Key Processes and Modules
1. Battery Cell Sorting Station
· Function: Sorts cylindrical cells based on voltage, internal resistance, and capacity to ensure balanced modules.
· Specifications:
o Sorting Accuracy: ±1 mV (voltage), ±0.1 mΩ (resistance).
o Sorting Throughput: 1200 cells/hour.
2. Cell Grouping and Holder Insertion
· Function: Groups cells based on sorting data and inserts them into plastic or metal holders.
· Specifications:
o Cell Diameter Range: 18–46 mm.
o Holder Positioning Accuracy: ±0.1 mm.
o Cycle Time: ≤5 seconds per cell.
3. Busbar Placement and Welding
· Function: Places busbars on cell terminals and welds them for electrical connections.
· Specifications:
o Welding Method: Laser welding or resistance welding
o Welding Power: 300–500 W (laser), 600W(resistance welding).
o Welding Accuracy: ±0.05 mm.
o Welding Speed: ≤5 seconds per weld.
4. Cooling Plate and Thermal Interface Material (TIM) Application
· Function: Installs cooling plates and applies TIM for thermal management.
· Specifications:
o TIM Application Accuracy: ±0.1 mm.
o Cooling Plate Compatibility: Aluminum, copper.
o Cycle Time: ≤20 seconds per module.
5. PACK Assembly and Integration
· Function: Integrates modules into the battery PACK, including high-voltage connectors and housing.
· Specifications:
o PACK Size Range:
■ Length: 600–1200 mm.
■ Width: 400–800 mm.
■ Height: 150–500 mm.
o Positioning Accuracy: ±0.3 mm.
o Cycle Time: ≤120 seconds per PACK.
6. Final Testing and Inspection
· Function: Conducts comprehensive electrical and safety tests on the final PACK.
· Specifications:
o Test Parameters: Voltage, current, insulation resistance, short-circuit protection, and helium leak detection.
o Testing Speed: ≤2 minutes per PACK.
o Pass/Fail Criteria: Programmable through the central control system.
Production Line Specifications
· Overall Dimensions:
o Length: 35,000 mm.
o Width: 5,000 mm.
o Height: 3,500 mm.
· Weight: Approximately 30,000 kg.
· Production Capacity: Up to 25 PACKs/hour.
· Automation Level: Fully automated with robotic systems.
Vision and Quality Inspection Systems
· Alignment Cameras:
o Accuracy: ±0.02 mm for cell placement and module stacking.
o Resolution: 12 MP.
· Defect Detection: welding, misalignment, and surface defects.
· Data Logging: Inspection results stored for traceability.
Control and Interface
· Control System: Centralized PLC with decentralized modules for each station.
· Human-Machine Interface (HMI):
o 15-inch touchscreen with multi-language support.
o Real-time monitoring and troubleshooting.
· IoT Connectivity:
o Remote diagnostics, production tracking, and analytics via cloud integration.
Safety Features
· Enclosures: Fully enclosed stations with interlocks.
· Emergency Stops: Strategically placed across the line.
· Laser Safety: Class 1 laser protection with certified viewing windows.
· Overcurrent Protection: Built-in sensors to prevent electrical overloads.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 180 kW.
· Control Voltage: 24V DC for auxiliary systems.
Cooling System
· Type: Centralized water cooling for welding systems and power electronics.
· Cooling Capacity: 18 kW.
· Flow Rate: 65 L/min.
Environmental Requirements
· Operating Environment:
o Temperature: 15–30°C.
o Humidity: ≤60% RH (non-condensing).
· Noise Level: ≤75 dB during operation.
· Installation Space: Minimum clearance of 2,000 mm around the line.
Maintenance and Warranty
· Maintenance Schedule:
o Weekly: Inspect welding systems, alignment mechanisms, and cooling systems.
o Monthly: Calibrate vision and testing equipment.
o Quarterly: Comprehensive diagnostics of the entire line.
· Warranty Period:
o Standard: 12 months.
o Extended: Up to 36 months available upon request.
