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Energy Storage Battery Enclosure1

ESS(ENERGY STORAGE SYSTEM) BATTERY ENCLOSURE ——BATTERY POWER SOLUTIONS(COMPREHENSIVE ANALYSIS)

2023-10-27

ESS(ENERGY STORAGE SYSTEM) BATTERY ENCLOSURE ——BATTERY POWER SOLUTIONS(COMPREHENSIVE ANALYSIS) Facebook Twitter LinkedIn Project Contact: Chris +86 193-5550-1188 Chris@xdthermal.com ESS(ENERGY STORAGE SYSTEM) BATTERY ENCLOSURE——BATTERY POWER SOLUTIONS(COMPREHENSIVE ANALYSIS) What Is ESS Battery Enclosure Battery enclosure is also known as the battery box (battery housing / battery tray) and is one of the most important components in Battery Pack. It provides a space, which is mechanically strong and water-dust proof, for battery cells, thermal management systems, BMS and so on. Besides Cells, BDU, BMS and PCS, battery enclosure is another important cost influencer in ESS system. ESS Battery enclosure design followed the same concept and structure from automotive industry in earlier years. By knowing the difference of use cases, ESS Battery enclosure evolved with its own unique features. Primary Focus of Battery Enclosures Materials The use of advanced materials and material composition has significantly improved the design and structure of battery packs in ESS(energy storage system). Now two main materials used, Aluminum and Steel. While steel is characterized by simple manufacturing processes and lower costs, it exhibits higher density and greater mass. With the evolution of lightweight design principles, aluminum alloys, owing to their lower density, lightweight nature, corrosion resistance, high strength, excellent die-casting capabilities, and greater sustainability, are enjoying a larger market share. Structure（in details） Normally, one ESS Battery case consists of top cover, lower case, cooling plate, frame panel, beams and bottom plate. The design of battery enclosures should be based on the overall spatial structure and layout of the energy storage system. For instance, whether it is necessary to integrate the water-cooling plate with the bottom protective plate to reduce costs. What position and dimensions should be chosen for the beams to enhance heat transfer efficiency? How much space should be left to ensure proper integration of battery cells with other electronic components. Frame…

friction stir welding-xd thermal

Friction stir welding

2023-10-27

Friction stir welding definition Friction stir welding refers to the process of locally melting the material to be welded using the heat generated by the high-speed rotation of a welding tool in friction. As the welding tool moves forward along the welding interface, the plasticized material flows from the front to the rear of the tool under the action of the rotational friction force and forms a dense solid-phase weld seam under the tool’s pressure. Friction Stir Welding Principle The principle of friction stir welding is similar to conventional friction welding, as it also utilizes friction heat and plastic deformation heat as the heat source for welding. The difference lies in the fact that in the friction stir welding process, a cylindrical or other shaped (such as a threaded cylinder) welding pin is inserted into the seam of the workpiece. Through the high-speed rotation of the welding head, it is brought into frictional contact with the material of the workpiece, thereby raising the temperature and softening the material at the joint. At the same time, material is subjected to stirring friction to complete the welding. Advantages of Friction Stir Welding 1.The microstructure changes in the heat-affected zone of the welded joint are minimal. Residual stresses are relatively low, and the welded workpiece is less prone to deformation. 2.High efficiency (capable of completing longer weld seams, large cross-sections, and welding in different positions in a single operation). 3.Convenient operating process (enabling mechanization and automation, simple equipment, low energy consumption, high efficiency, and low requirements on the working environment). 4.Low cost (no need for welding wire, no pre-deoxidation of aluminum alloys, and no need for shielding gas when welding). 5.Suitable for welding heat-crack-sensitive materials and for welding dissimilar materials. 6.Welding process is safe, pollution-free, smoke-free, and radiation-free. Disadvantages of Friction Stir Welding…

