Prismatic Battery Cap Manufacture Line

1. Equipment Overview

Equipment Name: Prismatic Battery Manufacturing Line

Model: HY-PBML5000

Application: Fully automated production line for prismatic battery cells, integrating critical processes such as explosion-proof valve welding, cover plate assembly welding, air-tightness testing, and impedance/performance testing.

Production Capacity: 20–30 cells per minute (process-dependent).

2. Mechanical Specifications

Equipment Dimensions:

Length: 15,000 mm

Width: 3,000 mm

Height: 2,200 mm

Weight: 8,500 kg ± 5%

Modular Structure: Individual stations interconnected with a conveyor system.

Frame Material: High-strength steel with powder-coated surface for corrosion resistance.

Worktable Material: Stainless steel with anti-static properties.

3. Key Stations and Specifications

3.1 Explosion-Proof Valve Welding Station

Welding Method: Precision laser welding.

Laser Specifications:

Wavelength: 1064 nm.

Power: 200 W (adjustable).

Welding Speed: 1–3 seconds per valve.

Welding Accuracy: ±0.02 mm.

Material Compatibility: Aluminum, stainless steel.

Vision System:

High-resolution CCD camera for precise valve alignment.

Real-time monitoring of weld quality.

3.2 Cover Plate Assembly Welding Station

Welding Method: Resistance or ultrasonic welding.

Welding Current: 50–500 A (programmable).

Welding Speed: 8–12 welds per minute.

Alignment Accuracy: ±0.03 mm.

Cover Plate Size Compatibility:

Length: 50–200 mm

Width: 30–100 mm

Material Compatibility: Aluminum, nickel-coated steel.

Pre-Welding Verification: Sensor-based detection of proper plate placement.

3.3 Air Tightness Testing Station

Testing Method: Helium leak detection.

Detection Range:

Minimum Leak Rate: 1 × 10⁻⁶ mbar·L/s.

Maximum Leak Rate: 1 × 10⁻² mbar·L/s.

Cycle Time: ≤20 seconds per cell.

Vacuum Chamber Dimensions:

Length: 50–300 mm

Width: 50–200 mm

Height: 5–100 mm

Helium Recovery Efficiency: ≥98%.

Pass/Fail Criteria: Configurable based on customer specifications.

3.4 Impedance and Performance Testing Station

Testing Parameters:

Internal Resistance (Impedance): 0.01–100 mΩ (accuracy: ±0.001 mΩ).

Voltage Range: 0–100 V (accuracy: ±0.01 V).

Current Range: 0–200 A (accuracy: ±0.1 A).

Testing Speed: Up to 30 cells per minute.

Performance Metrics: Conducts charge/discharge cycle simulation and resistance measurements.

Data Storage:

Internal Storage: 2 TB SSD for test results.

Export Formats: CSV, PDF via USB, Ethernet, or cloud.

4. Conveyor System Specifications

Transport Speed: Adjustable, up to 12 m/min.

Conveyor Material: ESD-safe belt with wear-resistant coating.

Load Capacity: 10–15 kg per cell.

Positioning Accuracy: ±0.05 mm with servo-driven indexing.

5. Control and Interface

Control System: PLC-based centralized system with integrated monitoring.

HMI:

15-inch capacitive touchscreen with multi-language support.

Intuitive GUI for station control and monitoring.

Data Management:

Recipe storage for different battery models.

Real-time analytics for production and quality metrics.

Communication Protocols: Modbus, Ethernet/IP, and OPC UA for factory integration.

6. Electrical Specifications

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

Maximum Power Consumption: 20 kW (entire line).

Control Voltage: 24V DC for auxiliary systems.

7. Safety Features

Emergency Stop: Multiple emergency stop buttons at each station.

Overload Protection: Integrated sensors for load monitoring in conveyors and welding stations.

Laser Safety: Class 1 laser enclosures with interlocks and safety curtains.

Helium Leak Detection Alarms: Audible and visual alerts for excessive leak rates.

Protective Barriers: Transparent enclosures with interlocks for operator safety.

8. Environmental and Installation Requirements

Operating Environment:

Temperature: 15–30°C

Humidity: ≤60% RH (non-condensing).

Noise Level: ≤75 dB during operation.

Installation Requirements:

Flat, vibration-free surface.

Minimum clearance: 1,000 mm around the equipment.

9. Optional Configurations

Dual Welding Heads: For higher throughput at welding stations.

Advanced Vision System: AI-based defect detection for welding and assembly processes.

Automated Loading/Unloading: Robotic integration for material handling.

IoT Connectivity: Cloud-based monitoring and remote diagnostics.

10. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect welding heads, check conveyor alignment, and clean vacuum chambers.

Monthly: Calibrate test stations and verify alignment systems.

Quarterly: Comprehensive diagnostics of electrical and mechanical systems.

Warranty Period:

Standard: 12 months.

Extended: Up to 36 months available upon request.