In the context of rapid development in energy storage technology, the efficient and stable operation of energy storage systems is critical. As a key device for maintaining an optimal temperature environment in energy storage systems, the performance of energy storage air conditioning directly affects the overall efficiency and lifespan of the entire energy storage system. As the core component of the water circulation system in energy storage air conditioning, DC water pumps are responsible for transporting coolants and enabling heat exchange. Due to the diverse application scenarios and complex operating conditions of energy storage air conditioning, it imposes extremely strict customization requirements on the performance, reliability, and adaptability of DC water pumps. Exploring the key customization design points of DC water pumps to meet the adaptation needs of energy storage air conditioning is of great significance for improving the overall performance of energy storage systems and promoting the widespread application of energy storage technology.

I. Working Principle of Energy Storage Air Conditioning and Demand Analysis for DC Water Pumps

1. Overview of the Working Principle of Energy Storage Air Conditioning

Energy storage air conditioning operates through the collaboration of two major systems: the refrigeration cycle and the water circulation. In the refrigeration cycle, the compressor compresses low-temperature, low-pressure refrigerant gas into high-temperature, high-pressure gas, which is then cooled and condensed into high-pressure liquid by the condenser. The liquid then passes through the expansion valve for throttling and pressure reduction before entering the evaporator, where it absorbs heat emitted by the energy storage system, causing the refrigerant to evaporate into low-temperature, low-pressure gas, thus completing a refrigeration cycle. The water circulation system, driven by a DC water pump, circulates coolant between the energy storage batteries and the evaporator. After absorbing heat from the batteries, the coolant transfers this heat to the refrigerant in the evaporator, achieving heat dissipation and cooling of the energy storage system.

2. Requirements for Flow Rate and Head of DC Water Pumps in Energy Storage Air Conditioning

Energy storage systems vary significantly in scale, with notable differences in the number, layout, and heat generation of energy storage batteries. This results in a wide range of flow rate requirements for DC water pumps in energy storage air conditioning. For example, small household energy storage systems, with their smaller storage capacity, may require a DC water pump with a flow rate of only a few liters per minute. In contrast, large centralized energy storage power stations, with storage capacities reaching the megawatt level, demand DC water pumps with flow rates of hundreds of liters per minute or higher to ensure efficient heat dissipation.

In terms of head, DC water pumps must overcome the frictional resistance, local resistance, and system head difference in the circulation pipeline. Factors such as pipeline length, diameter, number of elbows, and coolant flow rate all affect pipeline resistance. When energy storage air conditioning is installed in multi-story buildings or areas with significant terrain fluctuations, the system head difference also requires the DC water pump to provide sufficient head to overcome it.

3. Strict Requirements for Reliability and Stability of DC Water Pumps

Energy storage systems need to operate continuously and stably throughout the year. As a key supporting device, the reliability and stability of DC water pumps directly affect the normal operation of energy storage air conditioning and even the entire energy storage system. In practical operation, any failure of the DC water pump—such as impeller damage, motor burnout, or coolant leakage due to seal failure—will drastically reduce the heat dissipation capacity of the energy storage air conditioning. This leads to excessive temperatures in energy storage batteries, causing performance degradation, shortened lifespan, and even safety accidents due to thermal runaway. Therefore, DC water pumps must exhibit extremely high reliability and stability to ensure trouble-free operation during long-term continuous use.

4. Special Requirements for Adapting to Complex Environmental Conditions

Energy storage systems are deployed in a wide range of scenarios, including deserts, coastal areas, and high-altitude regions. In desert environments, DC water pumps must withstand high temperatures and sand erosion: high temperatures can degrade motor insulation, while sand may cause wear and blockage of internal components. Coastal areas, with high humidity and salt spray, pose severe challenges to the corrosion resistance of DC water pumps; ordinary metal components are prone to corrosion, reducing the pump’s service life. In high-altitude regions, low air pressure and thin air hinder motor heat dissipation, while the reduced boiling point of coolants can lead to cavitation, severely damaging the pump body. Thus, DC water pumps must demonstrate excellent environmental adaptability to operate stably in various harsh conditions.

