How to Choose Battery for Tracker?

Tracker Battery Application

Compared to general consumer electronics, tracker batteries are typically compact in size with limited installation space, yet they are expected to deliver long-lasting performance and remain stable in extreme environments such as high and low temperatures. Persistent industry pain points—such as battery swelling, leakage, low-temperature failure, and short charge-discharge cycle life—have long troubled both device manufacturers and end users. Against this backdrop, choosing a safe, stable, and high-performance tracker battery has become a crucial factor in determining product experience and brand reputation.

Tracker Battery Guide | How to Choose Battery for Tracker?

In the era of rapid development of the global Internet of Things and smart positioning systems, various intelligent tracking devices—such as GPS trackers, pet locators, logistics trackers, and vehicle anti-theft systems—are increasingly integrated into our daily lives and commercial operations. From the precise delivery of parcels to the protection of personal assets against loss or theft, tracker technology is becoming ever more indispensable. Behind these devices, the component responsible for continuous power supply and stable operation is the small yet high-performance-critical “tracker battery.”

1、What is a tracker battery?

A tracker battery is the core component that provides power to various tracking devices. It is commonly used in products such as GPS locators, pet trackers, vehicle anti-theft systems, logistics asset trackers, anti-lost devices for children or the elderly, and portable personal positioning terminals. These devices are typically compact and deployed across dispersed locations, often requiring the battery to operate independently—without relying on external power sources—for several days, weeks, or even months. Therefore, a tracker battery must deliver high energy density, low self-discharge, stable output, and long standby performance within a small physical footprint.

Functionally, a tracker works by receiving satellite signals and transmitting data over communication networks to enable real-time positioning. These functional modules—such as the GPS chip, communication module, microcontroller, Bluetooth, or Wi-Fi—place extremely high demands on the stability of the power supply. If the battery is interrupted, the device loses its tracking capability, directly affecting asset security and user experience, and potentially resulting in financial loss or reputational damage. Thus, the battery is not merely a “power source,” but a critical energy safeguard that ensures the stable operation of the entire system.

2、What are the basic requirements of a tracker battery?

Though small in size, the tracker battery serves as the lifeline of the entire positioning system. Unlike typical consumer electronics, tracker batteries must withstand complex, multi-scenario environments. Therefore, a tracker battery must meet the following fundamental requirements:

2.1 Ultra-long standby and high energy density

One of the defining characteristics of trackers is their long-term online status with low-frequency usage. Many devices only activate when triggered or during scheduled location uploads. As a result, a qualified battery must offer ultra-long standby capability, minimizing the need for frequent charging or replacement, and enabling continuous operation for several weeks or even months.

2.2 Miniaturization and lightweight design

Trackers are often installed in space-constrained locations such as pet collars, children’s backpacks, inside vehicles, or on cargo packages. This creates strict requirements for the battery’s size and weight. The battery must be slim and light, easily integrated with PCBs and electronic modules, and adaptable to various non-standard shapes. In this context, custom lithium batteries—especially soft-pack lithium polymer cells with flexible structures—have become essential.

2.3 Wide temperature performance

Many trackers are deployed outdoors or in harsh environments, such as under vehicle chassis, inside shipping containers, or attached to livestock. Batteries must be capable of discharging normally at temperatures as low as –20°C or even –30°C, while still functioning reliably in high-temperature environments up to 60°C.

2.4 Safety performance

As the core power source for unattended devices, the safety of tracker batteries is of critical importance. Incidents such as swelling, leakage, short circuits, or overheating can cause complete device failure or even fire hazards. Therefore, the battery must comply with safety regulations and certifications required by various countries or regions.

2.5 High reliability and low self-discharge

Trackers are often deployed and left unattended for long periods, placing high demands on battery reliability. The battery must resist aging, have a long cycle life (typically over 500 charge-discharge cycles), and maintain a low self-discharge rate to prevent significant capacity loss during extended storage or idle periods.

3、Common Types of Tracker Batteries and Their Comparison

The tracker market is expanding rapidly, with device types becoming increasingly diverse, leading to varied battery selection requirements. Currently, batteries used in trackers are mainly divided into two categories: primary batteries (non-rechargeable) and rechargeable batteries. Each type has its own advantages and disadvantages and is suited to different application scenarios.

Primary batteries were the earliest type used in basic GPS trackers, mainly including alkaline batteries, zinc-carbon batteries, and lithium primary batteries (such as Li-SOCl₂ and Li-MnO₂). Among these, lithium primary batteries are the most representative and are widely used in devices requiring ultra-long standby performance. As technology advances and user demands for environmental friendliness and reusability increase, rechargeable batteries have gradually become the mainstream, especially lithium-ion (Li-ion) and lithium polymer (Li-Po) batteries. Nickel-metal hydride (NiMH) batteries can still be found in some low-cost solutions but are gradually being phased out.

