Design Scheme of lithium Battery for Special Ignition and Starting Device Equipment

Author: admin
Published on: 2025-05-01 00:00
Read: 0

I.Background of Special ignition and Starting Device equipment
   With the continuous development of modern human technological progress and the Industrial Revolution, more and more industrial mechanization has replaced traditional manual labor, covering all areas of human life, such as aerospace, daily automobiles, construction machinery, shipbuilding operations, military fields, underwater navigation and other mechanical equipment power start-up guarantees, ensuring that the equipment can start and work normally in any environment. With the continuous development of technology, the requirements for power supply security of equipment are showing characteristics such as high power, lightweight, long endurance, high safety, and ultra-low temperature. Along with the rapid development of new energy technology, lithium batteries, with their advantages of high energy density, long cycle life, and environmental friendliness, are gradually replacing traditional batteries as power supply security and have become the best preferred solution for the power systems of special equipment. This solution is designed to meet the lithium battery application requirements of special ignition and starting device equipment, ensuring that the equipment can provide a stable, safe, lightweight and efficient power supply solution under extreme conditions.

II. Analysis of Equipment Demand Characteristics
1. Equipment application characteristics
▲ Device type: Device startup in a global environment, battery life guarantee, etc.
▲ Working environment: Temperature range, -40℃ to +70℃.
▲ Power demand: Large continuous/peak power, long battery life. The voltage platform generally adopts 12V/24V/48V and other voltage platforms.

2. Core requirements for lithium batteries
▲ High safety: Meets the explosion-proof, shock-proof, waterproof and corrosion-resistant requirements of special equipment under harsh working conditions.
▲ Long cycle life: ≥2000 times (80% capacity retention rate).
▲ Fast charging: Supports 1 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 and corrosion-resistant enclosure (suitable for extreme corrosive environments 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. Air cooling 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.

6. 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 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 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, deep sea, aerospace) 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.

Share

Recommended Posts