Product
Prismatic Battery Cap Manufacture Line
- Product description
-
- Commodity name: Prismatic Battery Cap Manufacture Line
- Commodity ID: 方形铝壳电芯盖板智能生产线
Fully automated production line for prismatic battery cells, integrating critical processes such as explosion-proof valve welding, cover plate assembly welding, air-tightness testing, and impedance/performance testing.
1. Equipment Overview
- Equipment Name: Prismatic Battery Manufacturing Line
- Model: HY-PBML5000
- Application: Fully automated production line for prismatic battery cells, integrating critical processes such as explosion-proof valve welding, cover plate assembly welding, air-tightness testing, and impedance/performance testing.
- Production Capacity: 20–30 cells per minute (process-dependent).
2. Mechanical Specifications
- Equipment Dimensions:
- Length: 15,000 mm
- Width: 3,000 mm
- 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.
3. Key Stations and Specifications
3.1 Explosion-Proof Valve Welding Station
- Welding Method: Precision laser welding.
- Laser Specifications:
- Wavelength: 1064 nm.
- Power: 200 W (adjustable).
- Welding Speed: 1–3 seconds per valve.
- Welding Accuracy: ±0.02 mm.
- Material Compatibility: Aluminum, stainless steel.
- Vision System:
- High-resolution CCD camera for precise valve alignment.
- Real-time monitoring of weld quality.
3.2 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:
- Length: 50–200 mm
- Width: 30–100 mm
- Material Compatibility: Aluminum, nickel-coated steel.
- Pre-Welding Verification: Sensor-based detection of proper plate placement.
3.3 Air Tightness Testing Station
- Testing Method: Helium leak detection.
- Detection Range:
- Minimum Leak Rate: 1 × 10⁻⁶ mbar·L/s.
- Maximum Leak Rate: 1 × 10⁻² mbar·L/s.
- Cycle Time: ≤20 seconds per cell.
- Vacuum Chamber Dimensions:
- Length: 50–300 mm
- Width: 50–200 mm
- Height: 5–100 mm
- Helium Recovery Efficiency: ≥98%.
- Pass/Fail Criteria: Configurable based on customer specifications.
3.4 Impedance and Performance Testing Station
- Testing Parameters:
- Internal Resistance (Impedance): 0.01–100 mΩ (accuracy: ±0.001 mΩ).
- Voltage Range: 0–100 V (accuracy: ±0.01 V).
- 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:
- Internal Storage: 2 TB SSD for test results.
- Export Formats: CSV, PDF via USB, Ethernet, or cloud.
4. 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.
5. Control and Interface
- Control System: PLC-based centralized system with integrated monitoring.
- HMI:
- 15-inch capacitive touchscreen with multi-language support.
- Intuitive GUI for station control and monitoring.
- Data Management:
- Recipe storage for different battery models.
- Real-time analytics for production and quality metrics.
- Communication Protocols: Modbus, Ethernet/IP, and OPC UA for factory integration.
6. 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.
7. 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.
8. Environmental and Installation Requirements
- Operating Environment:
- Temperature: 15–30°C
- Humidity: ≤60% RH (non-condensing).
- Noise Level: ≤75 dB during operation.
- Installation Requirements:
- Flat, vibration-free surface.
- Minimum clearance: 1,000 mm around the equipment.
9. 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.
10. Maintenance and Warranty
- Maintenance Schedule:
- Weekly: Inspect welding heads, check conveyor alignment, and clean vacuum chambers.
- Monthly: Calibrate test stations and verify alignment systems.
- Quarterly: Comprehensive diagnostics of electrical and mechanical systems.
- Warranty Period:
- Standard: 12 months.
Extended: Up to 36 months available upon request.
Key words:
Prismatic Battery Cap Manufacture 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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