Empowering Data Centers: Can Simulation Tools Expedite Safe Energy Storage System Design?

In the digital age, where innovations like blockchain, machine learning, and artificial intelligence are driving transformative changes, the demand for data center services is skyrocketing. However, with this surge in demand comes the pressing concern of energy consumption and its environmental impact.

Data centers and transmission networks together account for up to 1.5% of global electricity use and emit approximately 330?million tons of CO2 equivalent annually, according to the International Energy Agency (IEA) . To put it into perspective, that's roughly the same carbon footprint as Brazil.

These statistics underscore the urgent need for sustainable solutions to power our data-driven world and Battery Energy Storage Systems (BESS), hold the key to meeting the increased power demands of AI while minimizing its environmental impact.

At its core, a BESS stores energy harnessed from renewable sources and releases it as electricity when needed, providing a cleaner alternative to fossil fuels for power generation. According to data from the U.S. Department of Energy (DOE) the most popular battery technologies in terms of installed or planned capacity in grid applications are Li-ion batteries, accounting for more than 80% of the battery energy storage capacity .

So, what are some of the challenges associated with the development of BESS, and how they can be addressed?

Integrating BESS into data center or electric grid infrastructure comes with several challenges, including scalability, cost-effectiveness, policy drivers and, most importantly, safety requirements.

When it comes to safety, catastrophic events associated with Li-ion batteries fall into three categories: electrical, mechanical, and environmental failures. Each presents unique challenges, but solutions abound.

The Role of Smart Battery Management System (BMS)

Among the various types of failures, electrical failures are perhaps the most common and can result from over-charge, over-discharge, and both external and internal short circuits.

One of the primary functions of a BMS is to regulate voltage levels during the charging process. Overcharging can cause irreversible damage to batteries, leading to reduced capacity or complete failure. By continuously monitoring and controlling voltage levels, the BMS ensures that they remain within safe limits, thereby safeguarding the battery.

Li-ion battery packs consist of multiple individual cells, each with unique characteristics. During charging, these cells can become imbalanced, resulting in overcharging of some cells and undercharging of others. A BMS helps address this issue by actively balancing the cells, optimizing their lifespan, and maintaining consistent performance.

Another critical role of a BMS is to detect abnormalities or faults during the charging process. By monitoring parameters such as temperature levels, current flow, and potential short circuits, the BMS can identify any issues and take necessary actions to mitigate them. This proactive approach helps prevent further damage and ensures the safe operation of the battery.

Designing an effective BMS requires realistic battery and holistic electric control unit (ECU) models with embedded software for co-simulation. Siemens Xcelerator? portfolio enables engineering teams to develop BMS and battery packs simultaneously using a model-based approach, saving time and costs. The solution includes a scalable model-based design testing framework and integrates electrical systems with network design. Virtual verification and validation of embedded software ensure defect-free performance before hardware is commissioned, enhancing overall reliability and safety. Currently Siemens offers a 30-day Battery Pack Simulation Free Trial to companies meeting certain requirements.

The Role of Virtual Vibration Testing

Mechanical safety of battery systems is paramount to prevent catastrophic failures. Mechanical hazards such as vibration, shock, and impact pose significant risks, especially during transportation and deployment.

To mitigate these risks, mechanical testing plays a crucial role, albeit at a significant cost and time investment. Vibration tests, for instance, involve mounting batteries on shaker tables and subjecting them to defined excitations as per industry standards. The goal is to identify any potential failures. However, the process of redesigning and retesting failed batteries can quickly escalate costs and delay project timelines.

Virtual vibration testing is a cost-effective solution offered by Siemens Digital Industries Software . It allows designers to simulate mechanical stresses and assess the performance of battery designs in a virtual environment. By conducting what-if studies, designers can iterate on design changes and identify potential failure points before physical testing, reducing the need for extensive testing iterations.

To learn more about virtual battery vibration testing, Siemens offers a series of blogs on this topic.

The Role of Battery Thermal Management System (BTMS)

In the realm of battery energy storage systems (BESS), managing environmental hazards, particularly overheating, is of paramount importance.

Temperature exerts a profound influence on various aspects of battery operation, including electrochemical processes, efficiency, power capability, reliability, and lifecycle cost. While higher temperatures can enhance capacity, they also accelerate capacity fade and compromise performance. Conversely, low temperatures can impair battery performance, leading to reduced efficiency and reliability. Moreover, excessive or uneven temperature distribution within a battery pack can significantly diminish lifecycle and pose safety risks.

Designing an effective battery thermal management system (BTMS) requires careful consideration and advanced modeling techniques. Siemens' software empowers designers to explore various cooling system designs, simulate thermal runaway events, and ensure temperature uniformity across cells and packs. By leveraging virtual development tools, manufacturers can enhance performance, extend lifecycle, and improve overall safety of battery systems.

Siemens offers an on-demand webinar that a multi-physics system simulation approach that can support the design of efficient battery thermal management systems.