Case Study on Model Production of Energy Storage Container System

Case Study on Model Production of Energy Storage Container System

The purpose of this project is to customize an energy storage container system model for a certain new energy enterprise for large-scale exhibitions, in order to visually display the appearance, internal structure, and working principle of its core product - large industrial and commercial energy storage containers. The customer requires the model to have a high degree of simulation, which can dynamically demonstrate the charging and discharging process through lighting, and restore details such as the battery layout, temperature control system, and fire pipeline inside the container.

In the early stages of production, we conducted in-depth research on the product drawings and on-site photos provided by the client, and established the production standards of "industrial grade texture, miniature restoration, and dynamic visualization".

1、 Production process and material selection

The production of the model follows a rigorous process from skeleton to shell, from internal equipment to external details.

Main frame and box structure

The skeleton of the model is welded with high-strength aluminum alloy profiles to ensure the stability of the overall structure and to withstand long-distance transportation and frequent handling. The outer shell of the container is made of 1.5mm thick cold-rolled steel plate, which is cut and bent by laser cutting to completely replicate the corrugated and flat structure of the real container. In order to ensure the flatness and linearity of the box, each side panel has undergone leveling treatment.

Production of internal core components

The internal battery module is the focus of the display. We have abandoned simple color block pasting and instead used high-precision 3D printing technology to print the battery tray and cell casing layer by layer. Each battery cell has subtle heat dissipation patterns arranged neatly, reproducing the assembly process of a real production line. The shell of the battery module is made of frosted engineering plastic, simulating the tactile sensation of an industrial grade protective box.

Temperature control and fire protection system

To showcase the complex internal system, we used transparent acrylic tubes and colored copper tubes to create liquid cooled temperature control pipelines, clearly demonstrating the circulation path of the coolant. The fire protection system is simulated through thin red hoses and metal nozzles. Although the size is reduced, every bend and every fixed buckle is finely positioned to ensure consistency with the real layout.

2、 Post processing and coloring techniques

In order to achieve a visual fidelity of over 90%, post-processing is the key factor determining success or failure.

Surface polishing and finishing

After welding, all metal box plates undergo fine polishing and atomic ash filling at the weld seams to ensure a smooth and mirror like surface. The 3D printed battery components have removed support residues and have been polished with multiple layers of sandpaper to eliminate layering, making them look like precision injection molded parts.

Industrial grade spraying

The coating of the box is strictly adjusted according to the customer's product standard color card. We have adopted an automotive grade two-component baking paint process, with three layers of protection: primer, color paint, and clear paint. The industrial gray color of the main body of the container is steady and atmospheric, while the warning signs and operating instructions on the container door are printed with high-precision screen printing, with clear and sharp fonts and no burrs on the edges. For the simulated metal components, we also performed local aging treatment, adding a subtle frosted texture to avoid the model appearing too "new" and lacking realism.

3、 Integration and dynamic demonstration

Finally, we will integrate the intelligent control system into the model. We have achieved dynamic simulation of lighting through embedded LED light strips and independent control modules. At the beginning of the demonstration, blue light flows between battery modules to simulate the charging state; The red light shuttles through the pipeline, representing the operation of the thermal management system. Combined with the sound and light alarm system, it can simulate the emergency response process during high temperature warning.

The energy storage container model successfully condenses complex industrial energy storage systems into a single inch through exquisite sheet metal craftsmanship, realistic 3D printing details, professional paint coloring, and intelligent dynamic demonstrations. It is not only a display item, but also an "industrial artwork" that can accurately convey the technical strength of the enterprise. It has attracted a large number of professional visitors to stop at the exhibition and become the most dazzling focus on the booth.