Key Processes and Modules
1. Battery Cell Sorting Station
· Function: Automatic sorting of battery cells based on voltage, capacity, and internal resistance.
· Specifications:
o Sorting Accuracy: ±0.01% rdg.±3 dgt (voltage), +0.5% rdg. +10 dgt (resistance).
o Throughput: 720 cells/hour.
2. Module Frame Assembly
· Function: Automatic assembly of prismatic battery cells into the module frame.
· Specifications:
o Frame Size: Customizable for module dimensions.
o Positioning Accuracy: ±0.1 mm.
o Cycle Time: ≤5 seconds per cell.
3. Busbar Welding Station
· Function: Laser welding of busbars to battery terminals for electrical connection.
· Specifications:
o Laser Type: Fiber laser, 3000-4000w.
o Welding Accuracy: ±0.05 mm.
o Welding Speed: ≤5 seconds per weld.
4. Insulation and Protection Assembly
· Function: Placement of insulating materials and protective components to ensure safety.
· Specifications:
o Material Compatibility: Mylar, foam pads, and plastic shields.
o Placement Accuracy: ±0.1 mm.
o Automation Level: Fully automated with robotic handling.
5. Module Testing Station
· Function: Electrical and functional testing of assembled modules.
· Specifications:
o Testing Parameters: Voltage, internal resistance, insulation, and thermal performance.
o Testing Speed: ≤30 seconds per module.
o Data Storage: Test results logged for traceability.
6. PACK Assembly and Integration
· Function: Assembly of battery modules into the PACK housing, including cooling system and connectors.
· Specifications:
o PACK Size Range:
■ Length: 500–1200 mm.
■ Width: 400–800 mm.
■ Height: 100–300 mm.
o Positioning Accuracy: ±0.2 mm.
o Cycle Time: ≤120 seconds per PACK.
7. Final Testing and Inspection
· Function: Comprehensive testing of the final PACK for performance and safety.
· Specifications:
o Testing Parameters: Voltage, capacity, insulation, short-circuit, and helium leak detection.
o Testing Speed: ≤2 minutes per PACK.
o Quality Criteria: Pass/fail thresholds programmable via software.
Production Line Specifications
· Overall Dimensions:
o Length: 50,000 mm.
o Width: 8,000 mm.
o Height: 3,000 mm.
· Weight: Approximately 25,000 kg.
· Production Capacity: Up to 30 PACKs/hour.
· Automation Level: Fully automated with robotic and vision systems.
Vision and Quality Inspection Systems
· Alignment Cameras:
o Accuracy: ±0.02 mm for component placement.
o Resolution: 5 MP high-speed cameras.
· Defect Detection: AI-based algorithms for weld quality, misalignment, and surface anomalies.
· Data Logging: All inspection results stored for traceability.
Control and Interface
· Control System: Modular PLC with real-time monitoring and control.
· Human-Machine Interface (HMI):
o 10-inch touchscreen with multi-language support.
o Parameter adjustment and process monitoring.
· IoT Connectivity:
o Remote diagnostics, software updates, and production analytics.
Safety Features
· Enclosures: Fully enclosed with interlocks for each station.
· Emergency Stops: Strategically placed along the line.
· Welding Safety: Laser enclosures and certified protective glass.
· Electrical Safety: Overload and fault detection systems.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 250 kW.
· Control Voltage: 24V DC for auxiliary systems.
Cooling System
· Type: Centralized water cooling for laser systems and high-power electronics.
· Cooling Capacity: 10kw.
· Flow Rate: 20–40 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 vision systems, welders, and alignment mechanisms.
o Monthly: Calibration of testing equipment and laser systems.
o Quarterly: Comprehensive diagnostics of all stations.
· Warranty Period:
o Standard: 12 months.
o Extended: Up to 36 months available upon request.
