Transportation Vibration Simulation Verification and 5000-kilometer Road Test Validation
In the context of global energy transition, commercial and industrial energy storage systems, as key technologies for balancing energy supply and demand and improving energy utilization efficiency, are showing a trend of rapid growth and diversified development. In particular, liquid-cooling energy storage systems, with their excellent thermal management performance, precise temperature control, and the advantage of significantly extending battery life, have quickly become the focus in the energy storage industry, have achieved breakthrough progress in technological innovation and the expansion of application scenarios, and their market scale has also shown explosive growth. They are widely applied in various fields such as factories, shopping malls, office buildings, data centers, grid energy storage, renewable energy grid integration, and microgrid energy storage, and have become one of the most dynamic and promising technological directions in the current energy storage sector.
However, with the widespread application of commercial and industrial liquid-cooling energy storage systems in various fields, the environmental adaptability challenges they face in complex and dynamic operating conditions have become increasingly prominent. Whether in the large-scale production scenarios of factories, the diverse functional areas of commercial buildings, or the vast geographic scope and varying operational conditions of distributed energy systems, commercial and industrial liquid-cooling energy storage systems must cope with numerous harsh environmental challenges. These challenges include not only changes in common environmental factors such as temperature and humidity, but also extreme events like snow loads, strong winds, and earthquakes, as well as complex conditions such as vibrations and shocks. All of these pose significant threats to the stable operation and performance of the energy storage system, making them key issues that need to be addressed in the practical application of commercial and industrialenergy storage systems.
Although the industry has recognized these challenges and is striving to improve the environmental adaptability of energy storage systems, current solutions still have limitations. Many product designs have not fully considered the impact of extreme environments during the design phase, leading to reduced equipment performance, increased failure rates, and even potential safety incidents, posing serious threats to the surrounding environment and personnel safety.
To address such issues, Pylontech, in collaboration with TÜV Rheinland has jointly released the "High Environmental Adaptability White Paper for commercial and industrial Liquid-Cooling Energy Storage Systems." The paper aims to explore the high environmental adaptability of commercial and industrial liquid-cooling energy storage products, analysing its importance and necessity. We will examine the topic from multiple angles, including application scenarios, market demand, current technological development, and accident case studies. The white paper will also highlight Pylontech's technological innovations and practices in enhancing product environmental adaptability. The goal is to provide the industry with a basis of reference to drive technological advancements in the environmental adaptability of commercial and industrial liquid-cooling energy storage products, ensuring their safe and reliable operation in various complex environments, and contributing to a green and sustainable energy future.
1.1 Analysis of Application Scenario
The mismatch between power supply and demand can occur at any stage of power generation, transmission, distribution, or consumption. The core value of energy storage technology lies in its ability to effectively address the differences between power supply and demand in the dimensions of time, space and capacity. Energy storage technology has been widely applied on the generation side, grid side, and user side. They include but are not limited to the following scenarios:
Generation side
1. Power generation level
Renewable energy power smoothing
Enhancing the dispatchability of renewable energy generation
2. Ancillary power services level
FM service Reserve capacity service (RCS)
Grid side
1. Power transmission level
Improving the utilization of transmission lines
Enhancing the stability of the transmission system
2. Power distribution level
Improving power quality
Optimizing the operation and the distribution network
3. Grid ancillary services level
Peak shaving service
Black start service
User side
1.
Basic electricity consumption level
Reducing electricity costs, achieve arbitrage between peak and off-peak hours and manage demand
Improving electricity reliability: backup power support, microgrid construction
2. Energy management and optimization level
Participating in demand response: obtain subsidy benefits and optimize energy utilization
Achieving integrated energy utilization and smart management
Commercial and industrial energy storage, as a typical application of user-side energy storage, is rapidly penetrating various fields during the critical period of energy transition and power system transformation. From independent energy storage configurations within enterprises to complex campus-level integrated energy utilization, and emerging applications in distributed energy integration and power market innovations, commercial and industrial energy storage systems are bringing new opportunities and models to energy management and operations, profoundly influencing power supply structures and energy utilization efficiency.
