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The containerized energy system with its solar canopy on site

Containerized Energy System

40 ft HMG: product engineering, FEA and CFD

HUSK / Product Development

Containerized Energy System

High-cube container platform
40 ft
Solar array in the design basis
70 modules
Documented tilt configurations
10° / 25°

Development Programme

The engineering process

  1. Step 01: Configure

    Arrange the container, equipment zones and solar array

  2. Step 02: Develop

    Resolve the supports, joints and internal assemblies

  3. Step 03: Analyse

    Study wind response and ventilation behaviour

  4. Step 04: Detail

    Translate assemblies into drawings and parts lists

  5. Step 05: Document

    Present the design and the findings for review

01 / Product Architecture

A container platform with an integrated solar canopy

The product combines a high-cube container with a solar module mounting structure. The array extends beyond the container footprint, so its supports and braces form a major part of the product architecture. Raised supports provide the foundation interface shown in the design

Render of the container with the solar canopy on raised supports
Recorded product arrangement
DESIGN FEATURERECORDED ARRANGEMENT
Container envelope12,192 × 2,438 × 2,896 mm in the general arrangement
10° module layout40 modules on one array section and 30 on the other
Interior zonesBattery room, inverter room and front / guard room
Integration featuresEquipment racks, partitions, ducts, cable routing and access

Design basis: general arrangement dated 12 July 2022. Dimensions describe the container, not the complete canopy footprint.

02 / Configuration Development

Solar-angle and configuration development

  • Concept sheet with the 25° solar plane above the container

    25° concept arrangement

    The early concept sheet sets out a 70-module solar plane above the container and establishes the overall envelope and support positions

  • General arrangement drawing of the 10° split solar array

    10° general arrangement

    The later general arrangement records a split array of 40 and 30 modules and connects the external form to the internal container layout

03 / Structural Development

Canopy supports and container connections

  • Underside render of the canopy rafters, purlins and bracing

    Rafters, purlins and bracing

    The underside view exposes the member arrangement beneath the modules. Repeated rafters and purlins support the solar plane, while diagonal members connect the outer edges to the main structure

  • End view render of the canopy overhang and bracing

    Container and support interfaces

    The end view makes the canopy overhang and bracing geometry clear. Pivot blocks, column bases and ISO corner-casting connections appear as specific interfaces in the structural analysis

Render of the canopy frame assembled on the container

An assembly of defined interfaces

Member geometry, attachment locations and connection details were developed together. The analysis then examined the overall frame and the local regions where forces pass between parts

04 / Internal Packaging

Equipment zoning and service access

The internal layout separates the battery, inverter and front-room zones. Battery racks and electrical panels occupy defined locations along the container, with partitions and openings shaping both access and airflow. The overhead exhaust duct and cable routes need to coexist with these equipment zones

Cutaway render of the battery, inverter and front-room zones
Internal general arrangement drawing with sections
Original internal general arrangement: equipment locations, room divisions, sections, doors, cable ducts and exhaust features

05 / Equipment Integration

Mounting frames, insulation and access assemblies

  1. 01 Battery mounting frame

    Drawing of the battery mounting frame

    The frame drawing defines the supporting members and plate interfaces beneath the battery equipment, with dimensions and a fastener schedule

  2. 02 Panel support rack

    Drawing of the panel support rack in the container

    The rack drawing identifies the panel support structure and its mounting details within the container assembly

  3. 03 Insulation and compartment definition

    Drawing of the insulated panel assembly

    The PUF panel assembly describes the insulated enclosure arrangement and the openings that must align with the equipment and duct layout

  4. 04 Access to the raised container

    Drawing of the staircase assembly

    The staircase assembly provides the external access interface. The drawing package breaks the assembly down into components and fastening details

06 / Ducts and Cable Routes

Ventilation ducts and cable routes

  • Exhaust duct assembly drawing

    Exhaust duct assembly

    The duct drawing defines the route, branches, supports and local connection details. Its position links the battery and inverter zones to the exhaust path

  • Cable duct assembly drawing

    Cable duct assembly

    The cable duct drawing establishes a separate service route within the container. This helps coordinate electrical connections with doors, partitions and equipment mounting

The internal assembly brings these details together with the main door, mesh doors, air-conditioning outdoor unit and panel rack. Together, these interfaces define the detailed container assembly

07 / Structural Analysis Setup

Module weight and wind-load definition

  • Finite element mesh of the solar-support frame

    Mesh and member arrangement

    The finite element model represents the solar-support frame and its connection regions. Local mesh views resolve the joints used to transfer forces between members

  • Frame model with the wind load applied to the module plane

    Wind-load application

    The report combines self-weight with wind loading. Its module basis is 70 panels at 35 kg each, with a specified wind pressure of 1,500 Pa per panel

  • Local mesh of the bracing and connection plates at a joint

    Connection-level representation

    The local mesh shows the bracing and connection plates at a joint, supporting closer review of force transfer and concentrated stress

  • Restraint locations on the frame model

    Model restraints

    The restraint view identifies the fixed locations used in this analysis. Interpretation of the results depends on these support assumptions

Revised FEA material basis: steel density 7,850 kg/m³, elastic modulus 200 GPa, Poisson ratio 0.29 and yield strength 240 MPa

08 / Structural Response

Deflection and stress across the assembly

  • Deformation contour plot of the canopy frame

    44.5 mm reported purlin deformation

    The revised report identifies the purlin as the location of maximum deformation. The contour shows where the frame is most flexible under the analysed load case

  • Overall stress contour plot of the canopy frame

    200 MPa displayed overall stress

    The overall stress view provides a first reading of the frame response. Separate local views reveal concentrations that need interpretation at the connection level

