EV Blade Battery Module PACK Line

1. Equipment Overview

The EV Blade Battery Module PACK Assembly Line is an advanced, automated production system specifically designed for the assembly of blade-type battery cells into modules and PACKs. This line ensures high efficiency, precision, and safety by integrating cell sorting, module assembly, welding, thermal management system installation, and comprehensive testing. It is tailored for large-scale electric vehicle (EV) battery manufacturing.

2. Key Processes and Modules

2.1 Blade Cell Sorting and Grouping Station

Function: Sorts blade cells by electrical characteristics such as voltage, internal resistance, and capacity to ensure consistent module performance.

Specifications:

Sorting Accuracy: ±1 mV (voltage), ±0.1 mΩ (resistance).

Sorting Throughput: 200 cells/hour.

2.2 Automatic Blade Cell Positioning and Stacking Station

Function: Precisely aligns and stacks blade cells into module configurations.

Specifications:

Cell Length Range: 300–1,200 mm.

Stacking Accuracy: ±0.2 mm.

Cycle Time: ≤15 seconds per cell.

2.3 Busbar and Tab Welding Station

Function: Joins blade cell tabs to busbars for electrical connectivity using advanced welding techniques.

Specifications:

Welding Method: Laser or ultrasonic welding.

Welding Power: 400–1,000 W (laser), 20 kHz (ultrasonic).

Welding Accuracy: ±0.05 mm.

Quality Monitoring: Real-time welding inspection with defect detection.

2.4 Module Frame Assembly Station

Function: Assembles blade cells into rigid structural frames for durability and alignment.

Specifications:

Frame Material: Aluminum alloy or composite material.

Assembly Accuracy: ±0.3 mm.

Cycle Time: ≤20 seconds per module.

2.5 Cooling System Integration Station

Function: Installs cooling plates or channels for thermal management and applies thermal interface material (TIM).

Specifications:

TIM Application Accuracy: ±0.1 mm.

Cooling Compatibility: Liquid cooling plates or integrated cooling pipes.

Cycle Time: ≤30 seconds per module.

2.6 Module to PACK Assembly Station

Function: Integrates multiple blade modules into a complete PACK, including structural housing, high-voltage wiring, and connectors.

Specifications:

PACK Size Range:

Length: 1,200–2,500 mm.

Width: 500–1,200 mm.

Height: 150–400 mm.

Assembly Accuracy: ±0.3 mm.

Cycle Time: ≤3 minutes per PACK.

2.7 Electrical and Safety Testing Station

Function: Performs a range of electrical and safety tests to validate the performance and reliability of modules and PACKs.

Specifications:

Test Parameters: Voltage, internal resistance, insulation, short-circuit protection, and current leakage.

Helium Leak Detection: Sensitivity ≤1x10⁻⁶ Pa·m³/s.

Testing Speed: ≤2 minutes per PACK

2.8 Final PACK Inspection and Quality Assurance

Function: Conducts visual inspection and automated quality checks for weld integrity, alignment, and surface defects.

Specifications:

AI Vision System Accuracy: ±0.05 mm.

Inspection Speed: ≤1 minute per PACK.

3. Production Line Specifications

Overall Dimensions:

Length: 70,000 mm.

Width: 12,000 mm.

Height: 3,800 mm.

Weight: Approximately 40,000 kg.

Production Capacity: 15–20 PACKs/hour.

Automation Level: Fully automated with robotic handling and vision-guided systems.

4. Vision and Quality Inspection Systems

Alignment Cameras: High-resolution (8 MP) cameras for real-time guidance and alignment.

Defect Detection: AI-driven algorithms for surface defects, misalignment, and welding inconsistencies.

Data Logging: All inspection results stored in a centralized database for analysis and traceability.

5. Control and Interface

Control System: Distributed PLC system with centralized coordination.

Human-Machine Interface (HMI):

15-inch touchscreen with multi-language support.

Real-time production monitoring, fault alerts, and diagnostics.

IoT and Cloud Connectivity: Enables predictive maintenance, remote monitoring, and production analytics.

6. Safety Features

Enclosure Design: Fully enclosed stations with interlocks for operational safety.

Emergency Stops: Strategically placed along the production line.

Laser Safety: Certified Class 1 enclosures with automatic shutdown in case of faults.

Electrical Safety: Includes overcurrent and surge protection systems.

7. Electrical Specifications

Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.

Maximum Power Consumption: 250 kW.

Control Voltage: 24V DC for auxiliary systems.

8. Cooling System

Type: Centralized water cooling for welding and power systems.

Cooling Capacity: 100 kW.

Flow Rate: 30–50 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: Check alignment systems, cooling units, and welding equipment.

Monthly: Calibrate vision systems and inspection tools.

Quarterly: Comprehensive diagnostics and software updates.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.