These diverse application scenarios are intertwined, creating a complex situation that imposes high requirements for environmental adaptability on commercial and industrial energy storage system manufacturers. Energy storage products need to adapt to different natural environmental conditions, such as high temperature, high humidity, heavy snow, strong winds, and more. At the same time, they must meet high standards in terms of technical performance, including physical protection, electrical performance, structural strength, and other aspects. Additionally, installation conditions, such as spatial layout, are also important factors to consider. Only by meeting these stringent requirements can energy storage systems maintain stable and reliable operation in diverse scenarios, ensuring that their key role in the energy sector is fully utilized, and providing a solid foundation and strong support for the sustainable development and energy transition of commercial and industrial sectors.
Scenario Classification
Considerations
Environmental temperature
Sand and dust protection
UV resistance
Adaptability to salt mist environments
Temperature and humidity control.
Electromagnetic interference and safety
Seismic resistance
Temperature and humidity
Chemical corrosion
Fire prevention and ventilation
Electromagnetic interference
Detailed Description
Energy storage systems need to adapt to both high and low-temperature environments. Liquid cooling systems must operate stably under high temperatures, while in cold regions, ensuring battery performance is crucial.
Energy storage systems must have a robust outer casing to prevent sand, dust, and other elements from affecting heat dissipation and electrical performance.
Energy storage systems must use UV-resistant materials to prevent material aging and ensure long-term stable operation of the system.
Energy storage systems in coastal areas must use corrosion-resistant materials and undergo special anti-corrosion treatment to ensure long-term stable operation.
Energy storage systems must operate stably within standard temperature and humidity ranges and be able to tolerate certain deviations from these ranges.
Energy storage systems must comply with electromagnetic radiation standards to avoid electromagnetic interference and meet fire safety and electrical safety standards.
Energy storage systems must consider seismic design, using anti-seismic brackets and vibration-damping measures to withstand earthquakes or other vibration disturbances.
Energy storage systems must be equipped with advanced thermal management technology to adapt to extreme temperature and humidity differences, ensuring battery efficiency and safety.
Energy storage systems must have a high protection rating, using corrosion-resistant materials and special coatings to withstand chemical corrosion and dust accumulation.
Energy storage systems must be fire-resistant and feature good ventilation design to ensure timely discharge of heat and harmful gases.
Energy storage systems must have excellent electromagnetic compatibility, ensuring signal stability through shielding measures and complying with electromagnetic radiation standards.
Specific Application Scenarios
Solar power plants, wind farms, photovoltaic (PV) systems, and other renewable energy generation systems.
Wind power stations, photovoltaic (PV) power plants in desert areas, and others.
Outdoor-installed energy storage systems, such as rooftop solar energy storage systems.
Coastal wind farms, photovoltaic (PV) power plants, and others.
Data centers, power trading venues, and other indoor environments.
Power market trading facilities, and areas with dense electronic equipment.
Seismic-prone areas, data centers, and other vibration-sensitive regions.
Industrial factories, commercial buildings, data centers, and others.
Chemical plants, cement factories, coal mines, and other industrial environments.
Commercial buildings, industrial factories, and other densely populated areas.
Industrial factories, commercial buildings, data centers, and other areas with high electromagnetic interference sources.
1.2 Analysis of Market Demand
The global demand for clean and sustainable energy solutions is continuously rising. In this background, market expectations for the performance of energy storage products are also increasing. Specifically, in terms of environmental adaptability, the market is no longer limited to considering a single environmental factor. Users now expect energy storage systems to handle a variety of potential and complex environmental conditions while maintaining stable operation to meet the demands of practical applications.
1.2.1 Demand for Operational Continuity
Commercial and industrial operations have extremely high requirements for the continuity of power supply. Regardless of the environment, energy storage systems must ensure stable charge and discharge performance and energy conversion efficiency. For example, preventing battery thermal runaway in high temperatures, ensuring battery activity in low temperatures, avoiding electrical short circuits in high humidity environments, maintaining signal stability in strong electromagnetic interference environments, and ensuring secure component connections in mechanical vibration environments. These measures help reduce downtime and ensure continuity of activities such as enterprise production, business services and data processing.
