Swap station for motorcycle battery-introduction and buying guide

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What is a swap station?

A swap station is where electric motorcycle owners quickly swap their empty batteries with fully charged ones. If you have an electric motorcycle or know anything about these rides, you already know that they run on rechargeable batteries. However, one problem with electric batteries is that charging can often take a while. So, rather than sit around until the batteries get charged, electric motorcycle owners can drop off dead batteries at swap stations and pick up a fully charged one. This process is known as battery swapping, and it helps overcome the problem of wasting time while charging motorcycle batteries.

Opportunities for Battery Swapping

Despite the risks and challenges associated with battery replacement for two-wheeled electric vehicles, their advantages in terms of rapid charging, infrastructure scalability and enhanced vehicle versatility contribute to the widespread adoption and integration of electric two-wheelers in transportation systems, while also offering additional opportunities.

Opportunities for Battery Swapping

Electric motorcycles have been nothing short of impressive since their introduction, and they are considered as one of the perfect alternative for carbon-emitting energy sources. Well, the battery-swapping process is one that you should be conversant

with if you wish to always keep your motorcycle in good working condition. Luckily, this article introduces everything you are curious about swap station, its functions, and the battery-swapping process.


Why do we need battery swapping station?

First, as mentioned earlier, it takes quite a long time to fully charge a motorcycle battery, while delivery workers and couriers need to charge several times a day due to the long mileage they dive, thereby wasting a chunk of precious time. With swap stations, this problem automatically eliminates itself, as riders don’t need to wait for their empty batteries to get recharged. Of course, you still need to submit the dead battery for recharge. But the waiting process is unnecessary, as you immediately get a full battery replacement to get back on the road as soon as possible.

Secondly, the power exchange cabinet can also ensure the safety of charging. When people charge themselves, there are often potential safety hazards due to improper charging methods or inability to observe and monitor the whole process. The battery swap cabinet has a built-in intelligent charging system, which can uniformly and safely charge the battery according to the charging curve, and monitor in real time. When a safety problem occurs, it can cut off the power in time and issue a warning, effectively improving safety performance.

In addition, changing the power cabinet can save money. Generally speaking, the motorcycle battery price accounts for a large percentage of the initial purchase cost of an electric motorcycle. Users of the battery swap station can directly use the batteries in the battery swap cabinet without buying batteries, which saves money to a large extent.

What is battery swapping technique?

Battery swapping technique includes various functions and devices of battery swapping cabinet, software technology of battery swapping APP and online management platform, as well as intelligent interconnection and adaptation among battery swapping cabinet, batteries and software. The most important technology in the battery swapping cabinet is the cabinet control technology, which can ensure convenient battery swapping service for users and unified intelligent and safe battery charging.


What are the challenges in battery swapping technology?

Here are some of the fundamental challenges of battery-swapping technology.

● The operation of the business model of motorcycle battery swap station requires a certain initial investment cost.

● Considering the particularity of the application scenario, the swap cabinet may be set outdoors, and the battery will be frequently used in a day. Therefore, the electric motorcycle swappable battery and swap cabinet need to be durable.

● Battery swapping success rate may also be limited by the fact that different electric motorcycle models may use unique batteries, thereby making the process more complicated.

How a swap station works and how to use a swap station

The working process of a swap station is pretty simple, especially when handled properly. Here’s how it works; when an electric motorcycle comes in for battery swap, it is parked at the bay where the swapping occurs. The battery is then swapped manually or automatically by a robot arm. The empty batteries are racked up for inspection, after which they will get recharged and redistributed to other riders.

There are three main steps when using a swap station, including taking out the battery, swapping the battery and returning the battery. When taking out the battery, first log in to user page in the mobile APP. First-time users need to choose a deposit plan according to their own needs and pay the deposit, and then purchase the package. After completing the operation on the mobile phone, user need to click on the touch screen to get the battery on the battery swap cabinet, scan the code to take out the battery, and close the cabinet door.