The following is a comparison table of various types of batteries used in trackers:

Battery Type	Chemistry System	Representative Models	Advantages	Disadvantages	Typical Application Scenarios
Alkaline Battery	Zn–MnO₂	AA / AAA / 9V cylindrical cells	Low cost, widely available, no charging system required	Low capacity, high self-discharge, non-rechargeable, bulky, not environmentally friendly	Disposable trackers, low-cost pet tags, entry-level non-networked trackers
Zinc-Carbon Battery	Leclanché	AA / AAA cylindrical cells	Extremely low cost, suitable for low-power disposable devices	Low voltage platform, prone to leakage	Simple disposable logistics tags, non-communicative cargo trackers
Lithium Primary Battery	Li-SOCl₂ / Li-MnO₂	ER14250, CR123A, etc.	High energy density, long standby, wide temperature tolerance, stable	Non-rechargeable, relatively expensive, fixed size, not eco-friendly	Military trackers, long-term vehicle/container tracking, extreme remote environments
Nickel-Metal Hydride Battery	Ni-MH	AA / AAA / NH123, etc.	Rechargeable, relatively eco-friendly, mature solution	Low energy density, bulky, higher self-discharge, poor low-temperature performance	Legacy civilian trackers, simple vehicle modules, non-integrated devices
Cylindrical Lithium-Ion	Li-ion (liquid)	18650, 14500, 10440, etc.	Moderate cost, high energy density, long cycle life, mature technology	Fixed size, limited design flexibility	Mid-sized vehicle trackers, motorcycle anti-theft systems, non-miniaturized industrial trackers
Lithium Polymer (Pouch Cell)	Li-ion (polymer)	302030, 402530, 503035, etc.	Customizable size, lightweight, high energy density	Slightly higher cost	Smart pet trackers, magnetic micro trackers, ultra-thin vehicle remote trackers

4、Why Are More and More Trackers Choosing Lithium-Ion Batteries?

Over the past three decades, lithium-ion battery technology has developed rapidly and has been widely adopted in products such as power banks, mobile phones, laptops, and electric vehicles. Today, this trend is quickly expanding into other sectors. Increasingly, tracker device manufacturers are moving away from traditional primary battery solutions and opting for rechargeable lithium-ion batteries as their main power source. The shift toward lithium-ion batteries for trackers is driven by several key factors:

4.1 Higher Energy Density of Lithium-Ion Batteries

One of the core demands of trackers is long-term online operation. Compared to traditional NiMH and alkaline batteries, lithium-ion batteries offer significantly higher volumetric energy density (typically reaching 550–650 Wh/L). This allows for a substantial increase in battery capacity without increasing the device size. For example, a compact 300mAh lithium battery paired with a low-power module can support continuous operation for more than two weeks, whereas a NiMH battery of the same size may only last a few days.

4.2 Customizable Sizes and Shapes

As trackers become smaller and more discreet, their internal structural space becomes increasingly limited. Lithium-ion batteries—especially soft-pack lithium polymer cells—can be customized in size and shape according to product design, including ultra-thin, curved, elongated, or irregularly shaped formats. This flexibility allows lithium batteries to be widely adapted for various terminal devices, from pet collars and wristband trackers to magnetic asset locators.

4.3 Excellent Environmental Adaptability

Lithium-ion batteries can be engineered for different usage environments by optimizing the cathode and anode materials, electrolyte formulations, electrode structure design, and packaging methods. Batteries can be designed to withstand extreme conditions such as –40°C low temperatures, 60°C high heat, and high humidity or corrosion, making them ideal for the complex and diverse scenarios in which trackers are used.

4.4 Greater Environmental Friendliness

With the promotion of carbon neutrality policies and environmental regulations like the EU’s RoHS and REACH, battery systems in electronic products are facing increasing pressure for recyclability and sustainability. Primary batteries, which are non-rechargeable, polluting, and difficult to dispose of, are being restricted in many countries. In contrast, lithium-ion batteries are rechargeable and reusable, making them more aligned with the principles of a green supply chain.

5、How to Choose the Right Tracker Battery Supplier?

In the fast-growing tracker industry, batteries are no longer just simple “standard components”—they have become core elements that impact the entire system. A qualified battery supplier is not merely a provider of batteries; choosing the wrong one can lead to underperforming devices, frequent after-sales issues, project delays, or even large-scale recalls. Therefore, selecting a battery supplier requires careful and comprehensive evaluation. Below are several key factors to consider when choosing a tracker battery supplier:

5.1 R&D Technical Capabilities

A qualified battery supplier must not only be capable of manufacturing batteries, but also possess full-spectrum R&D capabilities, including joint development with customers, customized design, application guidance, and reserves of advanced battery technologies. Special attention should be given to the composition of the supplier’s R&D team, annual investment in research, and their technical innovations in next-generation battery systems.

5.2 Quality Control Capabilities

When quality issues arise in battery products, the consequences can be costly. A reliable battery supplier must establish a comprehensive quality management system, including IQC (Incoming Quality Control), IPQC (In-Process Quality Control), FQC (Final Quality Control), and a full suite of safety testing procedures. The supplier must also hold key certifications to ensure product safety, consistency, and compliance with relevant standards.

