Mechanical Specifications
· Equipment Dimensions:
o Length: 15,000 mm
o Width: 3,000 mm
o Height: 2,200 mm
· Weight: 8,500 kg ± 5%
· Modular Structure: Individual stations interconnected with a conveyor system.
· Frame Material: High-strength steel with powder-coated surface for corrosion resistance.
· Worktable Material: Stainless steel with anti-static properties.
Key Stations and Specifications
1. Explosion-Proof Valve Welding Station
· Welding Method: Precision laser welding.
· Laser Specifications:
o Wavelength: 1064 nm.
o Power: Spot welding 1500W, full welding 3000W
· Welding Speed: 1–3 seconds per valve.
· Welding Accuracy: ±0.02 mm.
· Material Compatibility: Aluminum, stainless steel.
· Vision System:
o High-resolution CCD camera for precise valve alignment.
o Real-time monitoring of weld quality.
2. Cover Plate Assembly Welding Station
· Welding Method: Resistance or ultrasonic welding.
· Welding Current: 50–500 A (programmable).
· Welding Speed: 8–12 welds per minute.
· Alignment Accuracy: ±0.03 mm.
· Cover Plate Size Compatibility:
o Length: 50–200 mm
o Width: 30–100 mm
· Material Compatibility: Aluminum, nickel-coated steel.
· Pre-Welding Verification: Sensor-based detection of proper plate placement.
3. Air Tightness Testing Station
· Testing Method: Helium leak detection.
· Detection Range:
o Minimum Leak Rate: 1*10-⁹ mbar·L/s.
o Maximum Leak Rate: 1 × 10⁻² mbar·L/s.
· Cycle Time: ≤20 seconds per cell.
· Vacuum Chamber Dimensions:
o Length: 50–300 mm
o Width: 50–200 mm
o Height: 5–100 mm
· Helium Recovery Efficiency: ≥98%.
· Pass/Fail Criteria: Configurable based on customer specifications.
4. Impedance and Performance Testing Station
· Testing Parameters:
o Internal Resistance (Impedance): 0.01–100 mΩ (accuracy: ±0.001 mΩ).
o Voltage Range: 0–100 V (accuracy: ±0.01 V).
o Current Range: 0–200 A (accuracy: ±0.1 A).
· Testing Speed: Up to 30 cells per minute.
· Performance Metrics: Conducts charge/discharge cycle simulation and resistance measurements.
· Data Storage:
o Internal Storage: 2 TB SSD for test results.
o Export Formats: CSV, PDF via USB, Ethernet, or cloud.
Conveyor System Specifications
· Transport Speed: Adjustable, up to 12 m/min.
· Conveyor Material: ESD-safe belt with wear-resistant coating.
· Load Capacity: 10–15 kg per cell.
· Positioning Accuracy: ±0.05 mm with servo-driven indexing.
Control and Interface
· Control System: PLC-based centralized system with integrated monitoring.
· HMI:
o 15-inch capacitive touchscreen with multi-language support.
o Intuitive GUI for station control and monitoring.
· Data Management:
o Recipe storage for different battery models.
o Real-time analytics for production and quality metrics.
· Communication Protocols: Modbus, Ethernet/IP, and OPC UA for factory integration.
Electrical Specifications
· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 20 kW (entire line).
· Control Voltage: 24V DC for auxiliary systems.
Safety Features
· Emergency Stop: Multiple emergency stop buttons at each station.
· Overload Protection: Integrated sensors for load monitoring in conveyors and welding stations.
· Laser Safety: Class 1 laser enclosures with interlocks and safety curtains.
· Helium Leak Detection Alarms: Audible and visual alerts for excessive leak rates.
· Protective Barriers: Transparent enclosures with interlocks for operator safety.
Environmental and Installation Requirements
· Operating Environment:
o Temperature: 15–30°C
o Humidity: ≤60% RH (non-condensing).
· Noise Level: ≤75 dB during operation.
· Installation Requirements:
o Flat, vibration-free surface.
o Minimum clearance: 1,000 mm around the equipment.
Optional Configurations
· Dual Welding Heads: For higher throughput at welding stations.
· Advanced Vision System: AI-based defect detection for welding and assembly processes.
· Automated Loading/Unloading: Robotic integration for material handling.
· IoT Connectivity: Cloud-based monitoring and remote diagnostics.
Maintenance and Warranty
· Maintenance Schedule:
o Weekly: Inspect welding heads, check conveyor alignment, and clean vacuum chambers.
o Monthly: Calibrate test stations and verify alignment systems.
o Quarterly: Comprehensive diagnostics of electrical and mechanical systems.
· Warranty Period:
o Standard: 12 months.
o Extended: Up to 36 months available upon request.