Data Centre Liquid Cooling Plate

Liquid Cooling Data Centers

2023-10-17

Advantages of Liquid Cooling Plates for Data Centers Lean Product Manufacturing Cost Optimization MANUFACTURING DESIGN DV (design verification) Why Data Centers Need Liquid Cooling Plates With the growing computational demands of servers supporting AI and other processor-intensive applications, rack power densities exceeding 20 KW are becoming commonplace, and many organizations now seek to deploy racks with 50 KW or higher power density requirements. While air cooling systems have evolved to handle higher densities and improve efficiency, they eventually reach a point where air lacks the efficient thermal conductivity required for effective cooling of high-heat-density racks. This leads to reduced server performance, reliability, and efficiency as rack power increases. As more high-power-density racks are deployed, air cooling becomes increasingly unsustainable from both economic and sustainability perspectives. To achieve higher heat dissipation in smaller spaces, many markets are exploring the feasibility of introducing liquid as a medium into racks to enhance data center cooling capacity and efficiency. Liquid cooling leverages the superior thermal conductivity properties of water or other fluids to support efficient and cost-effective cooling for high-heat-density racks. Learn More About XD THERMAL Liquid Cooling Design Contact Us How Data Centers Efficiently Utilize Liquid Cooling Plates for Heat Exchange The application of liquid cooling technology in data centers has come relatively late. It involves the use of a flowing liquid to transfer the heat generated by internal computer components to the outside of the computer, ensuring that the computer operates within a safe temperature range. The space through which the flowing liquid circulates is the liquid cooling plate. In contrast to conventional air-cooled servers, cold plate liquid cooling technology avoids direct contact between the cooling liquid and the server. It provides precise heat exchange for major heat sources such as CPUs and memory components. The liquid cooling channel consists of components…

DV(design verification)

The Difference Between Automotive Component DV Testing and PV Testing

2023-10-17

Automotive Component Definition The division of automotive components by design ownership can be classified into two categories: components designed by the original equipment manufacturer (OEM) and those designed by suppliers. Components designed by the OEM typically have their DFMEA (Design Failure Modes and Effects Analysis) and DVP (Design Verification Plan) authored by OEM engineers. The OEMs have various system-level and component-level design specifications and testing methods. Within the testing methods, there are specific requirements for test procedures, equipment, and testing frequency. Battery Cooling Tube Design Components designed by suppliers are often referred to as “black-box” components, and the DFMEA (Design Failure Modes and Effects Analysis) and DVP (Design Verification Plan) for these components are typically authored by the suppliers. Various testing specifications and testing method requirements from suppliers are usually not directly shared with the OEM, especially in the case of international suppliers, as access to DFMEA documents is typically restricted and may only be viewed at the supplier’s location (without the ability to take photographs). Definition of DV Testing and PV Testing Testing is divided into DV and PV. DV stands for Design Verification, it can be either prototype or tooling parts and verified by simulation. PV stands for Product Verification, and it must be tooled parts produced on the supplier’s mass production line, and it can be verified by the way of testing products. After PV, the parts undergo PPAP approval, granting them the qualification for mass production and supply. Battery Cooling Plate Design Difference Between DV Testing and PV Testing Timing of Testing Differs DV Testing: DV testing is conducted during the design and development phase. PV Testing: PV testing takes place during the formal production phase. Different Test Subjects DV Testing: The test subjects for DV testing are handcrafted parts of the vehicle, which are produced…

Unlocking Potential: The Power of Two-way V2G Charging

2023-10-13

What is V2G Charging? V2G stands for Vehicle-to-Grid, describing a novel energy system that utilizes bi-directional charging ports connected to homes. These ports link battery electric vehicles (BEVs) or plug-in hybrid electric vehicles (PHEVs) to the grid, enabling these electric vehicles not only to draw energy from the grid but also to feed excess energy back into it. V2G charging refers to the use of bi-directional EV chargers (DC to AC conversion systems) to supply power from EV batteries to the grid. V2G can assist in balancing and addressing local, regional, or national energy needs through intelligent charging. The Principle of Two-way V2G Charging The core idea behind V2G is to harness the energy stored in electric vehicle batteries when they are not in use and charge or discharge them as needed. When charging electric vehicles, they receive alternating current (AC) from the grid, which is then converted into direct current (DC) (either by an in-vehicle converter or an external charger). To utilize the energy stored in the EV battery to power a home or return it to the grid, the DC power from the vehicle must be converted back into AC, a task accomplished by the bi-directional charger. Two-way charging is particularly effective when supplemented with solar power, as it can generate additional energy during periods of strong sunlight. Advantages of Two-way V2G Charging 1. Large energy storage capacity in EV batteries, capable of storing up to 10 times more energy than typical 7 KWH lithium-ion batteries commonly found in residential solar photovoltaic systems. 2. Cost savings and efficiency enhancements for EV owners through rewards or reduced energy costs. Charging vehicles during off-peak hours at the lowest rates and feeding power back into the grid during peak-rate energy times can reduce overall energy expenses. 3. Alleviates grid stress during…

Notice of Mid-Autumn Festival and National Day Holidays

2023-09-27

The holiday period for Mid-Autumn Festival and National Day is from September 29th to October 6th. Please contact us in advance if you have any questions. Wishing everyone a pleasant holiday in advance!