Temperature adaptability
Maintain stable performance in high and low-temperature environments to ensure charging and discharging efficiency.
Electromagnetic interference protection
Effectively resist electromagnetic interference to protect the system's core components.
1.2.2 Demand for Specific Environment
Humidity tolerance
Maintain normal operation in high humidity environments to prevent damage to internal components.
Resistance to mechanical vibration
Maintain stability in continuous vibration environments to ensure long-term reliable operation.
Due to the differences in local environments and conditions, commercial and industrial users in different countries and regions are increasingly demanding customized energy storage systems. Users require tailored designs based on the geographical environment, climate conditions, and internal space layout and operational characteristics of their respective countries. For example, in earthquake-prone countries like Japan, commercial and industrial users demand energy storage systems with high seismic resistance to withstand frequent earthquake disasters. In European countries such as Germany, where environmental protection and safety standards are stringent, energy storage systems need to comply with local environmental regulations and safety standards, such as adopting solutions with higher environmental and safety performance in material selection and design.
Country
Environmental adaptability requirements
Protection level: The prefabricated cabin (cabinet) type lithium-ion battery energy storage system shall have a protection level of not less than IP54 [GB/T 4208], and the exposed connectors shall comply with IP67.
Working temperature range: -20℃ to 50℃(based on the requirements of GB/T 4208 and GB/T 44026-2024 for prefabricated cabin (cabinet) type lithium-ion battery energy storage systems. Some high altitude, extremely cold or hot areas may have special requirements)
Anti-corrosion performance: Coastal or high salt spray areas, in line with GB/T 30790.2 in the C3 grade [GB/T 44026-2024].
Seismic performance: AS 1170.4;2007, AS 2121:1979. China America
UV resistance: Under long-term outdoor lighting, the UV resistance of the external insulating parts of the cabin complies with GB/T 7251.1 [GB/T 44026-2024].
Seismic design: GB 18306-2015, at present, many governments such as Fujian Province has begun to pay attention to the requirements of the installed capacity of more than 1GW of energy storage power station to carry out site seismic safety evaluation
Working temperature range: -10℃ to 45℃ (Based on the requirements of UL 9540, Standard for Safety of Energy Storage Systems and Equipment, for energy storage equipment installed in areas susceptible to seismic activity, such as California)
Seismic requirement: Standards exist in different regions based on seismic risk levels. For example, UL 9540 “Standard for Safety of Energy Storage Systems and Equipment” stipulates that energy storage equipment installed in areas susceptible to seismic activity (e.g. California) should be evaluated for seismic resistance according to standards such as IEEE 693 and IEC 60980.
Battery thermal runaway prevention: UL9540A Test Required
Temperature control: Temperature difference ≤ 3°C (Based on the requirements of JEAG 5003 and SAE J2464 NOV 2009, for seismic performance testing)
Seismic performance: International standard IEEE 693, IEC 60980, Japanese local standard JEAG 5003, SAE J2464 NOV 2009, etc., and the cell needs to pass the specified extrusion test and puncture test, etc.
Environmental friendliness and energy efficiency: Liquid-cooling energy storage systems need to have efficient heat dissipation performance in accordance with the requirements of VDE-AR-E 2510-50 on heat dissipation efficiency.
Working temperature range: -15℃ to 40℃ (Based on the requirements of VDE-AR-E 2510-50, for liquid-cooling energy storage systems).
Heat dissipation performance and high-temperature adaptability: Normal operation in high-temperature environments of 45℃ and above (Based on the requirements of AS 1170.2:2011 Structural design actions-wind actions, for outdoor products)
UV performance: Outdoor product polymer shell and product labels need to have UV resistance; product labels need to be tested according to IEC 60068-2-5 Ed3 2018 for UV resistance.
Dustproof performance: Good dustproof performance.
Wind resistance: Refer to AS 1170.2:2011 Structural design actions-wind actions.
Corrosive performance: Salt spray test and evaluation with reference to IEC 60068-2-52.
