KR102921173B1 - Installation Process Of Energy Storage System Rack - Google Patents

Abstract

The present invention relates to an installation process of an ESS rack, and more specifically, to an installation process of an ESS rack, characterized by including a first step of assembling an ESS rack; a second step of performing a first inspection of the assembled ESS rack; a third step of storing the first inspection results; a fourth step of transporting the ESS rack, on which the first inspection has been completed, to a field site; a fifth step of performing a second inspection of the transported ESS rack; a sixth step of storing the second inspection results; a seventh step of comparing the first inspection results and the second inspection results of the ESS rack; and an eighth step of installing the ESS rack, on which the second inspection has been completed.

Description

Installation Process of Energy Storage System Rack

The present invention relates to an installation process of an ESS rack, and more specifically, to an installation process of an ESS rack that can accurately determine whether an ESS rack is abnormal by comparing and analyzing the ESS rack information at the time of shipment with the ESS rack information at the installation site using portable inspection equipment, thereby reducing the occurrence of accidents and increasing the efficiency of on-site installation.

Secondary batteries, which boast high electrical properties such as high energy density and easy applicability across a wide range of product categories, are widely used not only in portable devices but also in electric vehicles (EVs) and hybrid electric vehicles (HEVs) powered by electrical power sources. These batteries are attracting attention as a new energy source for environmental friendliness and energy efficiency, not only because they can dramatically reduce fossil fuel use, but also because they produce no byproducts from energy use.

These secondary batteries include lithium ion batteries, lithium polymer batteries, nickel cadmium batteries, nickel hydrogen batteries, and nickel zinc batteries, and a number of battery cells are connected in series or parallel to form a single battery module or battery pack.

Meanwhile, the recently garnering attention is the Energy Storage System (ESS), a device comprised of multiple ESS racks. This device maximizes power efficiency by storing generated electricity in batteries and then supplying it to consumers when needed. These ESSs are also used in conjunction with uninterruptible power supplies (UPSs), which ensure stable power supply in the event of sudden power outages or power outages, and solar power generation systems, which convert sunlight into electrical energy.

Fig. 1 is a conceptual diagram of an ESS rack according to the prior art. As illustrated in Fig. 1, the ESS rack may be configured to include a housing (20), a plurality of battery modules (10) stacked on the housing (20), and a connecting member (30) electrically connecting the plurality of battery modules (10).

The housing (20) has at least a portion of a vertical peripheral surface in the direction in which a plurality of battery modules (10) are stacked sealed, and the remaining peripheral surfaces are open. In addition, the plurality of battery modules (10) are electrically connected in series/parallel through a connecting member (30), and a battery rack controller (50) that controls the plurality of battery modules (10) is additionally provided. For example, the plurality of battery modules (10) can be connected to the battery rack controller (50) through the connecting member (30), and the battery rack controller (50) operates to prevent fire or explosion, etc., by blocking a high-voltage electrical connection when a short circuit occurs in any one of the plurality of battery modules (10).

Meanwhile, ESS racks are impossible to assemble on-site because hundreds of battery cells must be electrically connected, so they are usually shipped in ESS rack units and transported by various means of transportation before being installed.

However, battery cells can be damaged or fans can malfunction due to various factors, such as unintended impact or housing distortion during transportation or installation. Operating a defective ESS rack can lead to a major accident. Furthermore, even if problems are discovered before operation, repairs must be made or the ESS rack must be replaced, inevitably increasing costs and extending installation time.

Korean Patent Publication No. 2019-0124483

The present invention aims to provide an ESS rack installation process capable of efficiently installing a plurality of ESS racks in order to solve the above-mentioned problems.

In addition, the present invention aims to provide an installation process of an ESS rack that can contribute to accident prevention by accurately determining whether or not the ESS rack is defective.

