EV Cylindrical Battery Module PACK Assembly Lines

1. Equipment Overview

The EV Cylindrical Battery Module PACK Assembly Line is a fully automated production system designed for efficient assembly of cylindrical cells into battery modules and packs. It incorporates cell sorting, grouping, module assembly, electrical interconnection, testing, and PACK assembly to ensure high precision, traceability, and reliability. This line is optimized for EV applications with flexible configurations and integrated quality assurance systems.

2. Key Features

High Throughput: Fully automated line ensures consistent production efficiency.

Flexibility: Supports various cylindrical cell sizes (e.g., 18650, 21700, 4680).

Precision Welding: Advanced laser welding for interconnect reliability.

Quality Assurance: Inline testing and inspection at multiple stages.

Smart Integration: MES system compatibility for real-time data and process control.

3. Technical Specifications

3.1 Cell Sorting and Grouping

Sorting Accuracy:

Voltage: ±0.01 V.

Capacity: ±0.1 Ah.

Internal Resistance: ±0.1 mΩ.

Sorting Capacity: Up to 1,200 cells/hour.

Grouping Strategy: Automatic grouping by voltage, capacity, and resistance for balanced modules.

3.2 Module Assembly

Cell Arrangement: Supports various configurations, including parallel and series arrangements.

Fixture Accuracy: ±0.2 mm alignment for cylindrical cells.

Adhesive Application: Automated dispensing of thermal adhesive for structural integrity and heat dissipation.

Cycle Time: ≤40 seconds/module.

3.3 Electrical Interconnection

Connection Method:

Laser welding for busbar connections.

Optional ultrasonic welding for tab-to-tab connections.

Welding Precision: ±0.1 mm.

Busbar Material: Nickel or copper with optional conductive coatings.

Conductivity: ≤0.2 mΩ per connection.

3.4 PACK Assembly

PACK Design:

Customizable configurations for EV applications (e.g., 8s1p, 16s2p, etc.).

Casing Assembly: Automatic alignment and fastening of PACK enclosures.

Thermal Management Integration:

Liquid cooling plates or air-cooling channels added during assembly.

3.5 Integrated Testing and Inspection

Inline Testing:

Voltage, current, and internal resistance measurement.

Welding strength verification.

High-Pot Testing:

Voltage Range: 0–1,000 V DC.

Insulation Resistance: 0.1 MΩ–1 GΩ, ±1%.

Leakage Testing: Air tightness check with sensitivity of 1 × 10⁻³ Pa·m³/s.

Visual Inspection: Camera-based inspection for welding and assembly defects.

3.6 Automation and Control

Control System: PLC-based with integrated HMI for real-time monitoring and operation.

Data Management: MES integration for production tracking and traceability.

Alarm System: Automated fault detection with alerts for process deviations.

Programmable Recipes: Supports multiple product configurations with minimal changeover time.

3.7 Line Capacity and Efficiency

Production Rate: Up to 200 modules/day or 100 PACKs/day (depending on configuration).

Uptime Efficiency: ≥98%.

Changeover Time: ≤20 minutes for different configurations.

3.8 Safety Features

Emergency Stop: Strategically placed emergency stop buttons.

Laser Safety: Enclosed laser stations with Class 1 safety compliance.

High-Voltage Safety: Insulated workstations and automated power cut-off during testing.

Certifications: CE, UL, ISO 9001, ISO 14001 compliant.

3.9 Mechanical Design

Line Layout: Modular, customizable layout ranging from 30–80 meters.

Material Handling: Conveyor system with anti-static trays.

System Weight: 8,000–20,000 kg depending on configuration.

3.10 Environmental Requirements

Operating Temperature: 15–35°C.

Humidity: ≤60% RH (non-condensing).

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

Power Consumption: ≤120 kW.

4. Applications

Electric Vehicles: Cylindrical battery module and PACK assembly for EV powertrains.

Energy Storage: Modules for renewable energy storage systems.

Industrial Applications: Battery PACKs for robotics, backup power, and industrial automation.

5. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspection and cleaning of key components.

Monthly: Calibration of measurement tools and welding equipment.

Annually: Comprehensive diagnostics and software updates.

Warranty:

Standard: 1 year.

Extended: Customizable based on service agreement.