All Case StudiesEnergy Storage
500kW BESS Inverter
Power
500kW
Result
25% volume reduction
Industry
Energy Storage
OF
The Challenge
A grid-scale energy storage company needed to redesign their 500kW battery inverter to achieve a 25% reduction in enclosure volume without compromising thermal performance. Their existing air-cooled design was too large for standard shipping containers, increasing deployment costs significantly. The inverter needed to operate continuously at full power in 45°C ambient conditions while meeting UL 1741 SA requirements for grid support functions.
Our Approach
- Performed detailed thermal audit of existing air-cooled system
- Evaluated transition to hybrid liquid-air cooling architecture
- Designed compact cold plate assembly for SiC MOSFET power modules
- Optimized enclosure geometry for improved natural convection backup
- Integrated thermal management with EMC shielding requirements
- Conducted vibration analysis for transportation and seismic compliance
Results
25%
Volume Reduction
From 1.2m³ to 0.9m³ total volume
556 kW/m³
Power Density
Industry-leading density achieved
<0.1%
Efficiency Impact
Minimal efficiency loss from cooling