Assembly process of modular lead-acid storage battery energy storage system for large base station

Abstract

The invention relates to the technical field of energy storage systems, and discloses an assembly process of a modular lead-acid storage battery energy storage system for a large-scale base station, and the assembly process comprises the following steps: S1, standardized design and manufacturing of modules, S2, electrical connection, S3, integration of a heat dissipation system, S4, installation of a monitoring system, and S5, integration and debugging of the energy storage system. A plurality of batteries are integrated in a standard module (non-simple series connection), so that the influence of the fault of a single battery on the energy storage system is reduced, and the integration level and reliability of the energy storage system are improved; through optimization of air duct layout and fan configuration, a heat dissipation system is optimized, smooth ventilation and uniform temperature distribution between modules are ensured, the working temperature of a battery is reduced, and the service life of the battery is prolonged; key parameters such as voltage, current and temperature of the battery module are monitored in real time through the sensor and the data acquisition system, the monitoring precision of the module is improved, and early warning is given out in time when potential faults are found.

Description

Technical Field

[0001] The present invention relates to the technical field of energy storage systems, and is applied to scenarios such as communication base stations and data centers. The present invention specifically relates to an assembly process for a modular lead-acid battery energy storage system for a large base station. Background Art

[0002] Energy storage system is a technical device that can store energy in some form and release it when needed, including energy and material input and output, energy conversion and storage equipment. The basic task of energy storage system is to overcome the temporal or local differences between energy supply and demand.

[0003] After searching, the patent with application number CN201110127348.3 discloses a lead-acid battery assembly process, including the following steps: Step ①: put the battery pole group into the welding group box, shake the rocker of the welding group box, and compress the pole group; Step ②: install the combing plate and manually weld the pole group; Step ③: use the elevator to lift the pole group, check the corresponding position of the pole plate and the partition at the bottom of the pole group; Step ④: put on the PE bag, vacuum and compact the pole group. Step ⑤: put the pole group into the battery shell. This invention uses the welding group box to compress the battery pole group, the elevator to lift the module, and vacuum and compact the pole group, so as to reduce the labor intensity of workers, ensure the quality of the battery, and standardize the large-scale production of lead-acid batteries.

[0004] At present, energy storage systems used in base stations and other scenarios mainly use lead-acid batteries as energy storage devices. In the prior art, these energy storage systems have the following main problems in actual application:

[0005] 1. The system integration is low. The single cells are connected in traditional series. Once a single cell fails, it is easy to cause the entire battery string to fail, affecting the system reliability.

[0006] 2. The battery pack cooling system is not designed properly, and the ventilation between modules is not smooth, resulting in uneven temperature distribution and affecting the battery life;

[0007] 3. The monitoring system is not accurate enough to achieve accurate management and timely warning, which increases the difficulty of maintenance;

[0008] 4. The installation and maintenance efficiency is low and requires professional personnel to operate, resulting in high operation and maintenance costs.

[0009] Therefore, we need to propose an assembly process for modular lead-acid battery energy storage systems for large base stations to improve the integration and reliability of the energy storage system, optimize the heat dissipation system, increase battery life, improve the accuracy of the monitoring system, achieve precise management and timely warning, improve installation and maintenance efficiency, and reduce operation and maintenance costs. Summary of the invention

[0010] The purpose of the present invention is to provide an assembly process for a modular lead-acid battery energy storage system for a large base station. Through modular design, multiple batteries are integrated into a standard module (not simply connected in series), reducing the impact of a single battery failure on the energy storage system and improving the integration and reliability of the energy storage system; through the optimization of the air duct layout and the fan configuration, the heat dissipation system is optimized to ensure smooth ventilation and uniform temperature distribution between modules, reduce the operating temperature of the battery, and increase the battery life; through sensors and data acquisition systems, key parameters such as voltage, current, and temperature of the battery module are monitored in real time to improve the monitoring accuracy of the module and issue an early warning in time when a potential fault is found; through modular design and standardized assembly processes, the installation difficulty of the battery module is reduced, the dependence on professional installers is reduced, installation and maintenance are facilitated, installation and maintenance efficiency is improved, and operation and maintenance costs are reduced to solve the problems raised in the above-mentioned background technology.

