Key Design Points of Commercial & Industrial Energy Storage Systems – PACK Structure
Key Design Points of Commercial & Industrial Energy Storage Systems – PACK Structure
The structural design of energy storage PACKs plays a crucial role in ensuring the safety, performance, cost-effectiveness, and adaptability of the battery system to different application scenarios. The design process must meet several key criteria, including manufacturing process and assemblability, structural strength, environmental adaptability, safety protection, and thermal protection.
I. Manufacturing Process and Assemblability Design
The structural design of energy storage systems must meet specific criteria for manufacturing and assemblability. Common manufacturing processes for structural components include stamping, injection molding, casting, forging, and welding.
Key Considerations:
- Manufacturing Process:
- Production equipment, batch manufacturability, modeling, machining accuracy, heat treatment, and cost.
- The design must fully consider these factors to ensure manufacturability.
- Assemblability:
- The ability of structural components and their assembly elements (parts or sub-assemblies) to be easily assembled.
- Reasonable Layout:
- The overall layout of the energy storage system should be simple and divided into manageable components.
- Reliability and Safety:
- The design should adopt proven and mature structures to ensure reliability.
II. Structural Strength Design
The lifecycle of an energy storage product includes manufacturing, transportation, commissioning, and operation/maintenance. Each stage requires specific structural strength design guidelines.
Key Stages:
- Manufacturing Stage:
- Focus on production efficiency and safety during short-distance transportation (e.g., moving, handling, lifting).
- Main load: Vertical gravity acceleration.
- Transportation Stage:
- Includes sea/air transportation, road transportation, and field short-distance transportation.
- Commissioning Stage:
- Involves equipment lifting and positioning.
- As integration increases, system power expands from 1-2MWh to 3-6MWh.
- Operation and Maintenance Stage:
- Design must withstand harsh environments during operation and maintenance.
III. Environmental Adaptive Design
The energy storage system must meet local environmental and lifecycle design guidelines. Structural components must withstand rain, snow, salt spray, and other conditions.
Key Considerations:
- Climatic Environment:
- Salt spray test requirements: ≥96h (can extend to 168-480h or 720h for harsh environments).
- Outdoor Operating Environment:
- Structural design must meet IP rating guidelines (e.g., IP54 for general systems, IP55+ for high wind/sand/salt spray areas).
- Special Environmental Requirements:
- High wind/sand areas: Wind and sand resistance design.
- High-altitude areas: Heat dissipation design under low pressure.
IV. Safety Protection Design
Safety protection is critical due to the complexity and variability of the external and internal environments. Structural components must withstand disasters like wind, sand, falling rocks, and hail, as well as electromagnetic interference and temperature shocks.
Key Considerations:
- Internal/External Impact Prevention:
- The design must prevent structural failure caused by aging or battery cell failure.
- Multi-Level Protection:
- Multiple isolation and shutdown mechanisms to cut off abnormal current, voltage, or temperature.
V. Thermal Protection Design Guidelines
Thermal protection is essential to ensure the safe operation of energy storage systems.
Key Measures:
- Automatic Fire Suppression:
- Equip energy storage cabinets with automatic fire extinguishing devices.
- Combustible Gas and Smoke Detection:
- Early detection and response to fire hazards.
- Fire-Fighting Medium:
- Use environmentally friendly extinguishing agents like perfluorohexanone or sevofluoropropane.
- Thermal Management:
- Liquid or air cooling systems to maintain core temperature differences ≤5℃ (≤10℃ for air cooling).
- Environmental Adaptability:
- Operate at -20℃ to +50℃, altitude ≤2000m, and relative humidity ≤95%.
- Temperature Rise Limit:
- Meet standards for temperature rise limits.
- Active Fire Suppression:
- Actively intervene during thermal runaway to minimize system loss.
Conclusion
The structural design of energy storage PACKs is a comprehensive process that ensures safety, performance, and adaptability across various application scenarios. By adhering to manufacturing, strength, environmental, safety, and thermal protection guidelines, energy storage systems can achieve optimal reliability and efficiency.
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