II. Key Customization Design Points for DC Water Pumps

1. Motor Selection and Optimization

1.1 Use of High-Efficiency and Energy-Saving Motors

Given the high priority energy storage systems place on energy efficiency, DC water pumps should prioritize high-efficiency, energy-saving motors such as permanent magnet synchronous motors (PMSMs). PMSMs offer high power factors and efficiency; compared to traditional asynchronous motors, they significantly reduce energy consumption. Under the same flow rate and head conditions, DC water pumps driven by PMSMs can drastically cut power usage, lowering the operating costs of energy storage systems. Their efficient energy conversion also reduces motor heat generation, enhancing reliability and service life.

1.2 Motor Protection Rating and Heat Dissipation Design

For complex application environments, the motor’s protection rating must be appropriately determined. In dusty, humid environments, the motor should have a protection rating of at least IP54 to prevent dust ingress and water splashing damage. In high-humidity, salt-spray environments, the rating can be further increased to IP65 or higher. To ensure normal motor operation in high temperatures, enhanced heat dissipation designs are necessary—such as increasing heat sink area, optimizing heat sink structure, or integrating built-in cooling fans—to maintain the motor’s operating temperature within a normal range and stabilize performance.

1.3 Wide Voltage Adaptability Design

Considering that the power supply voltage of energy storage systems may vary across scenarios or due to fluctuations, DC water pump motors must feature wide voltage adaptability. Through optimized motor winding designs and advanced electronic control technologies, motors can operate stably over a broad voltage range—for example, maintaining stable torque output even with ±20% fluctuations around the rated voltage. This ensures the pump’s flow rate and head meet energy storage air conditioning requirements, improving adaptability to diverse power conditions.

2. Optimization of Pump Body Structure

2.1 Hydraulic Model Optimization

The hydraulic model is a key determinant of DC water pump performance. Using advanced computational fluid dynamics (CFD) software to simulate and analyze internal flow channels, optimize parameters such as flow channel shape/size, and impeller blade shape/quantity/angle, ensures smoother coolant flow within the pump. This reduces flow resistance and energy loss, improving hydraulic efficiency. Optimized hydraulic models enhance flow rate and head performance, lower energy consumption, reduce cavitation, and extend pump service life.

2.2 Seal Structure Design

To prevent coolant leakage, DC water pumps require reliable seal structures. Common sealing methods include mechanical seals and rubber seals. Mechanical seals, with superior sealing performance and long service life, are suitable for high-sealing-demand scenarios. In mechanical seal design, select wear-resistant and corrosion-resistant materials (e.g., silicon carbide, cemented carbide) for seal rings, and coolant-resistant rubber (e.g., fluororubber) for auxiliary seals. Optimizing the seal structure ensures tight contact between sealing surfaces, minimizing leakage risks. Rubber seals, with simple structures and low costs, are suitable for lower-sealing-demand applications. Regardless of the method, strict seal performance testing is required to ensure reliability under energy storage air conditioning operating conditions.

2.3 Compact and Lightweight Design

Space in energy storage air conditioning systems is often limited, so DC water pumps require compact and lightweight designs. By optimizing the pump body structure, adopting integrated design concepts, reducing component count, and rationalizing internal layout, the pump’s volume and weight are minimized without compromising performance. Using high-strength, lightweight materials (e.g., aluminum alloys, engineering plastics) for the pump body reduces weight, eases installation and maintenance, and minimizes space occupation in the overall system.

3. Integration of Intelligent Control Functions

3.1 Implementation of Flow Rate Regulation

To meet the precise coolant flow demands of energy storage air conditioning systems under varying operating conditions, DC water pumps should feature flow rate regulation. Installing frequency converters enables stepless motor speed regulation, allowing precise flow control. Based on real-time signals such as energy storage system temperature and load changes, the intelligent control system automatically adjusts pump speed to match coolant flow with heat dissipation needs. During low-load operation, reducing speed lowers flow and energy consumption; during high-load operation, increasing speed boosts flow to ensure efficient heat dissipation.

3.2 Fault Diagnosis and Early Warning Design

Integrating fault diagnosis and early warning functions into DC water pumps significantly improves the reliability and maintenance convenience of energy storage air conditioning systems. Sensors installed at key pump locations monitor real-time parameters such as motor current, temperature, pump vibration, and pressure. Intelligent control systems use data analysis algorithms to process these metrics; when anomalies occur, the system quickly identifies fault types and locations, issuing timely early warnings. For example, excessive motor current may indicate overload or bearing failure, while abnormal vibration may signal impeller wear or internal debris. This allows maintenance personnel to take proactive measures, preventing fault escalation, reducing downtime, and lowering maintenance costs.