Key Processes and Modules
1 Automatic Cell Feeding and Positioning Station
· Function: Automatically feeds and positions prismatic cells for alignment and welding.
· Specifications:
o Cell Size Compatibility: 120–300 mm (height), 50–200 mm (width), 20–100 mm (thickness).
o Positioning Accuracy: ±0.2 mm.
o Cycle Time: ≤5 seconds per cell.
2. Cell-to-Busbar Welding Station
· Function: Welds the terminals of prismatic cells to the pack's busbars.
· Specifications:
o Welding Method: Fiber laser.
o Welding Power: 3000–4000W.
o Welding Speed: ≤5 seconds per weld.
o Welding Accuracy: ±0.05 mm.
o Quality Control: Real-time weld monitoring with automatic defect detection.
3. Cooling Plate Integration and TIM Application Station
· Function: Installs cooling plates and applies thermal interface material (TIM) for heat dissipation.
· Specifications:
o TIM Application Accuracy: ±0.1 mm.
o Cooling Plate Types: Liquid or air-cooled aluminum plates.
o Cycle Time: ≤20 seconds per assembly.
4. Structural Bonding and Fastening Station
· Function: Bonds and fastens cells and supporting structures to enhance mechanical stability.
· Specifications:
o Adhesive Type: High-strength epoxy or UV-curable adhesive.
o Bonding Accuracy: ±0.2 mm.
o Fastening Type: Automated torque-controlled screws.
5. High-Voltage Connector and Harness Assembly Station
· Function: Assembles and connects high-voltage terminals, connectors, and harnesses for the battery pack.
· Specifications:
o Voltage Range: ≤1,000V DC.
o Assembly Accuracy: ±0.3 mm.
o Cycle Time: ≤30 seconds per connection.
6. Final Welding and Sealing Station
· Function: Performs final welding of pack enclosures and seals for protection against environmental factors.
· Specifications:
o Welding Type: Laser seam welding.
o Sealing Material: Silicone or polymer-based gasket.
o Weld Accuracy: ±0.1 mm.
7. Electrical Testing and Quality Inspection Station
· Function: Tests the electrical integrity, insulation, and performance of the assembled battery pack.
· Specifications:
o Test Parameters: Voltage, internal resistance, insulation resistance, and leakage current.
o Testing Speed: ≤3 minutes per PACK.
Production Line Specifications
· Overall Dimensions:
o Length: 80,000 mm.
o Width: 12,000 mm.
o Height: 4,000 mm.
· Weight: Approximately 50,000 kg.
· Production Capacity: 10–15 PACKs/hour.
· Automation Level: Fully automated with robotic systems and AI-driven quality control.
Vision and Quality Inspection Systems
· Alignment Cameras:
o Resolution: 8 MP industrial cameras.
o Alignment Accuracy: ±0.05 mm.
· Defect Detection: AI-based system for surface, weld, and assembly defect detection.
· Data Management: All inspection results stored in a centralized database with traceability.
Control and Interface
· Control System: Distributed PLC system with centralized supervision.
· Human-Machine Interface (HMI):
o 10-inch touchscreen interface with multi-language support.
o Real-time monitoring and diagnostic tools.
· IoT Integration: Remote monitoring, predictive maintenance, and cloud data storage for production analytics.
Safety Features
· Enclosure Design: Fully enclosed with interlocked safety doors and barriers.
· Emergency Stop System: Strategically placed for operator safety.
· Laser Safety: Class 1 laser enclosures with safety interlocks.
· Electrical Safety: Overcurrent and surge protection included.
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: Centralized water cooling system for welding and high-power equipment.
· Cooling Capacity: 10 kW.
· Flow Rate: 30–60 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.