The process for installing an ESS rack according to the present invention for solving the above problems is characterized by including a first step of assembling an ESS rack; a second step of performing a first inspection of the assembled ESS rack; a third step of storing the first inspection results; a fourth step of transporting the ESS rack on which the first inspection has been completed to a field site; a fifth step of performing a second inspection of the transported ESS rack; a sixth step of storing the second inspection results; a seventh step of comparing the first and second inspection results of the ESS rack; and an eighth step of installing the ESS rack on which the second inspection has been completed.

In addition, the installation process of the ESS rack according to the present invention may further include a ninth step of performing a third inspection of the installed ESS rack; a tenth step of storing the third inspection results; and an eleventh step of comparing the first inspection results, the second inspection results, and the third inspection results of the ESS rack.

In addition, in the installation process of the ESS rack according to the present invention, the first inspection and second inspection items are characterized by being at least one of SW/HW Ver., rack SOH (State Of Health), rack SOC (State Of Charge), active unit, rack voltage, PC/MC operation, module voltage, cell voltage, error signal, module serial number, BPU relay control, fan control, module thermistor, and voltage fluctuation rate.

In addition, in the installation process of the ESS rack according to the present invention, the first inspection and the second inspection are characterized in that they are performed by a portable EOL tester that can be connected to the ESS rack in a wired or wireless manner.

In addition, in the installation process of the ESS rack according to the present invention, the EOL tester is connected to the BPU (Battery Protection Unit) of the ESS rack, and the BPU (Battery Protection Unit) is characterized in that it receives power from the EOL tester.

In addition, in the installation process of the ESS rack according to the present invention, the storage of the first inspection result, the storage of the second inspection result, and the comparison of the first inspection result and the second inspection result are characterized in that they are performed by a portable terminal that can be connected to the EOL tester in a wired or wireless manner.

In addition, in the installation process of the ESS rack according to the present invention, the secondary inspection is characterized in that it is performed in a state where the external power supplied to the ESS rack is cut off.

In addition, in the installation process of the ESS rack according to the present invention, between the seventh and eighth steps, a step of determining a defect when the comparison values of the first and second inspection results of the ESS rack do not match is further performed.

In addition, in the installation process of the ESS rack according to the present invention, between the seventh and eighth steps, a step of determining a defect when the comparison value between the first inspection result and the second inspection result of the ESS rack is outside a predetermined range is further performed.

In addition, in the installation process of the ESS rack according to the present invention, it is characterized in that there are multiple ESS racks.

According to the installation process of the ESS rack according to the present invention, there is an advantage in that it is possible to check for damage to the ESS rack that may have occurred during the transport process by comparing and analyzing the ESS rack information at the time of shipment from the factory and the information after transport to the site.

In addition, according to the installation process of the ESS rack according to the present invention, the equipment for analyzing information of the ESS rack is portable, so that measurements can always be made with the same inspection equipment, which has the advantage of contributing to improving the reliability of the analysis results.

In addition, the installation process of the ESS rack according to the present invention has the advantage of saving the cost and time for reinstallation because information related to various items is inspected prior to on-site installation of the ESS rack.

Figure 1 is a conceptual diagram of an ESS rack according to conventional technology.
Figure 2 is a flowchart illustrating the installation process of an ESS rack according to a preferred embodiment of the present invention.
Figure 3 is a conceptual diagram of an ESS rack according to a preferred embodiment of the present invention.
Figure 4 is a conceptual diagram for explaining an inspection method of an ESS rack in the present invention.
Figure 5 is a conceptual diagram for explaining an example of an inspection result of an ESS rack in the present invention.

In this application, terms such as “includes,” “has,” or “comprises” are intended to specify the presence of a feature, number, step, component, part, or combination thereof described in the specification, and should be understood as not excluding in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

Additionally, the same drawing reference numerals are used for parts with similar functions and actions throughout the drawings. Throughout the specification, when a part is said to be connected to another part, this includes not only direct connections but also indirect connections with other elements intervening. Furthermore, inclusion of a component does not exclude other components unless specifically stated otherwise, but rather implies the inclusion of additional components.

Hereinafter, the installation process of a large-capacity ESS rack according to the present invention will be described.

