Renewable Energy

Container Design for Battery Storage System

The client is a leading Taiwanese energy storage solutions provider, specializing in the design and integration of battery storage systems for renewable energy and grid applications. Their focus lies in deploying robust, compact, and compliant solutions for global markets.

Scope

The client sought us to optimize the design of a 10-feet high cube-shaped container to house battery energy storage systems (BESS). The project required a delicate balance of weight reduction, structural integrity, thermal regulation, and safety compliance with international standards.

The scope of the project included:

Optimizing the BESS container design to reduce weight without compromising its structural integrity.
Ensuring the design adhered to relevant global safety standards, including ISO regulations for shipping containers.
Performing static structural simulations to verify its structural stability under standard loading conditions as per ISO regulations.
Integrating a robust cooling system to manage the heat generated by batteries, and transformer, maintaining safe operating temperatures in all conditions.

Challenge

The key challenges in designing the battery energy storage system container included:

Weight Reduction: The container design had to be lightweight yet strong enough to withstand operational stresses like shocks and seismic forces, ensuring the batteries were protected during transport and deployment.
Compliance with International Standards: The container design should meet stringent international standards for shipping containers.
Thermal Regulation: The design had to incorporate proper cooling and ventilation to withstand temperature fluctuations and prevent failure.
Weather Resistance: As the container would be kept outdoors, it must withstand environmental conditions like rain, extreme temperatures, and high winds, while keeping the internal components safe.
Doors, Frames and Handles: Aesthetic design was also a key consideration. We needed doors, frames, and handles to be visually appealing and easy to use.

Solution

To address these challenges and meet the client’s requirements, we leveraged our design team’s efficient product design capabilities. We conducted thorough research into the latest technologies and design standards, working closely with the client’s engineering teams to understand their needs. Based on the input, we developed several concept designs that complied with international standards.

Our effective solution included:

Optimized Material Selection

As the initial step in our BESS container design process, we conducted thorough research and performed detailed load calculations to determine the right material and thickness. We selected high-strength, lightweight materials like high-tensile steel for the frame and corrugated panels.

To ensure the container could withstand the required loads while staying strong and lightweight, a 2mm wall thickness was chosen based on load analysis and material performance.

Detailed Design of the Container

After selecting the material, we focused on identifying areas where we could reduce weight without compromising the container's strength. We designed a double-glazed wall system using thinner yet stronger steel sheets.
We added precise ribbed patterns to the inner panel of the container to enhance rigidity and reduce weight. The outer panel was kept flat for protection. A specialized insulation layer between the panels provided thermal regulation and shock absorption, ensuring safety.
We optimized the corner posts, cross members, and roof panels to balance strength and efficiency. The corner posts were reinforced to 4mm–6mm to withstand load stresses. This allowed us to reduce material in other areas without compromising durability. The bottom skid channels were also optimized for safer handling during transport and stacking.
The design included efficient battery racks with secure mounting points and internal partitions to maximize space and improve organization. The internal layout of the container was optimized to ensure smooth operation. We strategically added access points for easy maintenance and quick access to key components.
We added corner castings, mounting brackets, and internal structures to securely hold the battery components. The doors, frames, and handles were designed for both durability and visual appeal. Overall, the container design offered a modern, sleek look while ensuring ease of operation.

Static Structural Simulations

Once the container’ structure design was finalized, we used SolidWorks Simulation to test and validate its stability under static loads and impact during transport. The results confirmed the design could handle standard conditions without compromising integrity.

Thermal Management Design

To ensure optimal performance and safety of battery storage system, effective thermal management was a key consideration in the design. We integrated an efficient HVAC system into the container design by:

Incorporating two AC chillers to cool the battery area, regulating the temperature inside the container.
Installing two mounted fans on top of the transformer block to circulate the air and ensure efficient heat dissipation.

The design ensured that the temperature inside the container stayed within the required range, preventing excessive cooling or overheating. Additionally, we incorporated louver arrangement in the side walls and door to allow proper airflow, further preventing heat buildup inside the container.

Weather Resistance

An efficient weatherproof sealing was integrated into the design to protect the container from external environmental factors, ensuring long-term durability and safeguarding the internal systems.

All doors, joints, and access points were sealed with weather-resistant gaskets and sealants to prevent water entry.

We ensured the container complied with the IP54 Rating, ensuring protection against dust ingress and resistance to splashing water from all directions, especially during rains.

Compliance with Standards

We ensured the design adhered to ISO standards for shipping containers, specifically ISO 1496-1 for structural performance and ISO 668 for external dimensions. The design ensured the container can handle stacking loads up to 1.8 times its maximum gross weight, and its dimensions are accurate to meet functional requirements.

Final Design and Manufacturing Considerations

Leveraging our CAD expertise, we developed a 3D parametric model of the container to validate the design and ensure a precise fit for all components. We optimized the design for easy manufacturing by using standardized, globally available components, helping to lower material costs and reduce production lead times.

Our team also provided support to the client regarding fabrication techniques, including recommendations on where to use welded joints for strength and where mechanical fastening methods would be more efficient.

Our final deliverables to the client included a 3D model and assembly drawing of the battery energy storage system container.

BESS-container-3D-model

Value and Benefits

The final design achieved significant reduction in weight as per the requirement, contributing to cost savings in shipping and handling without compromising structural strength or safety.

Static simulations confirmed the container could safely handle expected operational stresses. The integrated HVAC system maintained the batteries' ideal temperature, improving durability and preventing overheating or freezing. The container was also weatherproof, offering protection against environmental elements.

Strategically placed access points and an optimized internal space simplified maintenance. The design helped the client reduce operational downtime and maintenance efforts.

The container met all relevant international standards including ISO 1496-1, ISO 668 and IP54 Rating, giving client peace of mind and reducing operational risks.