Design Scheme of Reliable lithium Battery for Remote Monitoring System of Border Defense Infrared Thermal Imager
I. Background of the Remote Monitoring System for Border Infrared Thermal Imagers
As an important monitoring instrument for national defense security and border protection, the application background of the border infrared thermal imager is mainly reflected in the following aspects:
▲ Complex terrain: The border area encompasses various terrains such as high mountains, deserts, forests, and grasslands. In some areas, transportation is inconvenient and natural conditions are harsh, posing challenges to border security. In areas with dense vegetation such as high mountains and forests, the field of view of ordinary monitoring equipment is limited, but infrared thermal imagers can penetrate the vegetation and detect targets hidden within.
▲ Threat of illegal border crossing: Criminals often choose remote and poorly monitored areas along the border to illegally cross the border for activities such as smuggling, illegal border crossing, and espionage. Infrared thermal imagers can monitor the entire border in real time. Once a person's body heat signal appears, they can issue a timely warning, helping border guards quickly detect and intercept.
▲ Smuggling of goods: Smugglers may use vehicles, ships and other means of transportation to carry out illegal smuggling of goods at the border. Infrared thermal imagers can detect the thermal signals of vehicles and ships, enabling them to track their movements even at night or in concealed environments, providing support for combating smuggling.
▲ Potential military threats: Manual patrols are restricted by geographical conditions and the physical strength of personnel. Their patrol range and frequency are limited, and they are prone to omissions in bad weather and at night, making it impossible to achieve full-time and all-round monitoring.
The shortcomings of ordinary monitoring equipment: Ordinary cameras rely on visible light for imaging and need supplementary lighting at night. Supplementary lighting can easily expose the monitoring position and the effect is not as good as that of infrared thermal imagers. Under bad weather conditions, its imaging quality drops significantly, making it difficult to effectively monitor the target.
The equipment features portability, stability, safety and long battery life under complex meteorological conditions. As for power supply guarantee, new energy lithium batteries, with their high energy density, long cycle life and environmental friendliness, have become the preferred solution for border defense infrared monitoring systems. This solution is aimed at the application requirements of lithium batteries in infrared monitoring equipment projects. Ensure that lithium batteries can provide safe, efficient and customized power solutions in special fields;
II. Analysis of Equipment Demand Characteristics
1. Equipment application characteristics
▲ Equipment types: Real-time monitoring operations in environments such as plains, forests, mountains, deserts, and oceans.
▲ Working environment: Temperature range, from -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 7.4V or 12V.
2. Core requirements for lithium batteries
▲ High safety: Meets the explosion-proof, shock-proof, waterproof and anti-interference requirements of the 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: 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 can be reduced. A physical cooling system 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.In terms of cost
▲ Lithium batteries require a relatively large initial investment, but they have an absolute advantage in terms of long-term usage costs.
2. Energy-saving benefits:
▲ The charging efficiency is over 95%, which can significantly reduce energy consumption compared with AC power supply.
3. Maintenance cost:
▲ Maintenance-free design reduces AC circuit maintenance and personnel costs.
VII. After-sales Service
1. Warranty period: 1 to 5 years of after-sales warranty, with a lifespan of 500 to 2,000 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 plateaus and the ocean) are involved, corresponding protective designs need to be added.
▲ It is recommended to conduct joint debugging with the equipment manufacturer to ensure that the battery is compatible with the entire machine system