Globally, as a long-term investment project, commercial and industrial energy storage systems are expected to maintain high environmental adaptability throughout their entire lifecycle. This means that the selection of materials for energy storage systems must consider environmental aging factors varying across different countries and regions. For example, in areas with strong ultraviolet radiation (UV) like Australia, the outer casing materials of the energy storage system should feature excellent UV - aging resistance; in regions with severe industrial pollution, they should also possess chemical corrosion resistance. The design and manufacturing processes must ensure that the system structure remains stable under long-term exposure to harsh environments, such as prolonged outdoor exposure, sudden temperature and humidity changes, and industrial chemical corrosion. This ensures the long-term reliable operation of energy storage systems across different countries and regions globally, achieving good return on investment and sustainable development.
1.2.4 Demand for Power Supply Reliability
In recent years, the frequency and intensity of extreme weather events have been on a significant upward trend. For instance, extreme weather phenomena such as heavy rainfall, floods, hurricanes, heatwaves, and freezing cold spells have become increasingly frequent, posing enormous pressure and challenges on power grids worldwide. These extreme weather events can lead to grid overloads, and may even cause grid failures and power outages, severely disrupting the normal functioning of society and impacting people's quality of life. In this context, energy storage systems, as crucial tools for ensuring the stability of power supply, must possess strong response capabilities, enabling them to quickly adapt to extreme environmental conditions and provide stable and reliable power support to the grid.
Fire and flood prevention design
Use high-grade waterproof enclosures to protect the system from heavy rain and flooding.
Wind-resistant structure
Reinforce the system structure to withstand high wind speeds and extreme weather conditions such as hurricanes.
Temperature regulation system
Equipped with advanced cooling and heating systems to handle extreme temperature fluctuations.
1.3.2
Withstanding Natural Disasters
Natural disasters, such as earthquakes and hurricanes, pose severe challenges to the installation and operation of energy storage systems, highlighting the crucial role of high environmental adaptability in ensuring product safety.
First, the impact of earthquakes on energy storage systems cannot be ignored. In seismic zones, energy storage equipment may be displaced, damaged, or even toppled due to seismic forces. Battery modules could suffer internal structural damage, increasing the risk of short circuits. For instance, In the 2011 Fukushima earthquake and tsunami event [1], some energy storage facilities were scrapped due to the earthquake and tsunami impacts, causing huge economic losses and highlighting the importance of high environmental adaptability in product safety. Therefore, in earthquake-prone regions, it is crucial to install energy storage systems with strong seismic resistance, which can maintain structural stability during an earthquake, minimize component damage, ensure power supply, reduce repair and replacement costs, and enhance the reliability and safety of the energy supply system.
Secondly, meteorological disasters also have a severe impact on energy storage systems. Strong winds can cause storage equipment supports to bend or break, while snowstorms and heavy rains can lead to deformation of the equipment housing and electrical short circuits. In 2021, Hurricane Ida struck Louisiana, USA [2], bringing strong winds and heavy rains that caused extensive damage to local commercial and industrial facilities. According to preliminary statistics from local power companies and authorities, approximately 25% of the commercial and industrial energy storage systems in the affected areas were damaged to varying degrees, significantly increasing repair and replacement costs. Energy storage systems with strong environmental adaptability can continue to operate normally during such disasters, reducing safety risks, lowering operational costs, and extending service life.[2]
Additionally, other environmental factors must also be considered. Energy storage products with high environmental adaptability need to resist the intrusion of dust and pollutants to reduce the risk of failure. In high-altitude areas, storage equipment requires special insulation designs and testing, as well as the use of specialized battery technologies or heating and insulation measures. In coastal regions, corrosion resistance must be prioritized, while in mountainous or other areas with complex terrain, the stability and durability of the mechanical structure must be taken into account.
In summary, the high environmental adaptability of commercial and industrial liquid-cooling energy storage products is a key factor to their stable operation in complex scenarios, ensuring personal safety, and reducing operational costs. As the market demand for high-performance, highly reliable energy storage products continues to grow, environmental adaptability will become an essential competitive advantage and development trend for commercial and industrial liquid-cooling energy storage products.