[0011] To achieve the above object, the present invention provides the following technical solution: an assembly process of a modular lead-acid battery energy storage system for a large base station, comprising the following steps:

[0012] S1. Standardized design and production of modules, including:

[0013] Module unit design: confirm the basic structure and physical dimensions of the module to facilitate standardized production and installation;

[0014] Module frame production: provide solid support and protection for the module, and meet the heat dissipation and shock absorption functions;

[0015] S2. Electrical connection, including:

[0016] Bus connection: realize electrical connection between batteries inside the module, so that current can be transmitted smoothly;

[0017] Quick connector design: realize fast and reliable electrical connection between modules or between modules and external devices;

[0018] S3, cooling system integration, including:

[0019] Air duct layout design: optimize the heat dissipation inside the module to keep the temperature stable during battery operation;

[0020] Fan system configuration: Provides forced heat dissipation for the module to prevent the battery temperature from continuing to rise and exceeding the temperature threshold that affects the stable operation of the battery;

[0021] S4. Install monitoring system, including:

[0022] Sensor layout: Real-time monitoring of the temperature, voltage and current parameters inside the module to ensure the safe operation of the energy storage system;

[0023] Data collection: collect sensor data, process and analyze the collected data, and then transmit the processed and analyzed data to the management platform;

[0024] S5. Energy storage system integration and commissioning, including:

[0025] Basic installation: Provide a stable installation foundation for the module to ensure stable operation of the energy storage system;

[0026] Module installation: Install the modules into the cabinet from bottom to top and from front to back using a drawer-type slide rail structure.

[0027] Preferably, when designing the module unit, 12 2V / 1000Ah lead-acid batteries are designed as a standard module unit. The overall dimensions of the module are: 1200mm (length) × 600mm (width) × 800mm (height). The weight of the module does not exceed 500KG. The module adopts a drawer-type slide rail structure to facilitate the installation and disassembly of the module in the cabinet. The installation operation can be completed by one person.

[0028] Preferably, when making the module frame, a 3mm thick galvanized steel plate is selected as the frame material, and a 45° fold is set at the corner of the frame to increase the structural strength;

[0029] The surface of the frame is electrostatically sprayed to form a coating of 80-120μm. In order to facilitate the timely removal of heat from the batteries inside the module, the frame reserves 20% of the heat dissipation space, and a shock-absorbing bracket is installed at the bottom of the frame. The hardness of the shock-absorbing bracket is 60±5HA.

[0030] Preferably, when the bus is connected, T2 copper is used to make the bus, and the surface of the bus is tinned, and the cross-sectional area of ​​the bus is set to 80mm. 2 , contact area ≥40mm 2 , use bolts to tightly connect the busbar and the battery terminal, control the torque of the bolts at 35±2N·m, and measure the contact resistance, which should not exceed 0.1mΩ.

[0031] Preferably, the quick connector uses a self-locking plug-in connector. The contact material of the quick connector is copper alloy, and the surface is silver-plated with 3-5μm. The insulating shell of the quick connector is flame-retardant PC material. The quick connector is provided with an anti-reverse connection mechanism, and a mechanical key design is used to prevent incorrect connection. The operating force of the quick connector is: insertion ≤50N, extraction ≤40N.

[0032] Preferably, when designing the air duct layout, an upper air inlet and lower air outlet air duct layout is adopted, and the spacing between modules is set to 100±5mm, the cross-sectional area of ​​the air duct is 0.12m2, the air flow speed in the air duct is 2-3m / s, and a guide plate is installed in the air duct to optimize the air flow distribution;

[0033] Fan system configuration: One set of fans is configured for every four modules. The maximum air volume of the fans is 2000m3 / h, the static pressure of the fans is 200Pa, and the noise of the fans is controlled to be ≤65dB. The fan configuration adopts N+1 redundant design.

[0034] Preferably, when arranging the sensors, the internal arrangement of each module is as follows:

[0035] Four temperature sensors: with an accuracy of ±0.5°C, they monitor the temperature inside the module;

[0036] Two voltage sampling sensors located at the head and tail of the module: with an accuracy of ±0.1%, they monitor the voltage changes inside the module;

[0037] Two current sampling sensors located at the positive and negative poles of the module: with an accuracy of ±0.2%, monitoring the current inside the module;

[0038] Signal line: Use shielded twisted pair cable with a cross-section of 0.5mm2.

[0039] Preferably, when collecting data: a 32-bit ARM architecture processor is selected, and the sampling frequency is set to 10 Hz, the processor is configured with a data storage device with a storage capacity of 32 GB, the processor uses CAN bus communication, the baud rate is 500 kbps, and the response time of the processor is ≤10 ms.

[0040] Preferably, when installing the foundation, ensure that the horizontality of the installation foundation is ≤2mm / m, use M16 anchor bolts to fix the foundation to the ground, the depth of the M16 anchor bolts into the ground is 150mm, and a shock-proof pad with a thickness of 20mm and a hardness of 60±5HA is installed on the foundation, and the grounding resistance on the foundation is ≤4Ω.

