Design Scheme of lithium batteries for high-altitude communication support equipment (high altitude + low air pressure environment)
I.Background of Communication support equipment in the plateau
With the rapid development of portable communication devices, the human demand for global communication and interconnection, national defense construction, and the guarantee of people's livelihood security, to ensure communication security in complex and special areas such as plateaus, mountainous areas, high-altitude or extremely cold regions, to ensure the power supply energy guarantee for communication central base stations and other facilities in complex environments, and to avoid the impact of conventional power supply products on high-altitude and low-pressure areas under complex climatic conditions, Under extremely cold and high humidity conditions, lithium batteries, with their advantages of high energy density, portability, long cycle life and environmental friendliness, have replaced traditional lead-acid batteries and become the preferred solution for communication systems due to their inpracticality. This solution is designed to meet the power supply application requirements of communication support equipment in high-altitude areas, catering to diverse application environments. Its lithium battery solution is applied in fields such as communication energy systems, ensuring that the power supply system provides safe, efficient, and customized power solutions under conditions of high altitude, low air pressure, extreme cold, high humidity, and high temperature.
II. Analysis of Equipment Demand Characteristics
1. Equipment application characteristics
▲ Equipment type: Communication in extreme environments, emergency rescue, unmanned operation, etc.
▲ Working environment: Temperature range, from -40℃ to +70℃, low pressure, high-temperature and high-humidity environment, etc.
▲ Power demand: Large continuous/peak power, long battery life, and the voltage platform generally adopts 3.7V or 7.4V and other voltage platforms.
2. Core requirements for lithium batteries
▲ High safety: Meets the requirements of explosion-proof, shock resistance, and resistance to high and low temperatures under the harsh working conditions of special equipment.
▲ Long cycle life: ≥2000 times (80% capacity retention rate).
▲ Fast charging: Supports 2 to 3 hours of fast charging, suitable for high-intensity work.
▲ High-power discharge: The battery supports continuous high-current discharge, meeting the high-current requirements of high-power devices and ensuring their continuous and stable operation.
▲ Intelligent management: The BMS (Battery Management System) is equipped with functions such as overcharge protection, overdischarge protection, overcurrent protection, short-circuit protection, temperature protection, and fault diagnosis, making the battery more intelligent.
Discharge temperature range: -40℃ to +70℃. In a low-temperature environment of -40℃, the battery's discharge efficiency is over 70%. A wider range of ambient temperature adaptability.
Charging temperature: -20℃ to +50℃ range, with a wider adaptability to environmental temperatures.
III. Scheme Design
1. Battery selection
▲ Cell types: Ternary lithium batteries (ultra-low temperature, high energy density, high safety), lithium iron phosphate batteries (ultra-low temperature, high safety, long life), sodium-ion batteries (high safety, long life, good low-temperature performance). Different system cells are selected and matched according to different application scenarios.
▲ Battery combination configuration structure: Series and parallel schemes are designed based on the required voltage and capacity of the equipment to meet the requirements of different output voltage platforms.
▲ Structural design: IP65-IP68 protection grade, shock-resistant structure, explosion-proof, corrosion-resistant enclosure (suitable for extreme or high-pressure environments).
2. BMS Management System
Core functions:
▲ Real-time monitoring of the voltage, temperature, SOC (State of Charge), and SOH (State of Health) of individual battery cells.
▲ The battery charging active balancing technology enhances the consistency of usage among battery cells and extends the lifespan of the battery pack.
▲ The I2C/SMBUS/CAN/RS485 communication interface enables data interaction and communication with the main control system of the equipment.
▲ The Coulomb computing method makes the battery SOC more accurate and the battery smarter.
3. Charging solution
▲ Charging equipment: Customized smart charger/charger/charging cabinet, supporting constant current and constant voltage (CC-CV) charging.
▲ Charging strategy: Select fast charging or slow charging mode based on the working conditions to prevent battery overload.
▲ Intelligent control and management: Based on the technical performance characteristics of the battery, the battery charging process and fault diagnosis are intelligently controlled.
IV. Safety and Compliance
1. Safety protection
▲ Thermal management: By adopting a reasonable structural layout, thermal runaway is reduced, and physical temperature control is possible (for high-power scenarios), ensuring temperature uniformity during battery use and effectively controlling battery thermal runaway.
▲ Fault protection: Multiple hardware protection mechanisms such as overcharge, overdischarge, short circuit, overcurrent, and over-temperature.
▲ Fault protection: Multiple hardware protection mechanisms such as short circuit, overcurrent, and over-temperature.
▲ Explosion-proof certification: The design can pass various safety regulations certifications.
2. Standard compliance
▲ It complies with national standards such as GB31241-2022 (Safety Technical Specification for Lithium-ion Batteries and Battery Packs for Portable Electronic Products), GB 17761-2024 (Safety Technical Specification for Electric Bicycles), GB/T 34131 (Lithium Batteries for Power Storage), GB 38031 (Safety Requirements for Batteries for Electric Vehicles), etc.
▲ How to obtain domestic and international certifications: GB certification, UN38.3 certification, UL certification, IEC certification, CE certification and other various certification requirements.
V. Project Implementation Plan
Number |
Progress stage |
Project content |
Periodic plan |
1 |
Demand research |
Equipment parameter and working condition data collection |
Within one week |
2 |
Scheme design |
Customized battery packs and BMS development |
2~3weeks |
3 |
Sample testing | Charging and discharging, high and low temperature, safety protection, structural performance verification testing, design compliance verification testing |
3~4weeks |
4 |
Small-batch trial production | Material preparation plan, production assembly, aging, and full inspection and testing |
2~3weeks |
5 |
Medium-batch trial production | Material preparation plan, production assembly, aging, and full inspection and testing |
2~3weeks |
6 |
Mass production | Material preparation plan, production assembly, aging, and full inspection and testing |
4~6weeks |
7 |
Delivery, transportation and maintenance | Installation and commissioning, operation training | Within one week |
VI. Economic Benefit Analysis
1. Cost direction
▲ As a new type of energy product, lithium batteries are energy-saving and environmentally friendly, portable and lightweight, with low costs and easy maintenance. Compared with AC wired power supply, they are superior.
2. Energy-saving benefits:
▲ The charging efficiency is over 95%, significantly reducing energy consumption.
3. Maintenance cost:
▲ The maintenance-free design significantly reduces manual inspection and manufacturing costs.
VII. After-sales Service
1. Warranty period: 1 to 5 years of after-sales warranty, with a lifespan of 500 to 3,000 cycles or more (whichever comes first).
2. Remote monitoring: According to the actual demand status, the cloud platform provides real-time monitoring of the battery status and early warning of potential faults.
3. Emergency Response: Respond within 4 hours, provide solutions within 8 hours, and offer on-site technical support within 24 to 48 hours.
Hint:
▲ The plan needs to be refined based on specific equipment parameters (such as voltage, capacity, and size limitations).
▲ If special environments (such as explosion-proof and shock-resistant) are involved, corresponding protective designs need to be added.
▲ It is recommended to conduct joint debugging with the equipment manufacturer to ensure the compatibility of the battery with the entire machine system.