When swapping the battery, user need to find a nearby battery swap station through the mobile APP, scan the code on swap cabinet and put the battery into the cabinet after the cabinet door is opened, plug in the battery charging port, close the cabinet door and wait for the other cabinet door to open, and take out the new battery to complete a battery swapping process.

When returning the battery, user need to click the button of returning the battery in the mobile phone APP, enter the scanning page, scan the QR code of the battery swapping cabinet, put the battery into the open door, and plug in the battery charging port, then close the cabinet door.

How long does the battery swap station take?

The battery-swapping process is usually quick and stress-free, and riders can be back on the road right away. The battery change typically takes less than 2 minutes to complete, which is one reason why it is much preferable.

What are the benefits of swap station


One major challenges that electric motorcycles generally faced in their earlier days was the time required to charge batteries. Well, swap stations have made this problem a thing of the past, and that’s one of its major benefits. With swap station, users can exchange battery with a fully charged one in a matter of minutes. Here are other significant benefits.

● Swap stations help protect battery life by ensuring controlled and healthy charging.

● Since users can use the batteries in the battery swap cabinet, they don’t have to buy batteries for their motorcycle, which is a big save of money.

● Instead of buying new batteries and dropping old ones, battery swapping mode is more eco-friendly.

● The governments of many countries and regions are implementing the policy of replacing fuel with electricity, battery swapping mode has an advantage of policy support.

What are the disadvantages of swap station?

For all the fascinating benefits of swap station, it becomes very difficult to spot a disadvantage. But it has shown to have some few demerits for all these years, which include:

● Standardization of the size and specifications of battery swapping.

● Need to set up daily maintenance personnel

Swap station vs fast charging, which is the best?

While swap station is revolutionizing the electric two wheelers’ world with its fast and effective battery-swapping technique, a few eyebrows have been raised about the costs. Well, fast charging is an economically-friendly alternative since it is significantly cheaper. But then, motorcycle owners are often caught between choices trying to decide which is best.

And here are some comparisons between battery swapping vs charging station.

 Swap StationFast Charging
within 2min4~5 hours
CostAbout $0.6 per swapAbout $0.15
per 2-3 hours
Floor areaA 9-slot swap cabinet covers an area of 1㎡A 10-slot charging pile covers an area of at least 20㎡
Charging separately inside each swap cabinet slotCharging in an open-air environment, multiple motorcycles are parked together
Professional operation and maintenance team regularly check the swap cabinet, 24 hours online customer serviceThe users go for repairment or maintenance when the motorcycle or battery breaks down


The specifications of battery swap cabinet

The common battery swap cabinets on the market usually have four types: 5 ports, 8 ports, 9 ports and 12 ports. Among them, the battery swap cabinets of TYCORUN Energy have all these four sizes. The following table takes TYCORUN products as an example to list the specifications of different battery swap cabinets.


