This article starts from the liquid-cooled industrial and commercial energy storage cabinets and details the safety design of the current mainstream liquid-cooled industrial and commercial energy storage systems cabinets in terms of cold liquid plates and other aspects like liquid aiir energy storage.
1. Industrial and commercial energy storage thermal management
- Cold liquid plate
In battery systems, metal radiators that are filled with indirect contact with liquid cooling fluid are called liquid cooling. Liquid cooling plates are generally made of metal plates or metal tubes extruded or stamped from aluminum alloy grinding tools, and then welded and formed.
- Water inlet and outlet connector
This is the water inlet and outlet used for the circulation of liquid-cooled working fluid. It is generally made of AL6061 material, machined and formed, and welded to the liquid-cooled plate.
- Thermal conductivity
Refers to the thermal conductivity of the liquid cooling plate, which is determined by the thermal conductivity of the liquid cooling plate material.
- Welding process type
There are three types of welding of liquid cooling plates: brazing, friction stir welding and solderless welding.
The brazing process is widely used in traditional automobile radiator welding. It uses liquid solder to wet the base metal, fill the interface gap and mutually diffuse the base metal to connect the welding parts. The advantage of welding is that it can weld complex structures and the thickness of the welding parts Can be made very thin.
Friction stir welding uses the heat generated by the mutual movement and friction between the welding head and the end face of the workpiece to make the end reach a thermoplastic state to complete the welding. This welding requires that the weldment itself has sufficient strength.
Material-free brazing is developed on the basis of brazing, and the thickness and weight of the welded parts can be minimized. Here are Top 10 manufacturers of liquid cooling products in China.
2.Cold plate design
The energy storage cold plate has double circuits and single circuits, which correspond to different flow channel layout standards.
The flow channel arrangement of the double circuit should keep the spacing of the flow channels as small as possible while meeting the process conditions, and set up more circulation loops, so that The battery is heated or cooled more evenly and the temperature difference is small.
For single-circuit flow channel arrangement, the spacing between the flow channels should be kept as small as possible while meeting the process conditions, so that the battery can be heated or cooled.
More uniform. All in all, no matter which structural type, if the layout space is satisfied, the double circuit is preferred, because in this way, hot and cold will exist at the same time and the temperature difference will be reduced.
The electrical main circuit of the energy storage system usually adopts a three-level fuse mechanism, that is, battery Pack loop DC fuse, battery cluster loop DC fuse, and PCS AC loop fuse. Hidden risks caused by electrical short-circuit faults are minimized through hierarchical fuses.
3. Key points of cold plate design
- the whole frame
For metal radiators filled with indirect contact liquid-cooling working fluid, when it is generally necessary to bear load and bear force, a friction stir welded cold plate of aluminum profiles with a thicker structure and higher strength is used.
- flow form
The characteristic of the double-circuit cold plate is that the water inlet and outlet are on the same side. Generally, it can ensure that the heat exchange surface of the module is hot and cold at the same time, which can reduce the temperature difference on the surface of the cold plate. The water inlet and outlet of the single-circuit are on both sides, and the inlet water temperature gradually increases. , give priority to double-circuit design if space arrangement allows
- Cold plate body
The main body of the cold plate is cut in sections from extruded aluminum profiles and machined by machine tools. Its function is to contact the hot surface of the battery core for heat exchange. Total thickness: 8~10mm Total width: 3360mm Upper and lower surface wall thickness: 15~2mm Split thickness: 21.5mm
- front plug
The installation position of double-circuit plug faucets is generally on the same side, and the installation position of single-circuit plug faucets is generally on both ends. When designing the spacing between faucets, the pipeline and installation space should be considered.
- Rear plug
The double-circuit rear plug is generally a wide and smooth cavity, and the cooling medium flows inside the aluminum profile, which is blocked and sealed by chlorine arc welding; the single-circuit rear plug is an aluminum profile or aluminum plug, which is used for friction stir or chlorine arc welding. Arc welding for sealing.
4. Arrangement and installation
Assume that the layout is a design plan for a sheet metal box of a certain model of car. The installation sequence is that the module, thermal pad, cold plate and box are threaded together and fixed with shared bolts. In this way, the cold plate is subject to more stress and requires greater strength.
 At the same time, when designing the cold plate, the welding seam position must avoid the severely stressed position and control the flatness of the cold plate (0.8~1 industry processing capacity)
The layout is an aluminum box layout. The module and the cold plate are fixed on the upper and lower parts of the box respectively. The box installation beam is divided into two steps. The module is fixed on the first step and the cold plate is fixed on the second step.
The thermal conductive material is in the middle. Filling, so that the cold plate is only subject to the downward pressure of the thermal pad, while minimizing the weight of the profile cold plate. Here is more imformation about thermal energy storage.
5. Energy storage thermal management safety design
- Active safety design
The active safety of the energy storage system is mainly through the management of battery cells to prevent “burning” before burning. Through internal short circuit diagnosis, cell internal resistance discrete analysis, and cell consistency analysis, the cell status is evaluated in real time, abnormal cells are promptly warned, and the safety of the energy storage system is turned from passive to active.
- Passive safety design
The passive safety of energy storage systems mainly relies on various fire-fighting facilities to promptly extinguish fires caused by thermal runaway of battery cells and prevent deflagration.
By setting up smoke sensors, temperature sensors, combustible gas detection, etc., a hierarchical fire warning and action mechanism can be achieved.
Set pressure relief valves, explosion vents, etc. at the cell, battery Pack, and system levels to prevent the accumulation of flammable gases that could lead to further deflagration.
Generally, when the secondary fire alarm activates the fire protection system, further thermal runaway is prevented by releasing fire gas and a large amount of water. Some manufacturers also add Pack-level fire protection configurations. Can be divided into the following categories:
- Multi-stage electrical fuse design
The electrical main circuit of the energy storage system usually adopts a three-level fuse mechanism, that is, battery Pack loop DC fuse, battery cluster loop DC fuse, and PCS AC loop fuse. Hidden risks caused by electrical short-circuit faults are minimized through graded fuses.
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