Process Flow and Technical Overview
Thermal Interface Material (TIM) Insertion
Process: Automated dispensing systems insert a consistent layer of TIM at the bottom of the prismatic battery box.
Technical Detail: The TIM is precisely dispensed to ensure uniform thickness and full coverage, ensuring optimal heat dissipation between the prismatic cells and the battery housing. This is critical for maintaining battery performance and longevity under load conditions.
Module Insertion and Alignment
Process: High-precision handling systems load prismatic battery modules into the battery box, ensuring proper orientation and mechanical alignment.
Technical Detail: Automated feeders, combined with vision systems, ensure that each module is aligned to within ±0.1mm accuracy to avoid misalignment issues during assembly. The modules are secured within the box using automated pressing mechanisms to ensure even distribution of mechanical forces.
Glue Application for Top Cover Assembly
Process: Precision glue dispensers apply an even layer of adhesive to the top of the battery box for secure attachment of the top cover.
Technical Detail: The glue dispensing system is calibrated for precise volume control, applying the correct adhesive amount for a uniform bond. This system is integrated with a real-time vision inspection system to verify glue pattern and volume consistency, ensuring a strong bond that adheres to industry standards.
Top Cover Mounting
Process: The top cover of the battery box is mounted automatically using robotic arms, followed by fastening using high-torque screwdrivers.
Technical Detail: Robotic arms (such as KUKA models) are programmed to handle the top cover, aligning it precisely with the battery box using vision-guided systems. Fastening is performed with torque-controlled screwdrivers to ensure consistent sealing pressure and to prevent over-tightening or under-tightening, which could compromise pack integrity.
End-of-Line (EOL) Testing
Process: Once the module is assembled, it undergoes a series of automated tests at the EOL station.
Technical Detail: The EOL testing station is equipped with electrical testing units that check key parameters such as voltage, capacity, impedance, and thermal behavior. Advanced diagnostic equipment performs high-voltage insulation resistance tests, overcharge/discharge simulations, and short-circuit fault injections to ensure that each module adheres to strict performance and safety standards. These tests ensure compliance with UL, IEC, and other international safety certifications.
Labeling and Custom Branding
Process: The final step involves labeling the completed battery pack with customer-specific branding and serial numbers.
Technical Detail: A fully automated labeling system uses high-precision printers and robotic placement arms to apply labels accurately and securely. The label includes critical information, such as battery specifications, date codes, and safety warnings, as required for traceability and compliance purposes.
Automation, Robotics, and Quality Control Systems
Robotic Arms and Automated Handling Systems:
The line utilizes a series of KUKA robotic arms, equipped with advanced vision systems and end-of-arm tooling (EOAT), for tasks including module handling, glue application, top cover assembly, and pack transfer. The robotic arms are configured for high payload capacity, speed, and flexibility, with precision repeatability of ±0.05mm to ensure optimal alignment and assembly.
Vision Inspection and Error Detection:
Integrated vision systems, such as high-resolution cameras and laser sensors, continuously monitor every step of the assembly process. These systems perform real-time quality inspections, verifying module placement, adhesive application, alignment, and torque settings. Any deviations from the predefined tolerances trigger automatic alerts and corrections to maintain production quality.
Conveyor Systems and Centralized Control:
The assembly line employs high-speed conveyor systems with modular design for flexible line configuration. A centralized PLC-based control system manages the entire process, ensuring synchronized operation between various stations. Real-time data monitoring and analytics allow for predictive maintenance, minimizing downtime and improving operational efficiency.
Technical Advantages
High Precision and Repeatability:
The use of robotics, vision-guided systems, and automated handling ensures that each module and pack assembly is executed with consistent precision, meeting tolerances of up to ±0.1mm in alignment and ±0.5% in component placement.
Throughput and Scalability:
The assembly line is designed for high throughput, capable of producing thousands of ESS prismatic battery packs per day. The modular design allows easy scalability for different production volumes, accommodating both small-batch and mass production needs.
Advanced Safety and Compliance:
The entire line is built with safety protocols aligned with international standards (e.g., ISO 26262, IEC 61508). This includes automated safety stops, emergency shutoff systems, and real-time monitoring of electrical, mechanical, and environmental parameters to safeguard against potential hazards during the assembly process.
Flexibility for Custom Configurations:
The line is highly adaptable, capable of handling multiple prismatic battery sizes and configurations. Whether dealing with different voltages (e.g., 12V, 48V) or customized pack designs, the system can be reconfigured rapidly with minimal downtime.
Cost Efficiency and Reduced Labor Dependency:
With a fully automated workflow, labor costs are reduced, and the risk of human error is minimized, ensuring optimal performance and cost-effective production.
Conclusion
The ESS Prismatic Battery Module PACK Assembly Line represents the next generation of automation in energy storage system manufacturing. By integrating advanced robotics, automated quality control, and high-precision assembly techniques, it offers manufacturers a robust, scalable solution for producing high-quality prismatic battery packs with reduced cycle times, enhanced safety, and compliance with international standards. This assembly line supports the growing demand for reliable, efficient energy storage solutions across a variety of industries, including renewable energy, electric vehicles, and grid stabilization.
