1. Automatic Blade Cell Feeding and Positioning Station
· Function: Automatically feeds blade cells into the line and ensures precise alignment for welding.
· Specifications:
o Cell Size Range: Length 400–1,200 mm, Width 80–150 mm, Thickness 10–40 mm.
o Positioning Accuracy: ±0.2 mm.
o Cycle Time: ≤8 seconds per cell.
2. Cell-to-Busbar Laser Welding Station
· Function: Performs high-precision laser welding to connect blade cell terminals to the busbar.
· Specifications:
o Welding Power: 600–1,500 W (fiber laser).
o Welding Accuracy: ±0.05 mm.
o Cycle Time: ≤5 seconds per weld.
o Real-Time Monitoring: Inline monitoring system for weld quality with defect detection.
3. Thermal Management System Installation Station
· Function: Installs cooling plates and applies thermal interface materials (TIM) to ensure efficient heat dissipation.
· Specifications:
o TIM Application Accuracy: ±0.1 mm.
o Cooling Plate Compatibility: Liquid or air-cooling systems.
o Cycle Time: ≤20 seconds per assembly.
4. Structural Bonding and Frame Assembly Station
· Function: Bonds and assembles the structural frame around the blade cells for mechanical stability.
· Specifications:
o Adhesive Type: Epoxy or UV-curable adhesive.
o Bonding Accuracy: ±0.2 mm.
o Frame Material: Aluminum or composite material.
5. High-Voltage Busbar and Connector Welding Station
· Function: Welds high-voltage connectors and busbars to create electrical paths between cells and the pack.
· Specifications:
o Welding Type: Laser or ultrasonic.
o Welding Accuracy: ±0.05 mm.
o Voltage Handling Capacity: Up to 1,000V DC.
o Cycle Time: ≤10 seconds per connection.
6. PACK Assembly and Sealing Station
· Function: Assembles multiple blade modules into the pack housing and seals it to protect against environmental factors.
· Specifications:
o Sealant Material: Silicone or polymer gaskets.
o Assembly Accuracy: ±0.3 mm.
o Cycle Time: ≤3 minutes per PACK.
7. Electrical and Safety Testing Station
· Function: Conducts comprehensive testing for electrical performance, insulation, and leakage.
· Specifications:
o Test Parameters: Voltage, resistance, insulation, short circuit, and leakage current.
o Helium Leak Detection: Sensitivity ≤1x10⁻⁶ Pa·m³/s.
o Testing Speed: ≤2 minutes per PACK.
8. Final Visual Inspection and Quality Assurance Station
· Function: Automated inspection of weld quality, assembly alignment, and surface defects.
· Specifications:
o Vision System Resolution: 8 MP industrial cameras.
o Inspection Speed: ≤1 minute per PACK.
o AI Algorithm Accuracy: ±0.05 mm for defect detection.
