In the era following the post-pandemic, amidst economic downturns, maximizing the input-output ratio through technological means and innovative production methods is a critical issue that all industrial technology enterprises need to focus on.

For manufacturing enterprises, electricity costs have always been a major expense,exacerbated by the intense demands of summer, which further increase power consumption.

Recently, COSLINK installed a 125kW/215kWh energy storage system at a site in Dongguan for a local enterprise. Due to space limitations, the system was configured using a combination of a modular power control cabinet and a distributed energy storage battery cabinet.

System Architecture

Power Control Cabinet

COSLINK Power Control Cabinet supports on-grid scenarios and parallel operation of multiple cabinets for pure grid operation. In this project, based on specific requirements, only one power control cabinet was configured, equipped with a 125kW PCS module (each power control cabinet can accommodate up to 5 PCS modules), as well as subsystems for temperature control, fire protection, local monitoring, access control, and water immersion. The entire cabinet is rated IP54 for outdoor protection and supports on-grid operation. COSLINK PCS module feature cluster-level battery management, enhancing intelligence and investment returns in distributed multi-cabinet applications.

Internal structure diagram

The local monitoring subsystem simultaneously collects BMS and inverter data from the energy storage cabinet, offering comprehensive statistical displays. Customers can customize charging and discharging strategies for the inverter based on battery conditions, thereby controlling system operation modes according to the strategies.

Energy Storage Cabinet

COSLINK 215kWh Active Control Energy Storage Cabinet consists of 15 high-energy-density LFP battery modules and a patented active-control box. These 15 battery modules are connected in series, each module containing 16 cells of 280Ah capacity connected in 1P16S configuration. The active-control box includes an active-control optimizer responsible for the overall management of the battery cluster. The nominal voltage of the battery cluster is 768V with a capacity of 280Ah.

The battery management system inside the energy storage cabinet operates on two levels: SBMU and SBCU. SBMU is situated within the battery module, responsible for collecting information from the 16-series cells inside the module and uploading the data to SBCU. It also executes cell-level balancing within the battery pack based on commands received from the BMS.

The SBCU is located within the active-control box and is responsible for actively managing the battery cluster.It gathers detailed data from the 15 SBMU units inside the energy storage cabinet, monitoring total voltage and current. The SBCU performs SOC and SOH estimation and correction, transmitting relevant data to the EMS to facilitate intelligent charge and discharge management of the energy storage cabinet. Based on the active-control optimizer enabling simultaneous charging and discharging and proactive management,the system supports mixed use of new and old batteries, facilitating convenient future expansion based on real-time demand.

Energy storage cabinet communication topology diagram

Energy Management System

COSLINK EMS consists of an energy storage controller, EMS unit, display screen, and 4G module. It operates according to on-grid energy storage strategies, supporting functions such as remote data uploading and enabling both local and cloud-based remote monitoring.

The Energy Storage Controller comprises hardware and software components, utilizing an IoT architecture based on edge computing. It enables the intelligent operation of the ESS by downloading decision models from backend or cloud systems. The controller collects data from the power control cabinet, energy storage cabinet, and internal BMS systems,transmitting it to backend or cloud systems via a 4G module.

Advantages of the Overall Solution

1. Distributed Energy Storage System: Suitable for limited installation spaces or phased deployment scenarios with flexible architecture, enabling minimal expansion modifications.

2. Cluster-Level Management: Each battery cabinet has independent PCS management, ensuring balanced charging and discharging, extending battery life, and enhancing system performance.

3. Self-Developed Intelligent EMS and Cloud Platform: Through real-time data analysis and remote control, it precisely manages the ESS, reducing operational and maintenance difficulties and avoiding resource wastage.

4. Full Lifecycle Value Management: Reduces overall investment difficulty for customers and maximizes investment returns.