The Current Status and Challenges of Technology Development
Comparison Items
Heat Dissipation Efficiency
Temperature Uniformity
Temperature Control Precision
Air - cooling Energy Storage System
Air has a low specific heat capacity, requiring large flow rates and resulting in temperature differences. The convective heat - transfer efficiency is low, and natural convection is even worse. It depends on the ambient temperature and air flow, with poor performance in high - temperature or non - ventilated conditions.
Uneven air flow, prone to local overheating.
It is difficult to ensure temperature consistency in large - scale systems.
Liquid - cooling Energy Storage System
Liquids have a high specific heat capacity and can absorb more heat. Direct contact heat transfer, with a short and efficient heat - transfer path.
Precisely control the flow rate and temperature of the coolant according to the battery's heat generation.
System Compactness
Low precision, ±2 - 5°C, difficult to meet high - precision requirements. Greatly affected by changes in ambient temperature, it is difficult to maintain a constant temperature.
Requires a large air - flow space, such as large heat - dissipation fins and ventilation channels.
Components (such as fans and heat - sinks) are large in size, with a loose structure and low space utilization.
Reasonable layout of liquidcooling pipelines ensures uniform temperature.
Adjust the flow rate and direction to balance temperature differences.
Advanced sensors and control systems with a precision of ±0.5°C. Fine - tune the coolant parameters to maintain a suitable temperature.
Noise Control
Obvious noise, with large noise generated by high - speed fan operation.
The evaporative - side heat exchanger of liquid - cooling is small in size, such as plate - type or shelltube heat exchangers.
Flexible pipeline layout, compact design, saving space and improving energy density.
Relies on coolant circulation, with low operating noise.
In recent years, safety incidents involving energy storage systems have occurred frequently. In 2019, a fire broke out at an energy storage facility in Arizona, USA [3], due to the failure of the cooling system under high temperatures, resulting in eight injuries.
In the same year, an energy storage system in a coastal area experienced performance degradation and eventual failure due to insufficient moisture-proof measures, which caused the batteries to deteriorate in a humid environment. Additionally, South Korea has witnessed multiple energy storage fires, such as the incident in Gyeongsangnam-do in 2017, where inadequate structural strength of the battery racks led to abnormal heating of a battery module, which compressed adjacent modules, causing sequential damage and rapid fire spread. In June 2024, a severe fire at a lithium battery factory in Hwaseong City, Gyeonggi Province, South Korea [4], resulted in 23 deaths and 8 injuries. The fire escalated from white smoke to open flames in just 30 seconds and took 22 hours to extinguish. These incidents underscore the necessity of considering high-temperature tolerance, moisture resistance, and structural strength in the design of energy storage systems to ensure safe and stable operation under various harsh environmental conditions.
Pylontech's Solutions
Pylontech has proposed a series of innovative technical strategies and solutions to address the environmental adaptability issues of commercial and industrial liquid-cooling energy storage products, ensuring the stability and safety of the products in various complex environments.
3.1 Intelligent Liquid-Cooling Strategy for Precise Temperature Control
Temperature control of the battery system is a critical factor in ensuring battery performance, safety, and longevity. Pylontech’s liquid-cooling battery energy storage system employs an advanced intelligent liquid-cooling strategy, which, through precise temperature control, ensures the cell is always at its optimal operating temperature over a wide temperature range. Taking the M7 liquid-cooling energy storage system as an example, this product can automatically switch between hot start, cold start, and insulation modes based on ambient temperature and battery status, ensuring stable operation even under extreme temperature conditions. The successful implementation of this strategy is attributed to Pylontech's meticulous design in the following aspects:
Wide Temperature Range:
The design of the intelligent liquid-cooling system enables it to adapt to various extreme temperatures, ensuring the stable operation of the energy storage system under these conditions. Pylontech’s M7 liquid-cooling energy storage product, can achieve smooth operation in outdoor environments ranging from -25°C to 45°C under the control of the liquid-cooling system, as shown in the figure below.
Cell Temperature Curve-25℃ 0.5P Cold Start & Charge/Discharge
During the cold start phase, the lowest temperature of the battery cell increased from -25.6°C to around 10°C in 11.2 hours, and it took 12.9 hours to reach 13°C to exit the heating phase.
