In-Depth Analysis of Key Technologies for Energy Storage Systems

This document provides a comprehensive analysis of key technologies in energy storage systems, focusing on bus design, module structures, electrical connections, thermal management, and safety. It details conductor selection for a 1500V system, including cross-section calculation and welding verification for aluminum busbars. The comparison between Tesla Megapack and CATL module solutions highlights cost and process differences, such as blister versus injection molding. Electrical connection reliability is addressed with bolted connection specifications and contact resistance control, including a case study of overheating improvement. Thermal management adhesive technology, exemplified by BYD blade battery, covers performance data and gluing process innovations. The document also explores electrical component design (relays, fuses), data acquisition boards with balancing strategies, insulation material selection (epoxy, PC/PBT, polyurethane), and thermal runaway protection using mica, aerogel, and fire suppressants. Welding process solutions (penetration and tailor welding) and insulation withstand voltage test design principles are included, emphasizing safety margins and environmental factors. Overall, it serves as a technical guide for engineers optimizing energy storage system reliability, cost, and performance.