This is a representative supporting project for Xingyuan Electric in the energy-storage industry (anonymized, not a named customer; figures below are representative industry ranges, not specific contract data). The client is an energy-storage system integrator in East China that wanted to move battery-rack and ESS-cabinet sheet-metal parts to us, mainly to fix two recurring problems: cumulative hole-position deviation and heavy-load sagging, and to turn multi-model parts into reusable standard supplies.
1. Client pain points
- Original shelves used thin trays that sagged mid-life under stacked loads, leaving uneven gaps that hurt both looks and load;
- Layer spacing was set by feel, so modules from different makers would not slide in or align, causing heavy rework;
- Busbar supports were too far apart; long-term vibration wore through insulation, a safety risk;
- Hole-position cumulative deviation exceeded ±1mm, forcing on-site reaming that broke the coating and shortened life.
2. Our solution
We started with a joint drawing review: every module outline, busbar route and BMS sampling position was pinned to coordinates, then key-dimension datum control held bending and welding cumulative deviation within ±0.3mm. Trays were thickened per load calculation with reinforced flanges; columns and base got equipotential-grounding design where insulation pads, sleeves and grounding did not conflict. Finishing was galvanized base + weathering powder for the required outdoor salt-spray grade.
3. Representative project parameters
| Item | Representative range |
|---|---|
| Load per rack | 0.8–2.0 t (stacked whole rack several tons) |
| Hole-position cumulative deviation | ≤ ±0.3 mm |
| Finishing | Galvanized base + weathering powder (salt-spray ≥720h) |
| Supply rhythm | Hundreds of sets/month after first article |
4. Outcome
After first-article approval we moved to volume supply with a sharply higher incoming pass rate and the on-site "hammer engineering" largely gone. The structure was later reused across several of the client's models as a standard supplied part, and became our standard method for ESS-cabinet sheet metal.
5. Reusable lesson
An ESS bracket is not just a frame — it carries five functions at once: load, positioning accuracy, insulated grounding, heat path and seismic resistance. Front-loading the drawing review and treating key dimensions as special characteristics is what prevents rework. This is the logic we have validated repeatedly in our ESS cabinet sheet metal work.