Semi-automatic Prismatic Battery Pack Assembly Line for Industrial and Commercial Energy Storage Application 

Product Introduction

This customized production line is mainly used to complete the assembly, inspection, assembly, and welding functions of the prismatic cell energy storage battery pack module. This semi-automatic line includes automatic up and down reflux of empty trays and manual feeding, Cell scanning and automatic sorting/manual stacking/automatic squeezing and bundling/manual scanning and grouping/automatic polarity detection/automatic pole cleaning/manual placement of busbars/automatic busbar welding/manual visual inspection of welding machine effect/total pressure internal resistance testing/lifting and offline assembly/automatic welding of wire harnesses/BMS scanning and binding/comprehensive testing/lifting and offline assembly.

The product is manually picked up and placed in the loading position, transported by the conveyor belt to a fixed position, scanned first, and then tested. After the test is completed, OK and NG cell products are distinguished according to the test results. OK products are automatically moved to the corresponding channel, and NG flows back to the loading station. After completion, they are transported to the manual stacking position, where the PACK module is manually assembled and stacked; Then transfer to the extrusion station through the automatic double speed chain, complete the automatic extrusion, and at the same time, tie the plastic steel strip at that station. The double speed chain belt is manually bound to the battery cells at the next station, generating battery modules and labels; The next station will automatically perform positive and negative CCD visual inspection, automatically detecting whether there is an error in the arrangement and grouping. When an error in the polarity of the grouping is detected, the station will automatically alarm and rule out any defective cars; The OK product will automatically flow to the next station, and the Pack module's positive and negative poles will be cleaned by an automatic laser cleaning machine. After the laser cleaning is completed, it will flow to the next station; Manually place the busbar, follow the start flow to the next station, and automatically complete the busbar laser welding; The next station will automatically test the total internal pressure and total internal resistance. When NG occurs, the machine will alarm, manually handle the alarm, eliminate the NG, and confirm. The Pack module will be manually lifted to the PACK assembly line, and the empty tray will automatically return to the starting point; Manually place the wiring harness at the next station, follow the starting flow to the next station, and automatically complete the wiring harness welding; The next step is to organize the wiring harness and BMS welding, scan the code and bind it to the module, form the product code and print it, and manually attach it; Press the start button to flow to the next workstation and automatically complete the comprehensive testing of semi-finished products. When NG occurs, the machine will alarm, manually handle the alarm, eliminate the NG, and confirm. The OK product will be manually lifted off the production line, and the empty tray will automatically return to the starting position.

Introduction to process flow

Manual feeding--Cell OCV sorting----(NG discharge)--Manual adhesive stacking--Automatic extrusion--Manual scanning and binding--Polarity detection--Pole cleaning--(NG discharge)--Manual placement of busbars--Laser Welding--Manual Visual Inspection--(NG discharge)--Total internal pressure and internal resistance test----(NG discharge)--Manual lifting and line replacement--Manual placement of wiring harnesses--Wire harness welding--Manual installation of BMS--Manual scanning and binding--EOL testing--Manual lifting offline

General equipment configuration and standards:

1. Scope of battery cell adaptation: A battery pack with an external size of 920mm * 500mm

2. Environmental conditions:

Air source pressure: 0.5~0.6 Mpa

Power supply voltage: 380V, 50Hz

Total power: ≤ 40KW

Area bearing capacity: ≥ 400kg/㎡

Environmental requirements: temperature between 10 and 40 ℃; Humidity 30-70%

Humidity: 20% -90%

3. Production line efficiency: The daily production capacity (10H/day) meets 240 sets (Pack module configuration method: 8PCS/set, that is 1920 cells/10H/day)

4. Equipment utilization rate:>95%

5. Product qualification rate:>99%

6. Meet safety production requirements, including product safety and battery safety;

7. Carrier size: 1000mm × 600mm

8. Line body: 37500mm (length) × 4000mm (width) × 2200 (height) mm (based on actual design) assembly line to ground height: 750mm ± 50mm

Introduction to the functions of loading and OCV sorting station equipment

The equipment is suitable for the sorting and grouping of incoming materials for square aluminum shell batteries. The voltage internal resistance of the product is tested through a testing instrument, and the upper and lower limits of the voltage internal resistance can be set on the human-machine interface.

The product is manually picked up and placed in the feeding position, and the equipment belt flows to the testing area. The battery code is first read by a high-speed code reader, and then automatically tested in sequence. After the test is completed, OK and NG products are automatically distinguished based on the test results. The test data is automatically saved locally and can be connected and exported; OK battery cells flow towards the corresponding channel, and then pack stacking is manually completed; Testing NG products will flow to the defective product buffer tank. When the defective buffer tank is stacked to a certain set quantity, the buzzer will sound an alarm and personnel will take out the defective products, making it convenient for personnel to operate.

