Huiyao Laser - EV Cylindrical Battery Module PACK Assembly Line
The EV Cylindrical Battery Module PACK Assembly Line is an automated system tailored for efficiently transforming cylindrical cells into fully-assembled battery modules and packs. This system seamlessly integrates cell sorting, grouping, module assembly, and electrical interconnection, complemented by stringent testing procedures. The assembly line is designed with high precision and traceability in mind, fortified by integrated quality assurance mechanisms to meet the demanding requirements of electric vehicle applications. Additionally, the line's flexibility allows it to support various assembly configurations, making it highly adaptable to different production needs. Safety features, automation control, and environmental considerations are meticulously incorporated into the line's mechanical design to ensure optimal performance. The assembly process effectively enhances manufacturing efficiency, aligning with the industry's best practices for reliability and consistent quality output.
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.
- 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.
3.1 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.