[0041] Preferably, when the modules are installed, the spacing between two adjacent modules is 100mm, and the positioning accuracy of the modules is ≤5mm. To ensure that the cabinet can bear the weight of the modules and batteries, the cabinet-level weighing is ≤2000KG. After the installation is completed, the module is debugged, and the debugging content includes electrical connection inspection and heat dissipation effect test, and the single debugging time is ≤2 hours.

[0042] Compared with the prior art, the present invention has the following beneficial effects:

[0043] 1. The present invention integrates multiple batteries into a standard module (not simply connected in series) through modular design, reducing the impact of a single battery failure on the energy storage system and improving the integration and reliability of the energy storage system;

[0044] 2. The present invention optimizes the heat dissipation system by optimizing the air duct layout and fan configuration, ensuring smooth ventilation and uniform temperature distribution between modules, reducing the battery operating temperature and increasing the battery life;

[0045] 3. The present invention monitors the key parameters of the battery module such as voltage, current, temperature, etc. in real time through sensors and data acquisition systems, improves the monitoring accuracy of the module, and issues early warnings in time when potential faults are found;

[0046] 4. The present invention reduces the difficulty of installing the battery module and the dependence on professional installers through modular design and standardized assembly process, facilitates installation and maintenance, improves installation and maintenance efficiency, and reduces operation and maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a flowchart of the present invention;

[0048] Figure 2 A flowchart of the standardized design and production of the module of the present invention;

[0049] Figure 3 A flowchart of the electrical connection of the present invention;

[0050] Figure 4 A flowchart of the heat dissipation system integration of the present invention;

[0051] Figure 5 A flowchart of the monitoring system for installing the present invention;

[0052] Figure 6 This is a flowchart of the integration and debugging of the energy storage system of the present invention. DETAILED DESCRIPTION

[0053] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0054] See also Figure 1-6 The present invention provides a technical solution: an assembly process of a modular lead-acid battery energy storage system for a large base station, comprising the following steps:

[0055] S1. Standardized design and production of modules, including:

[0056] Module unit design: confirm the basic structure and physical dimensions of the module to facilitate standardized production and installation;

[0057] When designing the module unit, 12 2V / 1000Ah lead-acid batteries are designed as a standard module unit. The module dimensions are: 1200mm (length) × 600mm (width) × 800mm (height), ensuring that the module size is moderate and easy to carry and install. The weight of the module does not exceed 500KG, ensuring that a single person or a small number of people can easily operate it. The module adopts a drawer-type slide rail structure to facilitate the installation and disassembly of the module in the cabinet, while ensuring the electrical connection and heat dissipation effect between the modules. A single person can complete the installation operation.

[0058] Module frame production: provide solid support and protection for the module, and meet the heat dissipation and shock absorption functions;

[0059] When making the module frame, 3mm thick galvanized steel plate is used as the frame material to provide sufficient strength and durability, and 45° folding edges are set at the corners of the frame to increase structural strength and facilitate connection with other components;

[0060] The surface of the frame is treated with electrostatic spraying to form a coating of 80-120μm to improve the corrosion resistance. In order to facilitate the timely removal of heat from the batteries inside the module, the frame reserves 20% of the heat dissipation space, and a shock-absorbing bracket is installed at the bottom of the frame. The hardness of the shock-absorbing bracket is 60±5HA to reduce the vibration and impact of the module during transportation and installation.

[0061] S2. Electrical connection, including:

[0062] Bus connection: realize electrical connection between batteries inside the module, so that current can be transmitted smoothly;

[0063] When connecting the busbar, use T2 copper to make the busbar, and tin the surface of the busbar to improve the conductivity and corrosion resistance, and set the cross-sectional area of ​​the busbar to 80mm 2 (Ensure that it can withstand the current output of the battery inside the module), contact area ≥ 40mm 2 (Reduce the heat generated by contact resistance), use bolts to tightly connect the busbar and the battery terminal, control the torque of the bolts at 35±2N·m to ensure a firm and reliable connection, and measure the contact resistance, which should not exceed 0.1mΩ to ensure current transmission efficiency.

[0064] Quick connector design: realize fast and reliable electrical connection between modules or between modules and external devices;

[0065] The quick connector uses a self-locking plug-in connector to ensure a stable connection and easy operation. The contact material of the quick connector is copper alloy, and the surface is silver-plated with 3-5μm to improve the conductivity and corrosion resistance. The insulating shell of the quick connector is flame-retardant PC material. The quick connector is equipped with an anti-reverse connection mechanism and a mechanical key design to prevent incorrect connection. The operating force of the quick connector is: insertion ≤50N, extraction ≤40N, which is easy for personnel to operate and effortless.