Functional Advantages

1. The defective product cache slot is divided into AB slots. When one slot accumulates to the upper limit, the equipment will automatically alarm and personnel will take away the defective product from the cache;

2. The test parameter condition values can be set independently on the human-machine interface;

3. The probe adopts a nickel plated probe assembly and is tested using the four wire method. The probe is cylindrical with a sharp angle at the bottom, which can adapt well to ensure contact. The nickel plating process of the probe greatly reduces impedance and improves testing accuracy;

4. The testing position and stroke are adjustable, suitable for customers with certain external dimensions of battery cells;

5. The device is equipped with a data system that can save test data locally, and has the ability to interact with data. The test results can be connected to backend devices through media such as Ethernet cables or USB drives;

6. If multiple readings of the code are invalid before the battery cell test, it shall be manually confirmed and eliminated;

7. The appearance of the equipment on this site adopts a combination of lower sheet metal and upper profiles. The equipment is equipped with alarm lights and buzzers;

8. The equipment operation control system is developed by our company, which reserves data transmission ports for customers to perform data transmission and export analysis. The export format is in txt format or Excel format;

1	Number of equipment sorting stages	3+1 Channels(OK and NG)/ 4+1 Channels(OK and NG)
2	Internal resistance detection accuracy	Range 0-60 mΩ; Accuracy ± 0.5% rdg;
3	Voltage measurement accuracy	Resolution 0.1mΩ
4	Station single machine failure rate	Range 0-60V; Basic accuracy ± 0.015% rdg;
5	Product qualification rate	Resolution 0.1mV
6	Equipment production capacity speed	≤ 2% (faults caused solely by equipment)
7	Suitable for battery models	≥ 99.5% (excluding defective incoming materials)
8	Equipment production capacity speed	10-12PPM
9	Suitable for battery models	Prismatic cell(Width range: 168-200/height range: 204-230/thickness range: 70-90)

Introduction to manual stacking, automatic extrusion, and manual bundling workstations

This workstation mainly realizes the main processes of manual stacking and assembly of packs, automatic extrusion of battery modules, and manual bundling of plastic steel strips. It is composed of a double speed chain body elevator/online stacking manual operation position/automatic extrusion device and other mechanisms.

Functional Advantages

The empty board is sent to the manual stacking station through the double speed chain line body lifting and translation mechanism, and the Pack end board and glued battery cells are manually picked up and neatly stacked and assembled in sequence;

After stacking is completed, press the start button, and the lifting and translation mechanism will send the load module carrier back to the double speed chain line body, flowing into the next station; When reaching the extrusion station, the cylinder is blocked from lifting, and the module carrier plate stops moving forward. The lifting and translation mechanism sends the stacked Pack modules to the automatic extrusion station for automatic extrusion. After the extrusion cylinder returns to its position, the plastic steel strip is manually tied; After the process is completed, manually press the start button, and the lifting and translation mechanism will once again send the compressed and bundled Pack module back to the automatic double speed chain, flowing to the next operator station;

The squeezing and tying mechanism can be set to [enable] or [disable] through the human-machine control interface

Automatic extrusion configuration with two sets of extrusion tooling boards, the size of the tooling board is designed according to the battery cell size provided by the customer

The manual bundling machine is provided and used by the customer

The extrusion cylinder adopts a 63 adjustable stroke cylinder, with a thrust of 1559N (163KG) and a pressure of not less than 0.5Mpa. The control method is to control the three position five way solenoid valve through the output signal of the pressure sensor. When the thrust reaches the set value, the output stops. The parameter setting value can be set through the human-machine interface;

Introduction to manual scanning and binding station equipment

This workstation is operated manually, mainly to scan and upload the battery cells composed of Pack modules in sequence, and generate the Pack module code barcode. At the same time, the label printer prints the Pack module barcode, and the barcode label is manually attached.