C2M liquid cold tube

Liquid Cooling Tube | Serpentine Tube

2023-09-25

Liquid Cooling Tube Liquid Cooling Tube, also known as liquid-cooling tubing / serpentine tubing, is composed of thermally conductive metals (typically copper or aluminium alloys) that have been extruded and corrugated to create an internal structure with a specific number of channels. These channels conform closely to the surface of the battery cells. Serpentine tubing functions as a heat exchanger component in indirect liquid cooling systems, utilizing the circulation of coolant within the channels to dissipate heat generated by the components. Typically, 1 to 2 rows of battery cells are sandwiched between every two serpentine flat tubes. This design effectively increases the heat exchange area on the side of the battery, resulting in a more uniform temperature distribution among individual cells during operation and reducing the temperature difference across the entire battery pack Serpentine tubing finds its primary application in which scenario? — Cylindrical battery side liquid cooling solutions Battery packs are composed of numerous battery cells arranged in a specific configuration. Therefore, when considering thermal management for batteries, the first aspect to account for is the inherent characteristics of the cells. For instance, square-shaped cells can be densely packed with a larger surface area, making them suitable for utilizing stamped liquid-cooling plates for bottom or side heat dissipation.    On the other hand, cylindrical cells offer more diverse arrangement possibilities with larger gaps between cells. Hence, they are better suited for side heat dissipation using serpentine tubing that conforms to the curvature of the battery’s surface. With the increasing market demand for cost-effective products, a series of cylindrical cells like 2170, 4680, and 4695 have emerged. It is expected that large cylindrical cells will gradually replace a portion of the market share held by square and pouch cells in the future. Efficient heat dissipation solutions for cylindrical cells of…

brazing-vacuume liquid cold plate - XD THERMAL

What Is The Vacuum Brazing Process?

2023-09-20

Brazing refers to a welding method in which a filler material with a melting point lower than that of the workpieces, and the workpieces themselves, are heated simultaneously to the melting temperature of the filler material. This method involves using the liquid solder to fill the gaps in the solid workpieces, thus creating a metallic connection. During soldering, it is essential to first remove any oxide layers and oil residues from the contact surfaces of the base materials. This facilitates the capillary action of the solder once it melts, enhancing the solder’s wetting and capillary flow properties. Brazing Process The workpieces, which have been cleaned on the surfaces, are assembled in a lap joint configuration, and the solder is placed near or between the joint gaps. When the workpieces and the solder are heated to slightly above the solder’s melting point temperature (the workpieces remain unmelted), the solder melts and, aided by capillary action, is drawn into and fills the gaps between the solid workpieces. The liquid solder and the workpiece metals mutually diffuse and dissolve into each other, forming the brazed joint upon cooling. Advantages of Brazing Process 1. The brazing process can reach temperatures of 500-700 degrees, and the strength of the aluminum sheet increases after cooling following the brazing process. 2. A continuous tunnel-type brazing furnace can accommodate the welding of large components, with typical cold plate dimensions for 52 battery cells reaching 120*85. 3. Brazing can join different types of aluminum sheets, such as pure aluminum and aluminum alloy sheets, with a high-strength brazed layer. 4. Brazing can join thin and thick plates without producing weld seam protrusions. Disadvantages of Brazing Process 1. Brazing furnaces have large volumes and consume significant energy. 2. Brazing requires the use of flux, which may lead to environmental pollution. 3….

Data Centre Liquid Cooling Plate

Data Center Liquid Cooling Plate

2023-09-18

The carbon emissions generated by the electricity consumption of data center cooling and air conditioning systems are quite significant. Carbon reduction is one of the four main pathways to achieving carbon neutrality (carbon substitution, carbon reduction, carbon sequestration, and carbon recycling). In order to achieve energy efficiency and emissions reduction in data center cooling and air conditioning systems, the industry has conducted extensive research in various cooling methods, including aisle containment, wind barriers airflow organization heat pipes river water cooling dynamic glycol cooling cooling towers air-cooled chillers refrigerant pumps indirect evaporative cooling enthalpy wheels and direct natural cooling with fresh air Liquid cooling technology can directly utilize natural cooling, significantly reducing power consumption, and helping to reduce the carbon emissions of data centers. Cooling server chips presents a serious challenge, and the temperature of chip packaging shells continues to rise, reaching the limits of air cooling. With a specific heat capacity of 1000 to 3500 times that of air and thermal conductivity 15 to 25 times higher than that of air, liquid cooling is the preferred choice for higher heat density cooling.

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