Solution
EV Blade Battery CTP Automatic Welding Line
- Product description
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- Commodity name: EV Blade Battery CTP Automatic Welding Line
- Commodity ID: 动力刀片电池CTP自动焊接线
Automatically feeds blade cells into the line and ensures precise alignment for welding.
1. Equipment Overview
The EV Blade Battery CTP (Cell-to-Pack) Automatic Welding Line is a cutting-edge automated solution tailored for the direct assembly of blade battery cells into robust packs without intermediate modules. This line combines high-precision handling, advanced laser welding, and quality inspection systems to ensure efficient, high-throughput production while meeting the demanding safety and performance requirements of EV batteries.
2. Key Processes and Modules
2.1 Automatic Blade Cell Feeding and Positioning Station
- Function: Automatically feeds blade cells into the line and ensures precise alignment for welding.
- Specifications:
- Cell Size Range: Length 400–1,200 mm, Width 80–150 mm, Thickness 10–40 mm.
- Positioning Accuracy: ±0.2 mm.
- Cycle Time: ≤8 seconds per cell.
2.2 Cell-to-Busbar Laser Welding Station
- Function: Performs high-precision laser welding to connect blade cell terminals to the busbar.
- Specifications:
- Welding Power: 600–1,500 W (fiber laser).
- Welding Accuracy: ±0.05 mm.
- Cycle Time: ≤5 seconds per weld.
- Real-Time Monitoring: Inline monitoring system for weld quality with defect detection.
2.3 Thermal Management System Installation Station
- Function: Installs cooling plates and applies thermal interface materials (TIM) to ensure efficient heat dissipation.
- Specifications:
- TIM Application Accuracy: ±0.1 mm.
- Cooling Plate Compatibility: Liquid or air-cooling systems.
- Cycle Time: ≤20 seconds per assembly.
2.4 Structural Bonding and Frame Assembly Station
- Function: Bonds and assembles the structural frame around the blade cells for mechanical stability.
- Specifications:
- Adhesive Type: Epoxy or UV-curable adhesive.
- Bonding Accuracy: ±0.2 mm.
- Frame Material: Aluminum or composite material.
2.5 High-Voltage Busbar and Connector Welding Station
- Function: Welds high-voltage connectors and busbars to create electrical paths between cells and the pack.
- Specifications:
- Welding Type: Laser or ultrasonic.
- Welding Accuracy: ±0.05 mm.
- Voltage Handling Capacity: Up to 1,000V DC.
- Cycle Time: ≤10 seconds per connection.
2.6 PACK Assembly and Sealing Station
- Function: Assembles multiple blade modules into the pack housing and seals it to protect against environmental factors.
- Specifications:
- Sealant Material: Silicone or polymer gaskets.
- Assembly Accuracy: ±0.3 mm.
- Cycle Time: ≤3 minutes per PACK.
2.7 Electrical and Safety Testing Station
- Function: Conducts comprehensive testing for electrical performance, insulation, and leakage.
- Specifications:
- Test Parameters: Voltage, resistance, insulation, short circuit, and leakage current.
- Helium Leak Detection: Sensitivity ≤1x10⁻⁶ Pa·m³/s.
- Testing Speed: ≤2 minutes per PACK.
2.8 Final Visual Inspection and Quality Assurance Station
- Function: Automated inspection of weld quality, assembly alignment, and surface defects.
- Specifications:
- Vision System Resolution: 8 MP industrial cameras.
- Inspection Speed: ≤1 minute per PACK.
- AI Algorithm Accuracy: ±0.05 mm for defect detection.
3. Production Line Specifications
- Overall Dimensions:
- Length: 85,000 mm.
- Width: 12,000 mm.
- Height: 4,000 mm.
- Weight: Approximately 55,000 kg.
- Production Capacity: 12–15 PACKs/hour.
- Automation Level: Fully automated with robotic handling and AI-powered monitoring.
4. Vision and Quality Control Systems
- Defect Detection: AI-driven system for weld and assembly defect detection.
- Data Logging: Centralized database for traceability and production analytics.
- Inspection Accuracy: ±0.05 mm for weld and surface defects.
5. Control and Interface
- Control System: Distributed PLC and HMI for centralized operation.
- HMI Features:
- 17-inch touchscreen with multilingual support.
- Real-time monitoring and diagnostics.
- IoT Integration: Remote access for predictive maintenance and data analysis.
6. Safety Features
- Enclosure Design: Fully enclosed with interlocks for safety.
- Emergency Stops: Strategically placed along the line.
- Laser Safety: Class 1 certified enclosures with auto shutdown on fault detection.
- Electrical Protection: Surge and overcurrent protection systems.
7. Electrical Specifications
- Power Supply: AC 380V ±10%, 50/60 Hz, 3-phase.
- Maximum Power Consumption: 320 kW.
- Control Voltage: 24V DC for auxiliary systems.
8. Cooling System
- Type: Centralized water cooling for welding and power systems.
- Cooling Capacity: 150 kW.
- Flow Rate: 40–60 L/min.
9. Environmental Requirements
- Operating Conditions:
- Temperature: 15–30°C.
- Humidity: ≤60% RH (non-condensing).
- Noise Level: ≤75 dB during operation.
- Installation Space: Minimum clearance of 2,000 mm around the line.
10. Maintenance and Warranty
- Maintenance Schedule:
- Weekly: Check alignment, weld quality, and cooling systems.
- Monthly: Calibrate vision and inspection tools.
- Quarterly: Comprehensive diagnostics and software updates.
- Warranty Period:
- Standard: 12 months.
- Extended: Available upon request.
Key words:
EV Blade Battery CTP Automatic Welding Line
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FAQ
Q
How do you ensure consistent weld quality in the assembly of Prismatic battery packs?
A
Q
What are the best practices for cell alignment and stacking in a Prismatic battery PACK assembly?
A
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