Design Scheme of lithium Battery for Solar Monitoring System

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Published on: 2025-05-01 00:00
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I. Project Background of Solar Energy Monitoring System Equipment
   With the growth of monitoring demands: The demand for monitoring systems has increased in multiple fields, especially in remote and complex environments. These areas are far from the power grid, and the traditional power supply methods are costly and difficult to implement.
▲ Municipal power supply issue: Unstable municipal power supply may cause monitoring interruptions and pose safety hazards. In addition, the operating cost is high, and electricity charges become a burden when deployed on a large scale.
Advantages of solar-powered monitoring: Solar-powered monitoring systems solve the power supply problem in remote areas, are flexible to install, have no carbon emissions, and are in line with the concept of sustainable development.
▲ Advancements in lithium battery technology: The energy density and chargation-discharge efficiency of lithium batteries have significantly improved, their cycle life has been extended, and costs and maintenance have been reduced.
▲ The growth in market demand: The enhancement of security awareness and the development of Internet of Things (iot) technology have driven the increase in demand for solar monitoring systems and lithium batteries.
▲ Policy support: The government encourages the development of renewable energy and provides policy support.
   New energy lithium batteries, with their advantages of high energy density, light weight, long cycle life and environmental friendliness, have gradually become the preferred solution for solar monitoring systems. This solution is designed to meet the application requirements of lithium batteries in solar monitoring system equipment projects, ensuring that lithium batteries provide safe, efficient and customized power solutions for their equipment.

II. Analysis of Equipment Demand Characteristics
1. Equipment application characteristics
▲ Equipment type: Real-time security monitoring in extreme environments, etc.
▲ Working environment: Temperature range, -40℃ to +70℃, high temperature, extremely cold, high humidity environment, etc.
▲ Power demand: Large continuous/peak power, long battery life, and the voltage platform generally adopts high-voltage platforms such as 12V or 24V.

2. Core requirements for lithium batteries
▲ High safety: Meets the explosion-proof, shock-proof and waterproof requirements of special equipment under harsh working conditions.
▲ Long cycle life: ≥2000 times (80% capacity retention rate).
▲ Fast charging: Supports 1 to 2 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 to IP68 protection grade, shock-resistant structure, explosion-proof enclosure (suitable for extreme environments or flammable and explosive 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. Air cooling/liquid cooling systems can be used (for high-power scenarios) to ensure temperature uniformity during battery use and effectively control 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 comparison
▲ The initial investment in lithium batteries is about 30% to 50% higher than that in lead-acid batteries, but their lifespan is extended by more than three times and the long-term cost is reduced by 40% to 60%.
2. Energy-saving benefits:
▲ The charging efficiency is over 95%, significantly reducing energy consumption compared to lead-acid batteries (70% to 80%).
3. Maintenance cost:
▲ Maintenance-free design reduces the costs of manual inspection and electrolyte replenishment.

VII. After-sales Service
1. Warranty period: 1 to 5 years of after-sales warranty, with a lifespan of over 500 to 800 cycles (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 plateaus and wetlands) 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.

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