Secure Storage

In supercapacitor module applications, this type of structure typically requires balancing electrical safety (protection against electric shock and insulation), environmental protection (resistance to water, dust, and moisture), and structural strength (resistance to vibration and shock).
With the deepening application of supercapacitors in energy storage systems, hybrid electric vehicles, grid frequency regulation, and high-end equipment, the role of their module structural components has evolved from mere physical support into a critical protective barrier that integrates electrical safety, protection against extreme environments, and resistance to vibration and shock. Addressing the specific demands of supercapacitor modules—particularly regarding the high sealing integrity, high structural strength, and non-standard customization required for "safety enclosure + skeletal frame" architectures—this paper proposes an integrated solution encompassing structural topology optimization, sealing interface design, precision machining, and comprehensive process validation. This solution aims to assist clients in resolving critical industry pain points, such as module protection failures, structural fatigue, and prolonged customization lead times encountered under complex operating conditions.

The specific product developed for this project is a Secure Storage unit designed for public transportation applications. With its robust steel construction and carefully controlled manufacturing processes, the unit is designed to provide reliable structural protection and stable performance in demanding transportation environments.

The Secure Storage has an overall size of approximately 1795 × 750 × 1020 mm and a total weight of approximately 348 kg. The main structural material is Q345, providing the required strength and durability for the application.

For surface protection, the unit undergoes electrical painting with the color specification RAL 6016. This treatment provides a uniform and durable surface finish while helping improve the product's resistance to environmental exposure during long-term use in public transportation applications.

The manufacturing process includes laser cutting, bending, welding, painting, and assembly. These processes are carefully coordinated to ensure accurate fabrication of the structural components, reliable welded joints, consistent surface treatment, and precise final assembly.

To verify the structural integrity and sealing performance of the finished unit, a hydrostatic test is conducted at 0.1 MPa, with the pressure maintained for 8 hours. During the test, no water droplets or mist shall appear on the tank walls or weld seams. This testing procedure helps ensure the reliability and integrity of the finished product under the specified operating conditions.

Designed for the public transportation sector, this Secure Storage unit demonstrates Hehua Machinery's capabilities in structural fabrication, welding, surface treatment, assembly, and comprehensive quality control. The combination of robust materials, controlled manufacturing processes, and strict hydrostatic testing enables the finished product to meet the demanding requirements of transportation-related applications.

The successful completion of this project further demonstrates our ability to transform customer requirements into reliable, application-specific mechanical products through integrated manufacturing and quality control capabilities.