Solution
EV Cylindrical Battery Module PACK Assembly Line
- Product description
-
- Commodity name: EV Cylindrical Battery Module PACK Assembly Line
- Commodity ID: 动力大圆柱电池模组PACK线
Sorts cylindrical cells based on voltage, internal resistance, and capacity to ensure balanced modules.
1. Equipment Overview
The EV Cylindrical Battery Module PACK Assembly Line is a state-of-the-art automated system designed for assembling cylindrical battery cells into modules and complete PACKs. It encompasses cell sorting, welding, module stacking, PACK integration, and comprehensive testing, ensuring high efficiency, precision, and safety for EV battery manufacturing.
2. Key Processes and Modules
2.1 Battery Cell Sorting Station
- Function: Sorts cylindrical cells based on voltage, internal resistance, and capacity to ensure balanced modules.
- Specifications:
- Sorting Accuracy: ±1 mV (voltage), ±0.1 mΩ (resistance).
- Sorting Throughput: 1200 cells/hour.
2.2 Cell Grouping and Holder Insertion
- Function: Groups cells based on sorting data and inserts them into plastic or metal holders.
- Specifications:
- Cell Diameter Range: 18–46 mm.
- Holder Positioning Accuracy: ±0.1 mm.
- Cycle Time: ≤5 seconds per cell.
2.3 Busbar Placement and Welding
- Function: Places busbars on cell terminals and welds them for electrical connections.
- Specifications:
- Welding Method: Laser welding or resistance welding.
- Welding Power: 600 W (resistance welding).
- Welding Accuracy: ±0.05 mm.
- Welding Speed: ≤5 seconds per weld.
2.4 Cooling Plate and Thermal Interface Material (TIM) Application
- Function: Installs cooling plates and applies TIM for thermal management.
- Specifications:
- TIM Application Accuracy: ±0.1 mm.
- Cooling Plate Compatibility: Aluminum, copper.
- Cycle Time: ≤20 seconds per module.
2.5 PACK Assembly and Integration
- Function: Integrates modules into the battery PACK, including high-voltage connectors and housing.
- Specifications:
- PACK Size Range:
- Length: 600–1200 mm.
- Width: 400–800 mm.
- Height: 150–500 mm.
- Positioning Accuracy: ±0.3 mm.
- Cycle Time: ≤120 seconds per PACK.
- PACK Size Range:
2.6 Final Testing and Inspection
- Function: Conducts comprehensive electrical and safety tests on the final PACK.
- Specifications:
- Test Parameters: Voltage, current, insulation resistance, short-circuit protection, and helium leak detection.
- Testing Speed: ≤2 minutes per PACK.
- Pass/Fail Criteria: Programmable through the central control system.
3. Production Line Specifications
- Overall Dimensions:
- Length: 35000 mm.
- Width: 5000 mm.
- Height: 3,500 mm.
- Weight: Approximately 30,000 kg.
- Production Capacity: Up to 25 PACKs/hour.
- Automation Level: Fully automated with robotic systems.
4. Vision and Quality Inspection Systems
- Alignment Cameras:
- Accuracy: ±0.02 mm for cell placement and module stacking.
- Resolution: 12 MP.
- Defect Detection: Algorithms for welding, misalignment, and surface defects.
- Data Logging: Inspection results stored for traceability.
5. Control and Interface
- Control System: Centralized PLC with decentralized modules for each station.
- Human-Machine Interface (HMI):
- 15-inch touchscreen with multi-language support.
- Real-time monitoring and troubleshooting.
- IoT Connectivity:
- Remote diagnostics, production tracking, and analytics via cloud integration.
6. Safety Features
- Enclosures: Fully enclosed stations with interlocks.
- Emergency Stops: Strategically placed across the line.
- Laser Safety: Class 1 laser protection with certified viewing windows.
- Overcurrent Protection: Built-in sensors to prevent electrical overloads.
7. Electrical Specifications
- Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.
- Maximum Power Consumption: 180 kW.
- Control Voltage: 24V DC for auxiliary systems.
8. Cooling System
- Type: Centralized water cooling for welding systems and power electronics.
- Cooling Capacity: 18 kW.
- Flow Rate: 65 L/min.
9. Environmental Requirements
- Operating Environment:
- 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: Inspect welding systems, alignment mechanisms, and cooling systems.
- Monthly: Calibrate vision and testing equipment.
- Quarterly: Comprehensive diagnostics of the entire line.
- Warranty Period:
- Standard: 12 months.
- Extended: Up to 36 months available upon request.
Key words:
EV Cylindrical Battery Module PACK Assembly 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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