Functional Advantages

1. After the load module reaches its position, it is blocked by the blocking cylinder and stops moving forward;

2. Manually scan all battery cells of the current PACK module one by one using a barcode scanner, and the scanned data is automatically uploaded to the local system. After the scanning is completed, the system generates the PACK module code;

3. The barcode printer automatically prints out the barcode and manually posts it in a fixed position on the Pack module;

4. The scanning and binding system and barcode generation system are developed by our company. The system reserves a data transmission port for customers to perform data transmission and export analysis. The export format is in txt or Excel format;

5. Maximum printing size for a single label: 104mm in length and 200mm in width, capable of printing QR codes and barcodes;

6. Wall mounted display, with personnel standing to operate the operation;

Introduction to cell Polarity detection station

This workstation mainly detects whether the positive and negative polarity of the Pack module battery cell arrangement is correct. The CCD camera XY moves to take photos and compare them automatically. When an error in polarity arrangement is detected, the equipment alarm is manually confirmed and discharged. If there is no abnormality, it flows to the next workstation.

Functional Advantages

1. After the load module reaches its position, it is blocked by a blocking cylinder and stops moving forward. The lifting mechanism lifts the moving carrier plate to ensure that the Pack module is stable and effectively detected during camera photography;

2. The CCD camera automatically moves to the detection target position and sequentially takes photos to compare and detect the arranged module battery cells;

3. The effective detection range of CCD at this station is: the maximum size range of Pack module is 800mm * 550mm;

4. The appearance of the equipment on this site adopts a combination of lower sheet metal and upper profiles, and the equipment is equipped with alarm lights and buzzers;

1	Effective detection size range	800mm * 550mm
2	Camera shooting speed	Around 200ms
3	CCD detection method	Feature point difference detection
4	Camera movement axis	XY axis
5	The camera installation height and focal length can be adjusted, suitable for different height and size battery cell modules

Introduction to cell poles laser cleaning station

This workstation mainly uses pulse laser to clean each pole of the Pack module one by one, and the cleaning path is completed through XY movement. The smoke and dust generated from cleaning are treated by a purification and recovery system, and the equipment operation is simple. The cleaning effect is manually visually inspected and confirmed.

Functional Advantages

1. After the load module reaches its position, it is blocked by a blocking cylinder and stops moving forward. The lifting mechanism lifts the moving load plate to ensure that the pole of the Pack module is stable and effective during the cleaning process;

2. Clean the laser in parallel and automatically clean all poles of the module within the range one by one;

3. After cleaning is completed, the lifting cylinder descends/blocks the cylinder from returning to its original position, and the module carrier board falls back to the double speed chain and flows to the next workstation;

4. The height of the laser can be set as a parameter value through the human-machine interface;

5. Cleaning scope: Clean pole dirt, oil stains, oxide layer, electrolyte, etc;

6. Using laser cleaning method, cleaning depth: 1-3 μ M;

7. Do not damage or damage the surface of the battery cell pole;

8. Cleaning speed: ＜ 6s/cell (2 poles);

9. The smoke and dust purifier is anti-static and explosion-proof, and the filter adopts a fireproof flower design. The filter material is flame retardant;

10. The appearance of the equipment on this site adopts a combination of lower sheet metal and upper profiles. The sheet metal color scheme is provided according to customer requirements, and the customer logo is screen printed on the outer surface of the sheet metal. The equipment is equipped with alarm lights and buzzers;

Machine body	Scope of structural work	1000 length × Width 500 × Height of 300MM	TMAX Automation self-made
	Machine tool cover	Lower precision sheet metal upper profile	TMAX Automation self-made
Optical maser	100W	wavelength F=160	Ruike (one set)
	Serial port connection cable	RS232 interface
Scanning galvanometer	Main structure	High speed and high precision digital galvanometer
Transmission motor	servo motor	standard	Xinjie
Control unit	PLC	standard	Xinjie
Purifier	Laser smoke and dust purifier	XL-300	Jingyanjing
Software	/	/	TMAX
IPC	Industrial control grade computer	4G memory Intel core CPU3.2G/64G solid-state drive	Industrial grade
	monitor	DELL19 inch industrial display	Dell

Introduction to BUSBAR laser welding station

The battery cells are connected in series using laser welding method, and can be compatible with soft pack, cylindrical battery, and square shell battery cell modules through welding power adjustment.