TYCORUN swap battery station for electric motorcycle batteries
Specification5 Ports8 Ports9 Ports12 Ports
Cabinet size400(W)*450(L)*1530(H)mm600(W)*560(L)*1682(H)mm790(W)*690(L)*1840(H)mm750(W)*540(L)*1800(H)mm
Maximum size in port260(W) *420(L) *200(H)mm128(W) *180(L) *330(H)mm160(W)*205(L)*365(H)mm260(W) *420(L) *200(H)mm
Number of battery ports5 ports(individual control)8 ports(individual control)9 ports12 ports (individual control)
Battery communicationRS485,CANRS485,CANRS485 2G ModuleRS485,CAN
Touch displayStandard, 5 inchesStandard, 13 inches Standard, 7 inches
Input voltage100~240VAC 50HZ100~240VAC 50HZ 100~240VAC 50HZ
Maximum input power3200W6200W 9200W/6500W(optional)
Single port maximum charging power750W900W 900W/1200W(optional)
Charge Voltage72V/60V/48V72V/60V/48V60V72V/60V/48V
Working environmentAltitude≤3000m, 0~55℃Altitude≤3000m,-10~55℃-10℃~+45℃Altitude≤3000m, 0~55℃
Dynamic Power AdjustmentDynamic safety fast charge, automatic monitoring and allocation, 24hbig data monitoringStandard Charging according to the BMS strategy Standard configuration, dynamically output charging power according to charging strategy
Protection performanceLightning protection / dustproof and waterproof IP54 / water immersion power-off protectionLightning protection / dustproof and waterproof IP54 / water immersion power-off protectionLightning protection / dustproof and waterproof IP54Lightning protection / dustproof and waterproof IP54 / water immersion power-off protection
Battery Health CheckStandard, need battery BMS supportOptional(need BMS support)StandardStandard configuration, cabinet inspection
High temperature detectionStandard, background warning functionStandard, background warning functionStandard, background warning functionStandard, background warning function
Remote monitoringStandard(Diagnose, manipulate online)Standard(Diagnose, manipulate online)Standard(Diagnose, manipulate online)Support (need to cooperate with management background, remote diagnosis/cabinet control)
Indicator lightStandard(3 colors’ LED)Standard(3 colors’ LED) Standard(3 colors’ LED)
CommunicationStandard 4G/WIFI, optional GPS/BTStandard 4G/WIFI, optional GPS/BTOff lineStandard 4G/BT, optional GPS/WIFI
Swapping methodScan QR / Reservation / Offline-swappingScan & Swap /Reservation/Offline-swappingSwapping stations can identify the battery SOC and pop out the fully charged one to useScan code to swap battery/reservation to swap battery/offline battery swap
CameraOptional (Outside with shelf)Optional(embedded or external) Optional(outlay)
Fire extinguisherS type aerosolS type gas-melt style S-type aerosol
AppearanceCan be customized according to customer needsUse the template or CustomizationCan be customized according to customer needsCan be customized according to customer needs


Can a swap station be customized?

Yes, swap station can be customized to specific motorcycle model to enable a fast and easy swapping process, and also, because we are cooperating with famous motorcycle manufacturers in China, custom electric motorcycle is also supported. But before setting up, you should consider your batteries’ model and availability.

The advantages of TYCORUN swap station

TYCORUN is a globally known manufacturer of high-tech custom lithium battery that have served electric motorcycle users reliably and efficiently. It is a top choice for swap station customization with their own manufacturing plants and automatic assembly equipment of high technology. Certainly, this is something you can expect for a manufacturer with over 16 years of experience performing at a high level, whose products have been exported to Europe, North America, South America, Africa, Middle East, Asia and other countries.


Are swap stations safe?

Like most modern technology, a common concern for many swap station customers is the safety level of these swap stations. Well, these concerns are not entirely misplaced, as swap stations come with a degree of risk. For example, operating a swap station wrongly can get you electrocuted or burnt. But then, these instances can only be triggered by the human factor which are as rare as they come. So, in general, swap stations can be very safe and reliable, posing minimal chances of danger to users.

And TYCORUN ENERGY’s battery swap cabinet ensures its safety due to the characteristics of multi-level protection. TYCORUN ENERGY’s battery swap cabinets are made of high-quality appearance materials, which will not fade for more than three years. The waterproof level is up to IP54, supports outdoor 24 hours of dust and rain prevention, also supports lightning protection and typhoon resistance. When the cabinet is flooded, it will provide power-off protection and early warning. When the power grid is overvoltage or undervoltage, it will start automatic protection.

How to install a battery swap cabinet

The battery swap cabinet is a significant part of a swap station, because it is the protective unit responsible for charging drained batteries and replacing damaged ones. It’s a system designed specially to eliminate the problem of slow charging to make the process much safer. But installing the swap cabinets can be tricky, and here are some pointers for your reference.

  • The first step requires you to plug in the external 4-core plugs in the correct order without error.
  • Secondly, start up the configuration, which can be done in three easy steps.
  • Turn on the leakage switch in the industrial control compartment.
  • Start up the cabinet by turning the power on.
  • Synchronize the bouncing threshold to activate as soon as a swap is initiated.