[0066] S3, cooling system integration, including:

[0067] Air duct layout design: optimize the heat dissipation inside the module to keep the temperature stable during battery operation;

[0068] When designing the air duct layout, the upper air inlet and lower air outlet layout is adopted to allow air to flow smoothly through the module. The spacing between modules is set to 100±5mm to provide enough space for the air duct. The cross-sectional area of ​​the air duct is 0.12m2 to achieve sufficient air flow. The air flow speed in the air duct is 2-3m / s to improve the heat dissipation efficiency. A guide plate is installed in the air duct to optimize the air flow distribution so that each part of the module can dissipate heat evenly.

[0069] Fan system configuration: Provides forced heat dissipation for the module to prevent the battery temperature from continuing to rise and exceeding the temperature threshold that affects the stable operation of the battery;

[0070] Fan system configuration: One set of fans is configured for every four modules. The maximum air volume of the fans is 2000m3 / h, which can provide sufficient air flow. The static pressure of the fans is 200Pa, which can provide sufficient pressure to send air into the module and control the noise of the fans to ≤65dB to reduce the impact on the environment and personnel. The fan configuration adopts N+1 redundant design to improve the reliability and stability of the fan system.

[0071] S4. Install monitoring system, including:

[0072] Sensor layout: Real-time monitoring of the temperature, voltage and current parameters inside the module to ensure the safe operation of the energy storage system;

[0073] When laying out the sensors, the internal layout of each module is as follows:

[0074] Four temperature sensors: with an accuracy of ±0.5°C, they monitor the temperature inside the module;

[0075] Two voltage sampling sensors located at the head and tail of the module: with an accuracy of ±0.1%, they monitor the voltage changes inside the module;

[0076] Two current sampling sensors located at the positive and negative poles of the module: with an accuracy of ±0.2%, monitoring the current inside the module;

[0077] Signal line: Use shielded twisted pair cable with a cross-section of 0.5mm2 to improve the transmission quality of sensor signals.

[0078] Data collection: collect sensor data, process and analyze the collected data, and then transmit the processed and analyzed data to the management platform;

[0079] When collecting data: a 32-bit ARM architecture processor is selected to improve data processing capabilities, and the sampling frequency is set to 10Hz, which can collect sensor data in real time. The processor is equipped with a data storage device with a storage capacity of 32GB for storing historical data and alarm records. The processor uses CAN bus communication with a baud rate of 500kbps, which can increase the data transmission speed, and the processor's response time is ≤10ms, which improves the real-time and reliability of the energy storage system.

[0080] S5. Energy storage system integration and commissioning, including:

[0081] Basic installation: Provide a stable installation foundation for the module to ensure stable operation of the energy storage system;

[0082] During foundation installation, ensure that the horizontality of the installation foundation is ≤2mm / m to achieve the accuracy of module installation. Use M16 anchor bolts to fix the foundation to the ground. The depth of the M16 anchor bolts into the ground is 150mm to provide sufficient support force. A shockproof pad with a thickness of 20mm and a hardness of 60±5HA is installed on the foundation to reduce the vibration and noise generated by the module during operation. The grounding resistance on the foundation is ≤4Ω, which can ensure the electrical safety of the energy storage system.

[0083] Module installation: Install the modules into the cabinet from bottom to top and from front to back using a drawer-type slide rail structure.

[0084] When installing the modules, the distance between two adjacent modules is 100mm to ensure the heat dissipation effect and installation accuracy. The positioning accuracy of the modules is ≤5mm to ensure the electrical connection and heat dissipation effect between the modules. To ensure that the cabinet can bear the weight of the modules and batteries, the cabinet level weighing is ≤2000KG. After the installation is completed, the module is debugged. The debugging content includes electrical connection inspection and heat dissipation effect test, and the single debugging time is ≤2 hours.