FIG. 2 is a flowchart illustrating an installation process of an ESS rack according to a preferred embodiment of the present invention. As illustrated in FIG. 2, the installation process of the present invention comprises a first step of assembling an ESS rack; a second step of performing a first inspection of the assembled ESS rack; a third step of storing the first inspection results; a fourth step of transporting the ESS rack, which has undergone the first inspection, to a field site; a fifth step of performing a second inspection of the transported ESS rack; a sixth step of storing the second inspection results; a seventh step of comparing the first and second inspection results of the ESS rack; an eighth step of installing the ESS rack, which has undergone the second inspection; a ninth step of performing a third inspection of the installed ESS rack; a tenth step of storing the third inspection results; and an eleventh step of comparing the first inspection results, the second inspection results, and the third inspection results of the ESS rack.

To explain each step in detail, the first step of assembling an ESS rack is to assemble one ESS rack by storing multiple battery packs in the space formed by the frame.

As shown in FIG. 3, which is a conceptual diagram of an ESS rack according to a preferred embodiment of the present invention, the ESS rack (100) includes a vertical frame (110), a horizontal frame (120), and a battery pack (130).

The vertical frames (110) can be positioned at a predetermined distance apart from each other, for example, four in number to support corner portions of a battery pack (130) having a roughly hexahedral shape, but the number can be changed to any number, such as six, as needed.

The horizontal frame (120) is positioned inside the vertical frame (110) so that multiple battery packs (130) can be stored in multiple stages. Specifically, the horizontal frame (120) has a roughly 'L' shape consisting of a vertical support member (121) fixed to the inner surface of the vertical frame (110) and a horizontal support member (122) extending perpendicularly from the lower edge of the vertical support member (121).

A plurality of horizontal frames (120) having the above configuration are provided at a predetermined interval along the height direction of the vertical frame (120) so that the storage space (S) in which the battery pack (130) can be stored, i.e., the bottom edges of the battery pack (130) can be supported by a pair of horizontal support members (122) facing each other.

And the battery pack (130) stored in the storage space (S) is composed of a plurality of unit modules, and each unit module has one or more battery cells connected in series or parallel, and although not shown in the drawing, a control unit (not shown) for controlling and managing the battery packs (130) is additionally provided.

Meanwhile, the above-described ESS rack (100) is only an example, and is not limited to the above shape as long as multiple battery packs (130) can be stored in a frame to form one ESS rack (100).

In the second step of performing a primary inspection of the assembled ESS rack, it is a step to inspect whether the ESS rack is operating normally, such as the multiple battery packs (130) stored in the rack, the unit modules constituting the battery pack (130), the multiple unit cells constituting the unit modules, and their electrical connection status, at the factory shipment stage.

Fig. 4 is a conceptual diagram for explaining an inspection method of an ESS rack in the present invention, and Fig. 5 is a conceptual diagram for explaining an example of an ESS rack inspection result in the present invention.

As shown in Fig. 4, inspection of the ESS rack can be performed using a portable EOL tester (200) and a portable terminal (300).

First, with respect to the portable EOL tester (200), one end of a CAN (Controller Area Network) cable is connected to the EOL tester (200) connector, and the other end is connected to the BPU (Battery Protection Unit) connector of the ESS rack, thereby allowing the EOL tester (200) and the ESS rack to communicate.

Here, the power required to operate the BPU (Battery Protection Unit) of the ESS rack can be supplied from the EOL tester (200), and the EOL tester (200) is supplied with power from an external source or is built-in with a rechargeable battery.

Although the EOL tester (200) and the ESS rack are expressed as CAN (Controller Area Network) cables in the drawing, a wireless communication method may be used if it can perform the same function.

The portable terminal (300) connected to the EOL tester (200) via a wired or wireless method has a built-in program for controlling the EOL tester (200). That is, while the EOL tester (200) and the ESS rack are connected via a CAN (Controller Area Network) cable, the inspector connects to a portable terminal (300) such as a laptop or PDA and inputs and controls various information necessary for the inspection, such as selection of items to be measured and start and end of the inspection.

