A leading energy manufacturer developing a next-generation grid-scale flow battery needed a cost-effective and highly accurate solution for monitoring the health of its battery stacks. Off-the-shelf commercial monitoring systems were either overbuilt with unnecessary features or prohibitively expensive, driving unit manufacturing costs far beyond program targets.
The challenge was to create a custom system capable of continuous real-time monitoring of individual cell voltages, full stack voltage, and fault conditions, all while maintaining long-term reliability and meeting strict cost constraints. Achieving this balance of accuracy, functionality, and affordability required specialized expertise in embedded hardware and software development, precision analog measurement, and high-voltage isolation design.
Re:Build assembled a multidisciplinary team to design and deliver a purpose-built monitoring system that would meet both the technical and economic requirements. The engagement began with gathering detailed input and design requirements from the customer and quickly transitioned into a phased execution plan.
Key elements of the approach included:
Throughout development, the team maintained close collaboration with the client’s engineers and operators, ensuring the solution integrated seamlessly into the larger energy storage system.
The result was the Stack Health Monitor (SHM), a custom embedded monitoring system engineered for grid-scale energy storage. The SHM continuously measures cell and stack voltages, detects faults such as open connections, and reports key data to the system controller in real time.
Key features of the solution included:
By combining low-cost design strategies with advanced monitoring capabilities, the SHM delivered both technical performance and economic efficiency.
The project produced a monitoring solution that exceeded expectations in performance, reliability, and cost efficiency. Internal studies showed the Re:Build system outperformed the original commercial alternative across all key metrics.
Let’s discuss how we can bring innovative solutions to your most challenging projects. Contact Re:Build Battery Solutions to learn more about our expertise in Battery Pack Design and Development for advanced applications.
