Storage

Sinovoltaics launches battery system analysis service to detect imbalances at the factory

Sinovoltaics launches battery system analysis service to detect imbalances at the factory
December 15, 2022 - Electrical engineering researcher Kurtis Buck opens the doors of the KORE POWER battery units outside the Energy Systems Integration Facility at the National Renewable Energy Laboratory (NREL). (Photo by Werner Slocum / NREL)

Sinovoltaics, a global provider of quality assurance for the battery energy storage system (BESS) and solar photovoltaic (PV) industries, has launched its BESSential analysis service, offering 100% battery pack review.

The service is meant to detect and correct thermal, electrical, and capacity imbalance issues directly at the BESS factory. It was launched in partnership with volytica diagnostics, a developer of cloud-based battery diagnostics software.

Battery systems are formed by stacking battery cells to create battery modules, which are then combined to form racks and installed into containers. These containers go through electrical and performance tests at the factory to ensure they meet industry standards. However, since these Factory Acceptance Tests (FATs) are performed at the container level, they can miss smaller defects and abnormal behaviors that may not become apparent for years. Additionally, some BESS integrators only perform sampling performance tests, Sinovoltaics said, and consequently, they often miss underlying issues in subsystems, racks, or battery packs that emerge after installation.

The BESSential analysis service collects and compiles data from the FAT and then evaluates each pack down to the cell level, according to Sinovoltaics. BESSential identifies volatility in individual battery packs and cells, such as temperature shifts, voltage irregularities, capacity imbalance, and other factors predictive of battery defects. These metrics are then used to model the micro-environment of each battery pack. Any anomalies that are found are flagged in the system for further inspection. Any volatile components are also removed and tested further, with BESSential-vetted replacements substituted for defective components.

“At Sinovoltaics, we want to protect our clients’ investments by ensuring the performance and safety of their BESS assets,” said Arthur Claire, director of technology. “Even a minor defect at the cell level can jeopardize an entire BESS investment. Our BESSential 100% pack analysis mitigates this risk, protecting the client’s physical asset while also securing their return on investment.”

Battery pack data analysis tests are usually performed during site commissioning, not at the factory, Sinovoltaics said, which can lead to a suboptimal testing environment. Also, if an issue is detected during commissioning, it can take months to replace defective modules, as the supplier needs to first review the defect and then replace the defective modules. According to a recent study by the Electric Power Research Institute, almost 50% of severe BESS failures occur in the first year after commissioning.

BESSential provides an analysis at the factory, before shipment, meant to ensure that only good components are shipped, avoiding project delays. volytica’s data-driven approach offers a diagnostic process, identifying performance inconsistencies, thermal inhomogeneity, charge imbalances, and early signs of cell degradation.

“In order to mitigate investment risk, thorough testing of energy storage systems prior to commissioning is essential,” says Claudius Jehle, managing director and CEO at volytica. “Current practices often miss critical defects by testing systems as a whole, rather than testing each element individually. At volytica, we’re transforming this method by rigorously testing 100% of all components: automatically. This meticulous approach significantly reduces the risk of post-deployment setbacks, saving time, money and avoiding disputes with OEMs.”

Sinovoltaics inspects solar panels with a proprietary AI-driven tool, SELMA (Sinovoltaics Electroluminescence Mass Analysis) which takes a look at 100% of purchased modules for microcracks and other defects, allowing the company to promise pre-shipment perfection. The software is up to 99% accurate.

Tags