How much does it cost to use a swap station?

The cost of a battery swap station is consists of the following few parts.

  • Cost of a swapping cabinet: the price varies according to the brand and manufacture, but a lithium ion battery swapping cabinets usually costs about $2500, installation fee included.
  • Cost of batteries: The average cost of one lithium ion battery pack is $450.
  • Cost of software development: software development fee is also a big cost of starting a battery swap station business. It usually costs $32,000 – $48,000 to develop a medium-complexity app.
  • Cost of after-sales service and maintenance personnel: an intelligent battery swapping system usually supports 24 hours online customer service, and professional maintenance team regularly check the swap cabinet status, and this cost varies according to different regions.
  • Rent: for a battery swap station, the rent basically depends on the location. As a rough reference, you may also calculate it by doubling the unit price of electricity of the base location.
  • Power costs: since electricity costs vary from place to place, this cost depends on the location of the swap station to a large extent.


What to consider when looking for a swap station manufacturer

It is not very difficult to find swap station manufacturers today. But then, the fact that there are so many options now calls for a degree of scrutiny when selecting your swap station manufacturer. Here are some factors to notice when selecting swap station supplier.

  • Design: One of the most important factors to consider is the type of battery you will need for your swap station. Your manufacturer must have the capability to set you up with the exact battery types you need for your station getting up and running.
  • Cost: Another significant factor to think about is cost. It often takes substantial money to set up a swap station, and manufacturers can usually present different prices. You may want to pick a manufacturer offering a price closest to your initial budget.
  • Credibility: It’s also crucial to confirm that the manufacturer is credible before going ahead to commit so that you can easily trust them to deliver quality services.

Rapid Battery Swapping

Two-wheeled battery swap stations allow users to exchange their depleted battery packs for fully charged ones within a matter of minutes. This significantly reduces charging time compared to traditional plug-in charging methods, enabling users to quickly get back on the road and continue their journey without lengthy waiting periods.

Extended Range and Flexibility

With a battery swap station, two-wheeled electric vehicle users can effectively extend their vehicle’s range. By swapping out depleted batteries for fully charged ones, users can cover longer distances without worrying about finding a charging station. This increased range and flexibility make electric vehicles more practical and versatile for various riding needs.

Elimination of Charging Infrastructure Dependency

Elimination of Charging Infrastructure Dependency

Battery swap stations eliminate the reliance on extensive charging infrastructure. Instead of waiting for charging stations to become available or worrying about compatibility, users can simply visit a battery swap station and exchange their battery pack. This reduces the need for widespread charging infrastructure deployment, making electric vehicle adoption more feasible in areas with limited charging infrastructure.

Improved Time and Cost Efficiency

Improved Time and Cost Efficiency

Battery swap stations offer time and cost efficiency for users. The quick swapping process saves users valuable time compared to waiting for a vehicle to charge. It also eliminates the need for individual vehicle owners to invest in expensive charging equipment, as the infrastructure and maintenance costs are managed by the battery swap station operator. This affordability can further promote the adoption of two-wheeled electric vehicles.

Scalability and Rapid Deployment

Scalability and Rapid Deployment

Two-wheeled battery swap stations can be rapidly deployed and scaled up to meet increasing demand. These stations can be strategically placed in high-traffic areas, allowing for easy accessibility and utilization by a large number of users. The compact size of two-wheeled electric vehicles and standardized battery packs facilitate the establishment of a dense network of swap stations, supporting rapid expansion and coverage in urban areas.

Related Articles

Top 10 battery swapping companies in Thailand

Top 10 battery swapping companies in Thailand

The top 10 battery swapping companies in Thailand are Winnonie, Batt Swap, Swap and go, H SEM Power Station, ETRAN, Honda PCX Battery Smart, EGAT, ZHI EV Station, Gogoro and Strom.

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