Equipping Energy Storage Stations with "Super Senses": Nexisense Multi-parameter Sensors Safeguard BESS Safety

With the official release and imminent implementation of the "General Technical Requirements for Fire Monitoring and Early Warning Systems for Electrochemical Energy Storage Stations" (GB/T 46261-2025), the field of electrochemical energy storage has entered a new stage of standardized and systematic fire risk prevention and control. The standard clarifies, for the first time, the performance requirements, control linkage logic, and reliability verification methods for multi-parameter monitoring (temperature, gas, smoke, pressure, etc.), providing a clear technical path for system integrators and engineering contractors.

As a professional sensor manufacturer, Nexisense has developed a series of high-reliability front-end sensing components aimed at the early identification needs of BESS thermal runaway. These sensors, centered on low drift, rapid response, and strong environmental adaptability, have been validated in multiple GW-level energy storage projects, becoming a reliable choice for building multi-dimensional fire monitoring and early warning systems that comply with national standards.

BESS Typical Application Scenarios and Integration Value

Fire risks in energy storage stations mainly stem from lithium battery thermal runaway, which evolves from abnormal temperature rise and gas release to smoke generation and open flame outbreak. Nexisense sensor networks achieve life-cycle risk perception through distributed deployment and data fusion.

· Containerized BESS Multi-point Monitoring: In large-scale ground power stations or user-side energy storage projects, sensors are deployed inside battery clusters, between modules, and on the cabin ceiling. Temperature sensors collect battery surface/internal temperatures in real-time, gas sensors monitor the rise in characteristic gas concentrations such as CO and H₂, smoke sensors capture particles accompanying thermal runaway, and flame sensors confirm open flames in the UV/IR bands. In actual projects, this combination advances the thermal runaway warning time to the gas release stage, with an average advance of 15-30 minutes, significantly improving the EMS linkage response window.

Typical containerized BESS fire monitoring layout example:

· Battery Pack/Module Level Fine Monitoring: For high-density battery clusters, Nexisense sensors support embedded integration, installed directly near battery trays or busbars. Combined with BMS data, sensor output is used for thermal runaway grading judgment (e.g., Stage 1: Abnormal temperature rise; Stage 2: Gas concentration exceeds threshold), achieving a shift from passive alarm to active intervention.

· Station-level Centralized Monitoring and Cloud-Edge Collaboration: Sensors connect to local control units via RS485 Modbus RTU or 4-20mA analog output, then upload to the EMS/SCADA platform via edge gateways. IoT solutions supporting the MQTT protocol can achieve remote zero-point drift monitoring and predictive maintenance.

BESS overall system architecture reference:

In these scenarios, Nexisense sensor networks not only meet national multi-parameter requirements but also significantly reduce false alarms of single parameters through fusion algorithms, enhancing system availability and project compliance.

Nexisense Sensor Selection Guide: Matching BESS Project Requirements

Selection needs to comprehensively consider monitoring parameters, response time, environmental tolerance, and interface compatibility. Core series parameter reference:

Selection Recommendations:

· Large Containerized Power Stations: Prioritize 3-in-1 gas+temperature+smoke combinations, emphasizing low power consumption and long-term stability.

· High-density User-side Energy Storage: Select miniaturized embedded temperature/gas sensors, focusing on vibration resistance and compact size.

· Fire Extinguishing Linkage Projects requiring Flame Confirmation: Add UV/IR flame sensors to ensure<5s response.

· IoT/Cloud Platform Solutions: Choose versions compatible with Modbus TCP gateways.

System Integration Considerations and Best Practices

To ensure sensors operate stably in complex BESS electromagnetic, thermal, humidity, and vibration environments, attention must be paid to:

· Deployment and Sampling: Temperature sensors should be close to battery core posts/negative posts; gas sensors should be placed at the low point of the ventilation path (H₂ rises, CO sinks); smoke/flame sensors should avoid direct light and dust blind spots.

· Signal Processing: Use differential input ADC to suppress noise; gas sensors require regular bump tests to verify sensitivity; field calibration is recommended every 12 months.

· Data Fusion: Realize multi-parameter logic AND (e.g., temperature >60℃ and CO >50ppm triggers level 1 alarm) through edge computing to reduce false positives.

· Electromagnetic Compatibility: Areas near PCS/transformers require shielded cables and filters, complying with GB/T 17626 series tests.

· Linkage Interface: Supports dry contact output to directly trigger aerosol/water mist fire extinguishing systems, alarm delay<2s.

· Maintenance Strategy: Integrated self-diagnostic functions (sensor disconnection, zero-point drift over-limit), combined with cloud platforms to achieve predictive replacement.

Projects following these practices have achieved over 24 months of continuous operation with no major false alarm records.

OEM Customization and Bulk Supply Advantages

Nexisense provides end-to-end support for B2B customers:

· OEM/White-label: Supports brand LOGO, packaging modification, and casing material customization.

· Custom Development: Specific gas combinations (e.g., H₂+CO+HF), enhanced resistance to specific interference, integrated pre-processing circuit boards.

· Bulk Guarantee: Annual capacity supports tens of thousands, high localization rate of raw materials, stable delivery (Standard products 4-6 weeks).

· Technical Collaboration: Provides complete integration guides, reference circuits, EMC test reports, and on-site debugging support.

· Supply Chain: Key components are self-developed to ensure continuous delivery amidst global supply chain fluctuations.

These services help integrators pass project tenders and national standard compliance audits quickly.

Frequently Asked Questions (FAQ)

1. How do Nexisense sensors meet the GB/T 46261-2025 multi-parameter requirements? It covers temperature, gas (CO/H₂), smoke, and flame monitoring, with performance indicators verified by third parties to meet the appendix requirements of the standard.

2. How much can the early thermal runaway warning time be advanced? Through gas + temperature fusion, early warning can be achieved during the gas release stage (Stage 1-2), typically 15-30 minutes in advance.

3. How to reduce the false alarm rate? Multi-parameter logic AND + algorithmic filtering; the actual project false alarm rate is<5%, significantly better than single-parameter systems.

4. How do sensors integrate with BMS/EMS/SCADA? Supports 4-20mA, Modbus RTU/TCP, MQTT; Nexisense provides protocol register tables and sample code.

5. What is the reliability in high humidity/salt spray environments? IP67 protection, -40 to +85℃ wide temperature range, passed IEC 60068 salt spray/damp heat tests.

6. What is the minimum order quantity (MOQ) and lead time for bulk procurement? Usually starts at 100 units; standard products 4-6 weeks, customized products 6-10 weeks.

7. Does it support remote calibration and diagnostics? Supports cloud-based zero-point drift monitoring and remote bump tests; predictive maintenance can be achieved when integrated with IoT gateways.

8. Does Nexisense provide a complete BESS fire monitoring solution? Focuses on sensor and front-end module supply, cooperating with system integrators to realize overall compliant solutions from the sensing layer to the control layer.

Summary: Partnering with Nexisense to Build a Compliant and Intelligent Energy Storage Safety System

Nexisense multi-parameter sensors, with their high reliability, rapid response, and fusion capabilities, provide a solid sensing foundation for BESS fire monitoring and early warning systems. Choosing us not only grants you core components that comply with GB/T 46261-2025 but also a strategic partner that reduces project risks, improves system availability, and optimizes life-cycle costs.

We welcome system integrators, IoT solution providers, and engineering contractors to contact us to discuss specific project adaptations, sample testing, or customization needs. Let advanced sensor technology become the core element of the safety and competitiveness of your energy storage project.