[0085] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An assembly process for a modular lead-acid battery energy storage system for a large base station, characterized in that: The following steps are involved: S1. Standardized design and production of modules, including: Module unit design: confirm the basic structure and physical dimensions of the module to facilitate standardized production and installation; Module frame production: provide solid support and protection for the module, and meet the heat dissipation and shock absorption functions; S2. Electrical connection, including: Bus connection: realize electrical connection between batteries inside the module, so that current can be transmitted smoothly; Quick connector design: realize fast and reliable electrical connection between modules or between modules and external devices; S3, cooling system integration, including: Air duct layout design: optimize the heat dissipation inside the module to keep the temperature stable during battery operation; Fan system configuration: Provides forced heat dissipation for the module to prevent the battery temperature from continuing to rise and exceeding the temperature threshold that affects the stable operation of the battery; S4. Install monitoring system, including: Sensor layout: Real-time monitoring of the temperature, voltage and current parameters inside the module to ensure the safe operation of the energy storage system; Data collection: collect sensor data, process and analyze the collected data, and then transmit the processed and analyzed data to the management platform; S5. Energy storage system integration and commissioning, including: Basic installation: Provide a stable installation foundation for the module to ensure stable operation of the energy storage system; Module installation: Install the modules into the cabinet from bottom to top and from front to back using a drawer-type slide rail structure.

2. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When designing the module unit, 12 2V / 1000Ah lead-acid batteries are designed as a standard module unit. The module dimensions are: 1200mm (length) × 600mm (width) × 800mm (height). The weight of the module does not exceed 500KG. The module adopts a drawer-type slide rail structure to facilitate the installation and removal of the module in the cabinet. One person can complete the installation operation.

3. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When making the module frame, 3mm thick galvanized steel plate is used as the frame material, and 45° folding edges are set at the corners of the frame to increase the structural strength; The surface of the frame is electrostatically sprayed to form a coating of 80-120μm. In order to facilitate the timely removal of heat from the batteries inside the module, the frame reserves 20% of the heat dissipation space, and a shock-absorbing bracket is installed at the bottom of the frame. The hardness of the shock-absorbing bracket is 60±5HA.

4. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When connecting the busbar, use T2 copper to make the busbar, tin the surface of the busbar, and set the cross-sectional area of ​​the busbar to 80mm 2 , contact area ≥40mm 2 , use bolts to tightly connect the busbar and the battery terminal, control the torque of the bolts at 35±2N·m, and measure the contact resistance, which should not exceed 0.1mΩ.

5. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: The quick connector uses a self-locking plug-in connector. The contact material of the quick connector is copper alloy, and the surface is silver-plated with 3-5μm. The insulating shell of the quick connector is flame-retardant PC material. The quick connector is equipped with an anti-reverse connection mechanism and a mechanical key design to prevent incorrect connection. The operating force of the quick connector is: insertion ≤50N, extraction ≤40N.

6. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When designing the air duct layout, adopt the upper air inlet and lower air outlet layout, set the spacing between modules to 100±5mm, the cross-sectional area of ​​the air duct to 0.12m2, the air flow speed in the air duct to 2-3m / s, and install guide plates in the air duct to optimize the air flow distribution; Fan system configuration: One set of fans is configured for every four modules. The maximum air volume of the fans is 2000m3 / h, the static pressure of the fans is 200Pa, and the noise of the fans is controlled to be ≤65dB. The fan configuration adopts N+1 redundant design.

7. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When laying out the sensors, the internal layout of each module is as follows: Four temperature sensors: with an accuracy of ±0.5°C, they monitor the temperature inside the module; Two voltage sampling sensors located at the head and tail of the module: with an accuracy of ±0.1%, they monitor the voltage changes inside the module; Two current sampling sensors located at the positive and negative poles of the module: with an accuracy of ±0.2%, monitoring the current inside the module; Signal line: Use shielded twisted pair cable with a cross-section of 0.5mm2.

8. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When collecting data: a 32-bit ARM architecture processor is selected, and the sampling frequency is set to 10 Hz. The processor is equipped with a data storage device with a storage capacity of 32 GB. The processor uses CAN bus communication with a baud rate of 500 kbps, and the response time of the processor is ≤10 ms.

9. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When installing the foundation, ensure that the horizontality of the installation foundation is ≤2mm / m, use M16 anchor bolts to fix the foundation to the ground, the depth of the M16 anchor bolts into the ground is 150mm, and a shock-proof pad with a thickness of 20mm and a hardness of 60±5HA is installed on the foundation, and the grounding resistance on the foundation is ≤4Ω.

10. The assembly process of a modular lead-acid battery energy storage system for a large base station according to claim 1, characterized in that: When installing the modules, the distance between two adjacent modules is 100mm, and the positioning accuracy of the modules is ≤5mm. To ensure that the cabinet can bear the weight of the modules and batteries, the cabinet level weighing is ≤2000KG. After the installation is completed, the module is debugged. The debugging content includes electrical connection inspection and heat dissipation effect test, and the single debugging time is ≤2 hours.

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