Meanwhile, the items to be inspected using the EOL tester (200) and the portable terminal (300) are preferably at least one of SW/HW Ver., rack SOH (State Of Health), rack SOC (State Of Charge), active unit, rack voltage, PC/MC operation, module voltage, cell voltage, error signal, module serial number, BPU relay control, fan control, module thermistor, and voltage fluctuation rate, and it is more preferable to inspect all of them.

To explain each item in more detail, SW/HW ver. is the version information of the software and hardware of the rack, rack SOH (State Of Health) is the ratio of the available capacity compared to the time of battery production, and rack SOC (State Of Charge) is the state of charge rate (%).

And the Active Unit checks the number and status of the units that make up the rack, that is, the modules, the PC/MC operation checks whether the Pre-Charge Contactor/Main Contactor is operating within the BPU (Battery Protection Unit), the error signal checks whether the rack, module, and cell are error signals, the BPU relay control checks the relay components within the BPU, and the fan control checks whether the fan of the module is operating.

Also, the module thermistor checks for abnormalities in the thermistor within the module, and lastly, the voltage fluctuation rate refers to the voltage fluctuation rate set considering the natural discharge of the battery cell.

When an abnormality occurs in BPU relay control, PC/MC operation, error signal, or fan control as a result of inspection using an EOL tester (200) and a portable terminal (300), the cause can be identified and follow-up measures can be taken, such as replacing parts, for example, the BPU itself.

Of course, if the rack SOH (State Of Health), rack SOC (State Of Charge), active unit, rack voltage, module voltage, and cell voltage fall within predetermined values or ranges, these tests can be terminated without any special action.

The above-described results can be expressed as various symbols, graphs, etc., including numbers, on the screen of a portable terminal, as shown in Fig. 5, and if an abnormal result is obtained, it can be confirmed immediately.

In the third step of saving the first inspection results, the aforementioned inspection items are saved in the EOL tester (200) and/or a portable terminal (300) connected to the EOL tester (200).

The primary inspection results saved in this way are used as reference data to determine whether any unexpected problems occurred during the process of transporting the ESS rack to the field site, and this will be described later.

The fourth step is to transport the ESS racks that have completed the first inspection to the field site. This step involves transporting them to the location where the ESS racks will be installed using various known means of transportation, such as vehicles or ships.

The fifth step of performing a secondary inspection of the transported ESS rack is a step of inspecting the ESS rack (100) transported by the transport vehicle once again.

As described above, a serious defect may occur in the ESS rack (100) during the transport process, and if an ESS rack (100) that is not functioning properly is installed on site, it may lead to a major accident.

Here, it is desirable to perform the secondary inspection items in the same manner as the primary inspection items.

Meanwhile, in the fifth step of performing the secondary inspection, it is more desirable to use the same EOL tester (200) and portable terminal (300) used in the primary inspection. In the ESS rack (100), accidents can occur due to small errors or differences, and therefore, it is recommended to use the same EOL tester (200) and portable terminal (300) for both the primary and secondary inspections to maximize accuracy.

The specific inspection method and items are the same as the first inspection described above, so repeated explanations will be omitted.

In the sixth step of saving the secondary inspection results, the inspected items and their results are saved in the EOL tester (200) and/or a portable terminal (300) connected to the EOL tester (200).

The seventh step, which compares the first and second inspection results of the ESS rack, is a step to determine whether a problem occurred in the ESS rack (100) during the transport process.

As shown in Figure 5, a conceptual diagram comparing the results of the first and second inspections of the ESS rack of the present invention, if the first and second inspection results are identical or differ within an acceptable range, the system can be considered normal. However, if the results fall outside the abnormal range, the cause must be identified and appropriate measures, such as component replacement, taken.

In the past, all racks were installed on site and then a test run of the ESS system was performed to check for defects. Therefore, if a problem occurred during the test run, there was a disadvantage in that the installation period was inevitably extended along with increased costs due to reinstallation.

