EV Cylindrical Battery Module PACK Assembly Line

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: 150 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: Ultrasonic or laser welding.

Welding Power: 300–500 W (laser), 20 kHz (ultrasonic).

Welding Accuracy: ±0.05 mm.

Welding Speed: ≤5 seconds per weld.

2.4 Module Stacking and Frame Assembly

Function: Stacks modules and assembles them into structural frames.

Specifications:

Module Size Range:

Length: 200–600 mm.

Width: 150–300 mm.

Height: 50–150 mm.

Stacking Accuracy: ±0.2 mm.

Cycle Time: ≤15 seconds per module.

2.5 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.

2.6 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.

2.7 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: 60,000 mm.

Width: 10,000 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: 5 MP.

Defect Detection: AI-driven 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: 60 kW.

Flow Rate: 20–40 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.