5.3 Production and Delivery Capabilities

The tracker market is characterized by fast product iterations and fluctuating order volumes. Especially during the initial prototyping stage, suppliers must meet tight delivery schedules and support small-batch production. A competent supplier should have flexible production capacity and rapid prototyping capabilities—not only delivering initial samples quickly but also ensuring stable supply during mass production to avoid disruptions in the customer’s manufacturing timeline.

5.4 After-Sales Support

Batteries are chemical energy products that can be flammable or hazardous. During use, faults or safety incidents may occur due to environmental conditions, usage methods, or structural compatibility. A qualified battery supplier must be able to respond quickly, assist customers in identifying power-related anomalies, and provide failure analysis reports and technical solutions in a timely manner.

6、What Are the Precautions for Using Tracker Batteries?

Although lithium-ion batteries have become the mainstream power source for trackers, they are still chemical energy systems that are sensitive to usage conditions. In long-term operation, complex environments, and uncontrolled usage scenarios, improper handling, poor structural design, or incorrect charging methods can lead to performance degradation, reduced battery life, and even serious safety hazards such as swelling, leakage, or thermal runaway. Therefore, battery usage and risk management must be prioritized throughout the entire process—from design to deployment.

Below are several important precautions for using tracker batteries:

During the early stages of product structural design, determine the battery’s key parameters such as voltage, capacity, discharge rate, and operating environment. Based on this, define the battery dimensions and reserve adequate space in the tracker’s battery compartment. The compartment must allow sufficient clearance to avoid deformation of soft-pack batteries caused by tight assembly. If the tracker includes heat-generating components such as GPS modules, communication chips, or MCUs, the battery should not be placed in direct contact with these parts. When necessary, design thermal insulation or venting structures to manage heat dissipation.
Battery storage conditions must be strictly controlled. The ideal storage environment is 20–25°C with humidity below 60%. Avoid exposure to sunlight, high temperatures, or excessive humidity, which may accelerate battery aging or increase safety risks.
During production and assembly, ensure battery handling safety. Batteries that have been dropped must be isolated and should not be used in normal assembly. Lithium battery output terminals are often made of FPC or nickel strips; during soldering or cable routing, avoid repeated bending or pulling to prevent wire breakage or poor electrical contact.
End users should be instructed to use the original charger to charge the tracker. Ensure the charging voltage and current are correctly matched to avoid overvoltage or overcurrent that could damage the battery cells or protection circuitry.

7、Which Manufacturers Specialize in the R&D and Production of Tracker Batteries?

Iray Energy is a professional battery manufacturer specializing in tracker batteries, with many years of experience in the lithium-ion battery industry. Iray Energy offers one-on-one engineering support to assist customers in developing customized battery solutions for various types of tracker devices.

Currently, Iray Energy operates a modern manufacturing facility of over 10,000 square meters, equipped with multiple fully automated PACK production lines. The company employs more than 300 staff members, including 32 R&D engineers, and possesses full development capabilities ranging from cell selection and structural design to system integration.
Iray Energy provides services such as battery model recommendations, structural compatibility evaluations, sample verification, and dedicated engineering support for joint development and fast response. The company also maintains a comprehensive certification and delivery system, with all products capable of meeting certifications such as UN38.3, MSDS, IEC62133, CE, and RoHS.
With rapid mold customization, short lead times for samples, and support for flexible small-batch orders starting from 1,000 pieces, Iray Energy is well-suited to meet the needs of small to mid-sized tracker brands and ODM projects.

FAQs About Tracker Battery

Can tracker batteries be replaced?

Some tracker batteries are built-in and do not support user replacement, while others are designed to be removable. For devices that support battery replacement, it is recommended to use batteries with the same voltage, capacity, and connector specifications as the original.

How long can a tracker run on a single charge?

Battery life depends on factors such as battery capacity, power consumption design, and location update frequency. A typical 300–500mAh lithium polymer battery in low-power mode can support operation for 1 to 4 weeks. High-performance devices tend to have shorter usage time.

What types of tracker batteries are there?

Common types include primary batteries (lithium primary, alkaline, zinc-carbon) and rechargeable batteries (lithium-ion, lithium polymer, nickel-metal hydride). Among these, soft-pack lithium polymer batteries are the most commonly used in micro tracker devices.

How do I know when a tracker battery needs to be replaced?

If the device shows significantly reduced standby time, longer charging times, abnormal battery heating, swelling, or inaccurate tracking signals, it is a sign that the battery needs to be replaced.

What is the lifespan of a tracker battery?

Typically, lithium-ion batteries support about 500 full charge-discharge cycles. Depending on actual usage frequency, the battery lifespan ranges from 1 to 3 years.

Can using an incompatible charger damage the battery?

Yes. Using a charger with mismatched voltage or current can lead to overcharging, overheating, or damage to the protection circuitry, which shortens battery life and may pose safety risks. Always use a charger that matches the battery’s specifications.

📌 Tip:
For professional Tracker Battery customization or replacement solutions, feel free to contact the IrayEnergy engineering team. We’re here to provide efficient, reliable, and high-performance power solutions!