During the insulation phase, the liquid cooler took about 2 hours each time to heat the lowest temperature of the battery cell from -10°C to above 13°C, and then restarted heating after an interval of about 2.4 hours.
Second round of charge/discharge
First round of charge/discharge
Adjustment Function:
The intelligent liquid-cooling system can automatically adjust its cooling strategy based on monitored temperature changes to adapt to different thermal loads and environmental temperatures, ensuring the battery maintains a stable temperature under various conditions.
Low Power Consumption Operation:
The intelligent liquid-cooling strategy ensures stable battery temperature while reducing the system's energy consumption . By optimizing temperature control logic, such as adjusting cooling temperatures, optimizing the startup time of the liquid-cooling unit, or activating the cooling mechanism only when necessary, energy waste is minimized.
Hot Start and Cold Start Functions:
In low-temperature environments, the intelligent liquid-cooling system can activate the cold start function to quickly raise the battery temperature to a suitable operating range, reducing battery preheating time and improving system responsiveness. In high-temperature environments, the hot start function can rapidly lower the battery temperature, preventing thermal runaway and performance degradation.
Precise Temperature Control:
Battery performance is highly sensitive to temperature, as excessively high or low temperatures can lead to capacity degradation, reduced cycle life, and even thermal runaway. The intelligent liquid-cooling strategy enables precise control of battery temperature. For instance, when the minimum cell temperature is ≤10°C, the heating mode is activated to consistently maintain it within the optimal operating range, ensuring the battery maintains excellent performance and longevity even in harsh environments.
Uniform Temperature Distribution:
Inconsistent temperature distribution within the battery module can lead to uneven battery performance and even safety risks. The intelligent liquid-cooling system ensures uniform temperature distribution within the battery module, preventing localized overheating or overcooling, thereby enhancing battery performance and safety. In high-temperature tests at 45°C, the maximum temperature difference among the cells was only 6.7°C, while in low-temperature tests at -25°C, the maximum temperature difference was merely 7.2°C, significantly improving the battery's stability and cycle life.
Highest and Lowest Temperatures of the Battery Cell During Two Charge and Discharge Cycles at -25°C
Max. and Min.Cell Temperatures for Rated Power Operation, at 45 °C
Time/HH:MM:SS
In summary, the intelligent liquid-cooling strategy, through precise temperature control, effectively resolves the adaptability challenges of commercial and industrial energy storage systems in harsh environments. It enhances system safety and reliability, extends battery lifespan, improves system efficiency, and provides users a safer, more reliable, and more efficient energy storage solution.
3.2 Optimizing
Structural Design
Enhances Overall Strength
Pylontech's liquid-cooling energy storage system utilizes high-strength materials, ensuring the system possesses excellent structural strength and stability even in harsh environments.
Taking Pylontech's latest M7 liquid-cooling energy storage product as an example, Pylontech adheres to an extremely rigorous scientific approach, employing Engineering simulation, Analog Computing, and Measured data verification, among other scientific methods, to conduct comprehensive and meticulous inspection and verification of the product from multiple perspectives. Through these methods, it has been clearly demonstrated that Pylontech's liquid-cooling system can maintain stable operation under extreme temperature and humidity, snow load, wind load, seismic impact, and transportation vibration conditions, perfectly adapting to various complex and harsh environmental scenarios, providing users with reliable and efficient energy storage solutions.
3.2.1 IP Protection Rating Test
The IP protection rating consists of two numbers, representing dust and water resistance capabilities, and is one of the core indicators for measuring the safety and reliability of energy storage systems. Pylontech's container has passed the IP55 rating test, and the liquid-cooling battery module has even met the IP67 or higher rating requirements, effectively protecting against dust and moisture intrusion. This ensures that the battery compartment maintains excellent safety, reliability, and performance even in harsh working environments, creating value for customers.