However, since the EOL tester (200) and the portable terminal (300) are used in the present invention to perform inspection once more at the time of shipment and before installation, the aforementioned problems can be prevented in advance.

The 8th step of installing the ESS rack after the secondary inspection is the step of installing the ESS rack (100) at a predetermined site. It is possible to perform the secondary inspection after installing the ESS rack (100) at the site, but it is recommended to perform the secondary inspection before installing at the site because usually hundreds to thousands of ESS racks (100) are installed at one site and the ESS rack (100) is very heavy and difficult to disassemble or transport.

Step 9, which performs a third inspection of the installed ESS rack, and Step 10, which stores the third inspection results, are performed substantially the same as Steps 2 and 3 described above.

In addition, the 11th step of comparing the results of the second and third inspections of the ESS rack is to determine whether any problems occurred during the process of installing the ESS rack (100) on site.

Meanwhile, in the ESS rack (100) inspection of the present invention, that is, the first inspection, the second inspection, and the third inspection, are performed in a state where the external power supplied to the ESS rack (100) is cut off, because the battery cells are charged to a predetermined amount at the time of shipment.

As described above, specific parts of the present invention have been described in detail. To those skilled in the art, such specific descriptions are merely preferred embodiments, and the scope of the present invention is not limited thereby. It is obvious to those skilled in the art that various changes and modifications are possible within the scope and technical idea of the present invention, and it is natural that such changes and modifications fall within the scope of the appended patent claims.

100: ESS Rack
110: Vertical frame
120: Horizontal frame
121: Vertical support 122: Horizontal support
130: Battery Pack
200: EOL Tester
300: Portable terminal

Claims (10)

Step 1 of assembling the ESS rack;
The second step is to perform a primary inspection of the assembled ESS rack;
Step 3: Saving the results of the first test;
Step 4: Transporting the ESS racks that have completed the first inspection to the field site;
Step 5: Performing secondary inspection of the transported ESS rack;
Step 6: Saving the secondary inspection results;
Step 7: Comparing the results of the first and second inspections of the ESS rack; and
Step 8: Installing the ESS rack after completing the secondary inspection;
The above first and second inspections are performed by the same portable EOL tester that can be connected to the ESS rack via wired or wireless means.
An ESS rack installation process characterized in that the storage of the first inspection results, the storage of the second inspection results, and the comparison of the first inspection results and the second inspection results are performed by a portable terminal that can be connected to the EOL tester in a wired or wireless manner.
In the first paragraph,
Step 9: Performing a 3rd inspection of the installed ESS rack;
Step 10: Saving the results of the third inspection; and
An ESS rack installation process characterized by further including an 11th step of comparing the first inspection results, the second inspection results, and the third inspection results of the ESS rack.
In the first paragraph,
The above first and second inspection items are characterized by at least one of SW/HW Ver., rack SOH (State Of Health), rack SOC (State Of Charge), active unit, rack voltage, PC/MC operation, module voltage, cell voltage, error signal, module serial number, BPU relay control, fan control, module thermistor, and voltage fluctuation rate.
delete In the first paragraph,
An installation process of an ESS rack, characterized in that the EOL tester is connected to a BPU (Battery Protection Unit) of an ESS rack, and the BPU (Battery Protection Unit) receives power from the EOL tester.
delete In the third paragraph,
An ESS rack installation process characterized in that the above secondary inspection is performed while the external power supplied to the ESS rack is cut off.
In the third paragraph,
An ESS rack installation process characterized in that, between the 7th and 8th steps, a step is further performed to determine a defect when the comparison values of the 1st and 2nd inspection results of the ESS rack do not match.
In the third paragraph,
An ESS rack installation process characterized in that, between the 7th and 8th steps, a step is further performed to determine a defect when the comparison value between the first and second inspection results of the ESS rack is outside a predetermined range.
In the first paragraph,
An installation process of an ESS rack, characterized in that the above ESS racks are multiple.