Key Processes and Modules
1. Battery Cell Sorting and Grouping Station
· Function: Automatically sorts and groups pouch cells based on electrical parameters such as voltage, capacity, and internal resistance.
· Specifications:
o Sorting Accuracy: ±0.01% rdg.±3 dgt mV (voltage), +0.5% rdg.+10 dgt mΩ (resistance).
o Sorting Capacity: 600 cells/hour.
2. Automatic Cell Stacking Station
· Function: Aligns and stacks pouch cells into precise module configurations.
· Specifications:
o Stacking Method: Robot automatic stacking
o Alignment Accuracy: ±0.1 mm.
o Stacking Speed: Each battery cell ≤3 seconds
3. Busbar and Tab Welding Station
· Function: Welds tabs and busbars for electrical interconnection.
· Specifications:
o Welding Type: Fiber laser.
o Welding Accuracy: ±0.05 mm.
o Welding Speed: ≤5 seconds per weld.
o Weld Quality Monitoring: Integrated real-time quality inspection.
4. Module Frame Assembly Station
· Function: Assembles pouch cells into a structural frame for mechanical stability.
· Specifications:
o Frame Material: Aluminum or polymer composites.
o Assembly Accuracy: ±0.2 mm.
o Cycle Time: ≤15 seconds per module.
5. Thermal Management Integration Station
· Function: Installs cooling plates or liquid cooling systems and applies thermal interface materials (TIM).
· Specifications:
o TIM Application Accuracy: ±0.1 mm.
o Cooling Plate Compatibility: Customizable for liquid or air cooling systems.
o Integration Speed: ≤30 seconds per module.
6. Module and PACK Assembly Station
· Function: Assembles multiple modules into a battery PACK, including high-voltage connectors and structural enclosures.
· Specifications:
o PACK Size Range:
■ Length: 600–1200 mm.
■ Width: 400–800 mm.
■ Height: 150–500 mm.
o Assembly Accuracy: ±0.3 mm.
o Cycle Time: ≤120 seconds per PACK.
7. Electrical and Functional Testing Station
· Function: Performs comprehensive electrical, functional, and safety tests on modules and PACKs.
· Specifications:
o Testing Parameters: Voltage, current, internal resistance, insulation resistance, and short-circuit testing.
o Testing Speed: ≤2 minutes per module/PACK.
o Data Logging: Automated data storage for traceability.
8. Final PACK Inspection and Quality Control Station
· Function: Conducts visual inspection and quality assurance tests, including insulation integrity.
· Specifications:
o Inspection Speed: ≤2 minutes per PACK.
Production Line Specifications
· Overall Dimensions:
o Length: 65,000 mm.
o Width: 10,000 mm.
o Height: 3,500 mm.
· Weight: Approximately 35,000 kg.
· Production Capacity: Up to 20 PACKs/hour.
· Automation Level: Fully automated with advanced robotics and vision systems.
Vision and Quality Inspection Systems
· Alignment Cameras:
o Resolution: 5 MP high-speed cameras.
o Alignment Accuracy: ±0.02 mm.
· Defect Detection: AI-powered algorithms for tab misalignment, welding defects, and frame assembly errors.
· Data Management: Inspection results stored in a centralized database for analysis and traceability.
Control and Interface
· Control System: Advanced PLC with distributed control for modular flexibility.
· Human-Machine Interface (HMI):
o 10-inch touchscreen with multi-language options.
o Real-time monitoring and diagnostics.
· IoT and Cloud Integration:
o Remote monitoring, predictive maintenance, and production analytics.
Safety Features
· Enclosure Design: Fully enclosed with safety interlocks and emergency stop buttons.
· Laser Safety: Class 1 laser enclosures with certified safety glass.
· Electrical Safety: Overcurrent and short-circuit protection.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 200 kW.
· Control Voltage: 24V DC for auxiliary systems.
Cooling System
· Type: water cooling for welding.
· Cooling Capacity: 10 kW.
· Flow Rate: 30–50 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 alignment, welding, and cooling systems.
o Monthly: Calibrate vision systems and test stations.
o Quarterly: Comprehensive diagnostics and software updates.
· Warranty Period:
o Standard: 12 months.
o Extended: Available upon request.