(M7 Liquid Cooling Energy Storage Battery Pack and System IP Testing)
3.2.2 Hoisting Simulation Verification
During the transportation of energy storage containers, lifting operations are often involved. If the structural strength and rigidity of the system are not properly designed, issues such as container deformation and difficulty in opening doors may occur after lifting. To avoid such problems, Pylontech conducted lifting simulations for the M7 liquid-cooling energy storage system, simulating a bottom diagonal lift with wire ropes applying a 2g gravitational acceleration to the container. The results showed that the maximum stress generated by the energy storage container under the 2g diagonal lifting condition was far below the material's yield strength, and the deformation was within acceptable limits. The structural strength of the container meets the requirements for a 2g diagonal lift.
S, Mises
SNEG, (fraction = -1.0)
(Avg: 75%)
+2.573e+01
+2.359+01
+2.144+01
+1.930+01
+1.715+01
+1.501+01
+1.286+01
+1.072+01
+8.577+00
+6.433+00
+4.289+00
+2.145+00
+5.608-04
3.2.4 Wind Load Verification
The primary purpose of wind load verification is to assess whether the structural design of the energy storage container can withstand the pressure exerted by specific wind speeds. This is crucial for ensuring the reliability and safety of the energy storage system during actual operation. Assuming a wind speed of 70 m/s (approximately 250 km/h) directly facing the side of the container at a 90° angle, rigorous theoretical calculations have demonstrated that the container will not tip over under a wind load of 70 m/s.
3.2.5 Seismic Simulation Verification
Seismic simulation is conducted to evaluate the structural stability of the container under seismic conditions. Seismic waves may cause severe vibrations and stress in the container structure, making seismic resistance a critical performance requirement. Pylontech performed simulations on the M7 liquid-cooling energy storage system in accordance with the IEEE 693 response spectrum (see figure below) to verify its seismic performance. The simulation results demonstrate that the maximum stress experienced by the system under X-direction, Y-direction, Z-direction, and simultaneous three-directional seismic impacts is lower than the material's yield strength, proving its excellent seismic resistance.
S, Mises
SNEG, (fraction = -1.0) (Avg: 75%)
+2.573e+01
+2.359+01
+2.144+01
+1.930+01
+1.715+01
+1.501+01
+1.286+01
+1.072+01
+8.577+00
+6.433+00
+4.289+00
+2.145+00
+5.608-04
Wind Pressure P
Container width b
Total container weight Container height H
Constrain
= -1.0)
75%)
+1.501+01
(fraction = -1.0) (Avg: 75%)
+1.715+01
S, Mises SNEG, (fraction
(Avg:
S, Mises SNEG,
S, Mises
SNEG, (fraction = -1.0) (Avg: 75%)
+1.715+01
(Seismic simulation of M7 liquid-cooling energy storage system)
3.2.6 Transport Vibration Simulation Verification and 5000-Kilometer Road Test Validation
To verify the structural strength and stability of the energy storage container during transportation, Pylontech conducted an ISTA-3E transport vibration simulation on the liquid-cooling energy storage system. This simulation replicates the random vibrations that the container may experience during transit, assessing the system's structural integrity and stability. The simulation results indicate that the maximum stress induced by transport vibrations is significantly less than one-third of the material's yield strength, meeting the requirements for transport vibration resistance.
S, Mises
SNEG, (fraction = -1.0)
(Avg: 75%)
+2.573e+01
+2.359+01
+2.144+01
+1.930+01
+1.715+01
+1.501+01
+1.286+01
+1.072+01
+8.577+00
+6.433+00
+4.289+00
+2.145+00
+5.608-04
(Simulation of transportation vibration of M7 liquid-cooling energy storage system)
To accurately reflect the actual operating conditions of the product and evaluate its performance during transportation, Pylontech conducted a 5,000-kilometer road test on the M7 liquid-cooling energy storage system. This test simulates various vibration scenarios that may occur during real-world transportation, comprehensively assessing the product's packaging, securing, insulation, and other aspects to ensure its safety and stability in practical applications. Additionally, during the road test, 19 sensors were strategically placed on the container's main beams, columns, battery packs, and other key locations to collect acceleration data and monitor temperature and humidity inside the container. The collected road spectrum data will serve as input for simulation calculations, avoiding under-design issues caused by relying solely on generic standards. This establishes a positive feedback loop of simulation, data collection, and simulation model optimization.
