EV Blade Battery CTP Automatic Welding Line

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.