,000 Cleantron batteries, and according to internal estimates and standard industry performance baselines, it was estimated that the batteries likely reduced VanRaam e-bike system malfunctions by 90%. When there was a global components shortage, Cleantron maintained 98% of its on-time delivery performance, which was essential in supporting VanRaam’s supply chain to operate efficiently to meet increasing demand.
A testament of this successful partnership is that more customers are associating VanRaam bikes with trust and durability, reflecting increasing confidence in independent mobility. Notably from 2021-2024, VanRaam’s annual sales units reportedly increased by over 20%.
Cleantron and its commitment to providing high performance solutions while supporting the environment
Cleantron is a leading European battery manufacturer, innovating advanced lithium-ion battery technology for a wide range of mobility applications, from e-bike battery systems to batteries for light electric vehicles, to custom-made lithium ion battery solutions, with each of its products being powered by custom engineering, robust BMS integration and a relentless dedication to long-term reliability.
The brand has also recently been granted a subsidy from the Dutch government to boost high-tech production of its advanced lithium batteries which are engineered and produced in the Netherlands, to help achieve Dutch climate objectives and contribute to a more sustainable future.