The road test spanned 10 days and was meticulously planned into three segments: the first leg stretched 2,000 kilometers from Shanghai to Chengdu; the second leg covered 1,800 kilometers from Chengdu to Zhangbei; and the final leg extended 1,300 kilometers from Zhangbei to Yizheng. The entire test project accumulated a total driving distance of 5,100 kilometers. From bustling cities to remote villages, and from smooth highways to rugged mountain paths, Pylontech containerized energy storage system endured a wide range of complex and varied road conditions. This journey successfully completed a comprehensive performance evaluation across multiple regions and climate zones.
Point)
CHENGDU
ZHANGBEI
YIZHENG (End Point)
SHANGHAI (Starting
After the road test, the electrical insulation withstand voltage, battery pack fixing bolt torque, and product appearance of the energy storage container were inspected, and all results were normal. Subsequently, charge-discharge tests were conducted, and the product functions were also found to be normal. The structural strength and functional stability of the system met expectations, with no abnormalities observed, fully complying with road transportation requirements.
Through a series of rigorous environmental adaptability simulations and road test validations using the M7 liquid-cooling energy storage system as an example, Pylontech has demonstrated the reliability and durability of its commercial and industrial liquid-cooling systems in diverse environments. Whether under extreme temperature fluctuations, snow loads, wind loads, seismic impacts, or transport vibrations, the system maintains stable operation and meets the demands of various harsh conditions. These simulation results further validate the structural strength of Pylontech's commercial and industrial liquid-cooling systems.
3.3 Other Safety Designs
In addition to the intelligent temperature control and environmental adaptability simulations mentioned above, to ensure the reliability of the liquid-cooling energy storage product under any operating conditions and the safety of personnel, Pylontech has also thoroughly considered the following aspects in the design of its liquid-cooling battery energy storage system:
Battery Management System (BMS)
The integrated high-performance BMS continuously monitors battery status, including voltage, current, temperature, and state of charge. It promptly responds to abnormalities by optimizing charging/discharging strategies and temperature control to prevent overcharging, over-discharging, overheating, and short circuits.
Multiple Protection Mechanisms
The system incorporates a series of hardware and software protection measures, including over-voltage protection, under-voltage protection, over-current protection, multi-level short-circuit protection, and temperature monitoring, to mitigate potential safety risks.
Mechanical Safety Design
Pylontech's liquid-cooling system cabinets are designed to meet stringent industrial standards, ensuring structural stability and reducing the risk of accidents. All access points are equipped with safety switches and emergency stop buttons to quickly cut off power when necessary.
Electrical Safety
The system's electrical design complies with the standards of the International Electrotechnical Commission (IEC) and the safety requirements of Underwriters Laboratories (UL). All electrical connections use reliable connectors and are properly insulated to prevent electric shocks and leakage.
Fire Suppression System
The integrated automatic fire suppression system can activate quickly upon detecting abnormal temperature rises, preventing the spread of fires.
Environmental Monitoring
The system is equipped with environmental monitoring capabilities to detect parameters such as temperature, humidity, and smoke in real time, ensuring the energy storage system operates under suitable environmental conditions.
Product Certification and Quality Control
Product certification plays a pivotal role in the energy storage system sector, serving as a critical measure to ensure the safe, stable, and reliable operation of energy storage systems. It is of immeasurable importance in guaranteeing that product quality meets high standards, facilitating market access, earning consumer trust, mitigating potential risks, and significantly enhancing a company's competitive edge in the market. Pylontech fully recognizes this crucial point, and its range of commercial and industrial energy storage system products has obtained multiple internationally recognized certifications, including IEC 62619, IEC 63056, VDE 2510-50, UL 1973, UL 9540, UL 9540A, NFPA 68, NFPA 69, and UN 38.3. These international certifications not only demonstrate that Pylontech's products fully comply with relevant regulations and standards in the global market, showcasing their high level of compliance, but also highlight their exceptional performance and reliability.
At the same time, Pylontech has taken into account the unique needs and specific requirements of different regional markets, conducting targeted certifications to ensure its products perfectly align with local standards and regulations. This region-specific certification strategy enables Pylontech's products to establish a strong foothold in diverse markets, meeting the varied needs of local customers.