Quoted results are from the July 2022 revised-thickness report. They describe that model and load case; a deformation acceptance limit is not stated in the supplied report

09 / Critical Structural Details

Stress concentrations at critical joints

  • Stress plot around a purlin bolt hole

    Purlin bolt-hole region

    The report records a local peak of 318 MPa and discusses the influence of the washer. It uses 150 MPa as a representative value. This local peak requires joint-level interpretation

  • Stress plot of the pivot at the ISO corner casting

    Corner-casting pivot

    The revised report records 77 MPa at the pivot fixed to the ISO corner casting. A separate pivot-block and column-base-plate assessment records 18 MPa

  • Stress plot along a rafter

    Rafter response

    The source describes a 220 MPa peak as a singularity and gives 170 MPa as the representative maximum for the rafter

  • Stress plot of the bracing at the gusset-to-column weld

    Bracing and weld region

    The source gives 150 MPa as the representative bracing stress after discussing the peak at the gusset-to-column weld region

The reported interpretations are retained here as analysis findings. Local peaks, washer/contact effects and weld details need appropriate connection review before engineering acceptance

10 / Thermal and Ventilation Setup

A container model in hot ambient conditions

  • CFD model of the container inside the external flow domain

    External flow domain

    The CFD model places the elevated container inside a full-scale external domain. The boundary-condition presentation specifies wind approaching from opposite the container door

  • CFD mesh of the container and its internal equipment

    Container and local mesh

    The mesh captures the surrounding air and the internal equipment arrangement. The proposed setup treats filters and mesh as porous regions based on their open area

Thermal simulation inputs
SIMULATION INPUTSPECIFIED CASE
Ambient conditions45°C, 1 atm; 1 m/s external wind
Solar loading1,100 W/m² irradiation
Battery heat input3,750 W distributed across four battery racks
Inverter heat input8,000 W applied over the inverter volume
Analysis approachSteady simulation; fan openings specified as interior

These heat loads are modelling assumptions in the boundary-condition report. They are not product output ratings or verified operating efficiencies

11 / Flow Development

Airflow through the compartments and exhaust route

Streamlines make the route through the openings, partitions and equipment zones visible. The section views add a local picture of the flow, showing stronger velocity along the duct and uneven circulation within the occupied compartments

Airflow streamlines through the container compartments and exhaust duct
  • Velocity contour in an internal section of the container

    Velocity in an internal section

    The velocity field helps identify the main flow path and regions with less air movement around the equipment

  • Temperature contour in the same internal section

    Temperature in the same section

    The temperature field connects the airflow pattern to local heating. The source legend spans 45–55°C in this plotted plane

Original simulation plots retain their legends. Different figures use different ranges, so colours should be interpreted within each plot

12 / Equipment Temperature Review

Room-air and equipment-surface temperatures

  • Temperature contours on the four battery racks

    Battery surfaces

    The battery contours show an uneven temperature distribution across the four racks. Area-weighted averages in the result file range from 58.0°C to 72.3°C

  • Temperature contours on the electrical panels

    Electrical panel surfaces

    The component plots highlight concentrated heating on the electrical panels. The result file reports a 90.2°C area-weighted average for the ACDB surface

Reported room-air and surface temperatures
REGION / COMPONENTREPORTED TEMPERATUREAVERAGE TYPE
Battery-room air48.2°CVolume average
Inverter-room air46.5°CVolume average
Front-room air45.7°CVolume average
Battery surfaces 1 / 2 / 3 / 467.8 / 72.3 / 69.1 / 58.0°CArea-weighted surface
Inverter surface56.5°CArea-weighted surface
ACDB surface90.2°CArea-weighted surface
MJB1 / MJB2 surfaces77.8 / 67.3°CArea-weighted surface

Source: CASE-1 / Temp values.txt. Values rounded to one decimal. Surface averages are distinct from room-air averages and local contour maxima

The useful finding: average air temperature alone is insufficient

The component results identify where thermal review should focus, even when room-air averages remain closer to ambient. This gives the design team a basis for reviewing heat inputs, airflow paths and component temperature limits before acceptance

13 / Fabrication Documentation

Assembly drawings and fabrication details

The internal assembly sheet ties the individual subsystems to one coordinated arrangement. Dimensions, sections and item references link the enclosure and equipment supports to their associated drawing numbers

Internal assembly drawing sheet with sections and item references
Drawing packages in the archive
PACKAGECONTENTS REPRESENTED IN THE ARCHIVE
Product arrangementConcept revisions, 10° general arrangement and render views
Solar mounting structure10° and 25° assembly / component drawings and BOM workbooks
Container internal assembliesInsulation, doors, ducts, battery mounting and panel rack
Access and service detailsStaircase, ladder, cable ducts and AC mounting assembly
Engineering analysisOriginal and revised FEA reports; CFD setup and case results

The archive contains successive revisions. Drawing selection and issue status should follow the project document register when the package is used for manufacturing

Project Outcome

A coordinated product design with documented analysis

Render of the completed containerized energy system
  1. Step 01: Defined product architecture

    Container zoning, equipment integration and the solar-support arrangement are captured in the design records

  2. Step 02: Analysis findings for review

    Structural contours identify member and joint response. CFD results identify airflow patterns and thermal concentrations

  3. Step 03: Detailed engineering package

    Assembly drawings, component details and BOMs connect the developed design to fabrication planning

Outcome

One product, coordinated in detail

The work connects the visible product to the engineering beneath it: the supporting structure, internal arrangement, analysis findings and manufacturing documentation The documented outcome covers design and analysis deliverables. The supplied archive does not establish final thermal acceptance, commissioning or measured field performance

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