EV Prismatic Battery Module PACK Assembly Line

1. Equipment Overview

The EV Prismatic Battery Module PACK Assembly Line is a fully automated production system for assembling prismatic battery modules into complete battery PACKs. This line integrates multiple processes including cell sorting, module assembly, welding, inspection, and PACK integration, ensuring high precision, efficiency, and product reliability.

2. Key Processes and Modules

2.1 Battery Cell Sorting Station

Function: Automatic sorting of battery cells based on voltage, capacity, and internal resistance.

pecifications:

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

Throughput: 120 cells/hour.

2.2 Module Frame Assembly

Function: Automatic assembly of prismatic battery cells into the module frame.

Specifications:

Frame Size: Customizable for module dimensions.

Positioning Accuracy: ±0.1 mm.

Cycle Time: ≤10 seconds per cell.

2.3 Busbar Welding Station

Function: Laser welding of busbars to battery terminals for electrical connection.

Specifications:

Laser Type: Fiber laser, 500–1000 W.

Welding Accuracy: ±0.05 mm.

Welding Speed: ≤5 seconds per weld.

2.4 Insulation and Protection Assembly

Function: Placement of insulating materials and protective components to ensure safety.

Specifications:

Material Compatibility: Mylar, foam pads, and plastic shields.

Placement Accuracy: ±0.1 mm.

Automation Level: Fully automated with robotic handling.

2.5 Module Testing Station

Function: Electrical and functional testing of assembled modules.

Specifications:

Testing Parameters: Voltage, internal resistance, insulation, and thermal performance.

Testing Speed: ≤30 seconds per module.

Data Storage: Test results logged for traceability.

2.6 PACK Assembly and Integration

Function: Assembly of battery modules into the PACK housing, including cooling system and connectors.

Specifications:

PACK Size Range:

Length: 500–1200 mm.

Width: 400–800 mm.

Height: 100–300 mm.

Positioning Accuracy: ±0.2 mm.

Cycle Time: ≤120 seconds per PACK.

2.7 Final Testing and Inspection

Function: Comprehensive testing of the final PACK for performance and safety.

Specifications:

Testing Parameters: Voltage, capacity, insulation, short-circuit, and helium leak detection.

Testing Speed: ≤2 minutes per PACK.

Quality Criteria: Pass/fail thresholds programmable via software.

3. Production Line Specifications

Overall Dimensions:

Length: 50,000 mm.

Width: 8,000 mm.

Height: 3,000 mm.

Weight: Approximately 25,000 kg.

Production Capacity: Up to 30 PACKs/hour.

Automation Level: Fully automated with robotic and vision systems.

4. Vision and Quality Inspection Systems

Alignment Cameras:

Accuracy: ±0.02 mm for component placement.

Resolution: 5 MP high-speed cameras.

Defect Detection: AI-based algorithms for weld quality, misalignment, and surface anomalies.

Data Logging: All inspection results stored for traceability.

5. Control and Interface

Control System: Modular PLC with real-time monitoring and control.

Human-Machine Interface (HMI):

15-inch touchscreen with multi-language support.

Parameter adjustment and process monitoring.

IoT Connectivity:

Remote diagnostics, software updates, and production analytics.

6. Safety Features

Enclosures: Fully enclosed with interlocks for each station.

Emergency Stops: Strategically placed along the line.

Welding Safety: Laser enclosures and certified protective glass.

Electrical Safety: Overload and fault detection systems.

7. Electrical Specifications

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

Maximum Power Consumption: 150 kW.

Control Voltage: 24V DC for auxiliary systems.

8. Cooling System

Type: Centralized water cooling for laser systems and high-power electronics.

Cooling Capacity: 50 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 vision systems, welders, and alignment mechanisms.

Monthly: Calibration of testing equipment and laser systems.

Quarterly: Comprehensive diagnostics of all stations.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.