The lithium-ion battery module and pack production line is a complex system consisting of multiple major units and associated equipment that work in concert to achieve high quality lithium-ion module and pack production.
The production line starts with the battery cell handling equipment, which is responsible for the initial handling and testing of the battery cells. At this stage, the internal resistance and voltage of the battery cells are measured to ensure that the quality of the battery cells meets the standards.
Battery Cell stacking is a critical step. In this process, the battery cells are stacked together in a specific arrangement and secured with spacers and end plates to form the basic structure of a battery module.
This process is used to detect and visually position the terminals to ensure the correct alignment of the battery cells, while the CCD system is used for high-precision addressing to ensure accurate alignment of the components.
In this process, the busbar will be welded to the terminals to realize the series-parallel connection of the battery cells. The quality of the welding is critical to the performance of the battery.
On the Pack assembly line, the battery modules are assembled into a complete pack, which includes the module casing, the heat dissipation system, the Battery Management Unit (BMU) and so on.
These equipment and systems are used to perform a variety of tests, quality control and monitoring of batteries to ensure that every pack produced meets high standards.
These systems are used to harmonize and connect the various units and equipment to achieve efficient operation of the entire production line and management of production data.
The process flow of Li-ion module and pack production line can be divided into the following main steps:
First, the battery cells are put into the production line manually, then the production line equipment automatically scans the battery cells, and at the same time carries out the internal resistance and voltage test, in order to screen out the battery cells with qualified quality.
After preliminary processing and testing, qualified battery cells are transported to the stacking area. Here, the battery cells are stacked and secured with spacers and end plates.
The stacked battery cells are transported to the next assembly line, ready for the next step.
At this stage, the end plates and terminals need to be visually positioned to ensure the correct alignment of the battery cells, a CCD system is used for precise positioning.
The staff will manually perform the installation of the battery busbar to ensure the current connection between the battery cells.
The equipment carries out laser welding of busbar and terminals to complete the series-parallel connection of battery cells.
After welding is completed, the weld seam is cleaned and vacuumed, and an inspection is performed to ensure the quality of the weld.
The staff installs the wiring harness to the battery module and welds the wiring harness to the busbar to ensure the transmission of battery data.
Detects the quality of wire harness welding and ensures the accuracy of data collection.
The whole battery module is conveyed through the speed chain conveyor with multiple stations, which can be operated according to the customer’s process requirements.
It is used to deal with unqualified products and repaired products, and at the same time carry out manual sampling.
At this stage, the battery module will be assembled into a complete energy storage battery pack, including the case, heat dissipation system, BMU and so on.
Each station is equipped with a “pause-reset-continue” function to support equipment pause and troubleshooting during operation.
The control system reserves multiple I/O interfaces for future expansion of related functions.
The doubling chain in the whole system is of robust welded construction with excellent static and dynamic stiffness. A high degree of accuracy and stability is ensured by vibration-ageing treatment and precision machining.
The main system components such as lasers, water chillers, and automatic logistics lines are well laid out and easy to operate and maintain. The welding area is protected by a safety shield, with automatic safety doors on the left and right sides, and safety pins on all entrances and exits. During the welding process, if any door is opened manually, the laser system will automatically stop and sound an alarm to ensure the safety of the operator.
A closed laser room is used in the production line to discharge the fumes and harmful gases generated, and is connected to the exhaust system or smoke purification system to ensure that the emission meets the national standards and protects the operator’s health and the environment.
UPS power supply is optional to prevent computer system crash or data loss caused by sudden power failure and improve the reliability of the system.
The whole system has no leakage of electricity, water, liquid or gas, which ensures the safety and stability of the production process.
The lithium-ion battery module and pack line is a key component in the field of modern battery technology. Its high degree of automation and rigorous process flow ensure high quality and efficiency in production.
In the future, lithium-ion module and pack production lines will continue to play a key role as energy storage technology continues to advance. More innovations are expected to increase energy density, reduce production costs and further improve environmental protection measures. This will help to meet the growing demand for batteries and drive the development of renewable energy, as well as the continued growth of electric transportation and industrial applications. Li-ion battery module and pack production lines will continue to play a key role in this field, pushing the frontiers of energy storage technology.
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