Traction batteries ZUBR LI-ION (LiFePO4)

Lithium iron phosphate batteries belong to the Li-ion group of batteries, but due to significant differences in characteristics they are separated into a separate subgroup. Like lithium-ion models, they accumulate a large amount of energy in a compact size and light weight, do not require maintenance and do not have a pronounced memory effect.

Additional advantages of LiFePO4 batteries are:
— stable structure;
— resistance to deep discharges and chemical degradation (aging);
— maintaining performance in the cold;
— no voltage drops under load;
— increased values of charging and discharging currents — the ability to quickly charge and autonomously power powerful equipment;
— maximum safety — resistance to fire and explosions, even during depressurization;
— increased resource — more than 3000 charge-discharge cycles.

Unlike other batteries of the Li-ion group, models of the LiFePO4 subgroup have a lower voltage — 3.2–3.3 V nominal, operating range — from 2.8 to 3.6 V. The specific capacity of such cells is on average 150 mAh/g, and power (energy-to-weight ratio) is about 510 Wh/kg.

Traction batteries ZUBR LI-ION on LiFePO4 cells are designed to operate in regular deep discharge mode and have all the advantages of lithium-iron-phosphate technology.

The battery configuration is performed by connecting blocks of cells in series to set the required voltage, because When connected in series, the source voltages add up. To collect capacity, a parallel connection of cells inside the blocks is used; with a parallel connection, the containers are folded. Thus, a battery with a voltage of 48 V and a capacity of 400 Ah will consist of 15 series-connected blocks of 4 cells (each has a voltage of 3.2 V and a capacity of 100 Ah). The structure of such a battery can be designated by the formula 15S4P. In total, such a battery will have 60 cells, the total weight of which will be only 120 kg (with the weight of one cell being 2 kg).

In warehouse equipment and special-purpose equipment, the battery plays the role of not only a source of energy, but also a counterweight. This is necessary for safely lifting loads to significant heights. Due to the fact that the ZUBR LI-ION battery weighs much less than its lead-acid counterpart, it is necessary to provide ballast in the design. Typically, the equipment manufacturer always indicates the minimum permissible weight of the battery. If there is no such information, then the weight of the acid battery is taken as the minimum weight.

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Figure 1 — Internal structure of the ZUBR LI-ION battery

For proper and long-term operation of the battery, the cells must be controlled by the BMS system. This system controls the processes of charging and discharging cells, monitors temperature conditions and currents. When using LiFePO4 cells, it is necessary to observe certain voltage levels during charging and discharging; failure to comply with the regime will lead to a rapid decrease in the residual capacity of the battery and failure.

The BMS system can be equipped with wireless communication modules (BlueTooth, Wi-Fi) for remote monitoring and diagnostics of the battery. The BMS control board records logs and allows you to analyze the operating modes of the battery. Thanks to a large number of settings, the ZUBR LI-ION battery can be optimized for the tasks of each client, taking into account the specific operation of his equipment.

The cells inside the battery are connected by copper or aluminum power bars. The configuration of the busbar depends on the charge and load currents and is calculated according to customer requirements and equipment parameters.

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Figure 2 — BMS system 48V 100A

All of the listed components are placed inside an all-metal welded housing with a wall thickness of 6 to 10 mm. A component fixation system is used inside, providing the battery with resistance to vibrations and shock loads.

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Figure 3 — LFP cells connected by power buses

Additionally, the battery can be equipped with:
— thermal insulation and heating system for operation at subzero temperatures without reducing capacity;
— an active balancing system, which additionally equalizes the cells by discharging the most charged to the least charged — this extends the service life of the battery.

The battery case is protected from moisture and dust according to the IP54 standard, and in a special version can provide a degree of protection IP65.

Each battery is equipped with a remote indicator to monitor the charge level, voltage and temperature of the battery. The indicator can also be placed on the battery case. Various display options available.

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Figure 4 — One of the options for a remote indicator

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Figure 5 — Another version of the remote indicator, shows the percentage of charge, voltage, effective current value and battery temperature

The technical parameters of each ZUBR LI-ION battery are designed according to the client’s requirements, and the range is presented in the table.

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For consultation, write to e-mail info@1ak-group. com