1) Welding thickness 3mm (adjustable);

2) Travel range 1000 * 500 * 300mm

3) Welding speed 30mm/s (adjustable);

4) Laser type: continuous;

5) Laser power: 6kw (adjustable);

6) Laser working medium: optical fiber;

7) Laser service life: ≥ 5 years;

welding technology

1) Welding material: aluminum bar, copper sheet nickel strip, and support composite welding (such as aluminum and copper nickel, copper nickel)

- Welding of aluminum and other materials;

2) Welding can be done in two modes: continuous welding and pulse spot welding;

3) Weld penetration depth: The contact surface penetration depth is adjustable by 3.6mm;

Welding strength: The tensile strength of the solder joint is greater than the material's failure strength;

Device Name	Module welding station
Power supply voltage (V)	380 ± 10% V AC 50/60Hz
Power supply capacity (kW)	10
Placement environment	Smooth, vibration free and impact free
Gas supply demand	Compressed air: pressure ≥ 0.6Mpa, gas consumption: 30 L/min;
Ground bearing requirements	Nitrogen: ≥ 0.4Mpa, gas consumption of 15 L/min (optional according to the process)
Environmental requirements	≥ 400kg/㎡
Qualification rate	Temperature 10-40 ℃; Humidity 30-70%
noise	≥ 99% (excluding incoming defects)
capacity	≤ 75dB (measured at a distance of 1m from the machine)

The laser adopts a 3000W continuous laser with chiller. 

Machine model	TMAX-DLY3000
source	220V ～/50HZ
Nominal cooling capacity	7.3KW
Maximum operating current	23.5A
Maximum operating power	5.17KW
discharge	＞33L/min
Water control range	8℃～30℃
Water tank capacity	38L
Refrigerant/Charge Quantity	R410A / 1.2KG
Operating ambient temperature	10℃～40℃

The relevant parameters are shown in the table:

Average output power	3000W
Center wavelength	1080 ± 10nm
Operation module	Continuous/Modulation
Maximum modulation frequency	5KHz
Output power stability	<1%
Red light	yes
Output connector	QBH
Output fiber length	10M
Input power supply	380V
control model	RS232/ADRS232/AD
Power adjustable range	(10-100)%
Power consumption	3000W (subject to actual customer usage)
weight	＜360KG
Cooling method	water-cooling
Working temperature ℃	10 ℃ -40 ℃

Introduction to total internal pressure and internal resistance test

The equipment on this site mainly tests the total pressure and internal resistance value of Pack modules that have been welded to Busbars using a daily tester, and sets its testing parameter range to determine whether they are qualified or unqualified.

Functional Advantages

1. After the load module reaches its position, it is blocked by a blocking cylinder and stops moving forward. The lifting mechanism lifts the moving load plate to ensure that the pole of the Pack module is stable and effective during the cleaning process;

After the module stabilizes, the test probe descends to the testing position for automatic testing;

3. If the total internal pressure and total internal resistance test results are within the range of test parameters, it is considered qualified and will continue to flow into the next station. If the test parameters are not met, it is considered uncooperative. The equipment alarm will be manually confirmed and discharged;

4. Adjust the position and height of the test probe by manually moving it;

5. The test parameter condition values can be set independently on the human-machine interface;

6. Can meet the testing requirements for dimensions of 850 * 600 * 80-400;

7. The probe adopts a nickel plated probe assembly and is tested using the four wire method. The probe is cylindrical with a sharp angle at the bottom, which can adapt well to ensure contact. The nickel plating process of the probe greatly reduces impedance and improves testing accuracy;

8. Daily tester production range: within 0-100V;

9. The workstation is controlled by PLC, and the testing status is only used to determine whether it is qualified or unqualified, without data transmission and record storage functions;

10. The appearance of the equipment on this site adopts a combination of lower sheet metal and upper profiles, and the equipment is equipped with alarm lights and buzzers;

Introduction to EOL testing station

Product model	Battery comprehensive tester TMAX-YLD100-200-400
Purpose	Used for testing semi-finished and finished products of battery packs below 100V
Basic function	Open circuit voltage test
	AC internal resistance test
	ID resistance test
	NTC Resistance Test
Charging performance testing	Battery PACK continuous charging function to verify if charging is normal
	Battery PACK charging overcurrent protection function test
Discharge performance testing	Continuous load capacity of battery PACK, continuous discharge check voltage drop
	Battery PACK discharge overcurrent protection function test
Short circuit Protection Test	Test battery positive and negative pole short circuit battery cut-off protection time (microsecond level)
Equipment protection function	Software protection function: power-off data protection
	Hardware protection: power failure protection, short circuit protection, battery reverse connection, and wrong connection protection

Testing class	Test items	Measuring range	Resolution ratio
Open circuit voltage	Open circuit voltage 1	10-100V	2mV
	Open circuit voltage 2	10-1ooV	2mV
Internal impedance	AC internal resistance test	0-1000mΩ	1mΩ
Discharge test	Starting voltage	0-150V	2mV
	End voltage	0-150V	2mV
	discharge current	0.1-200A	1mA
	Discharge time	0-60S	1mS
Discharge overcurrent test	Overdischarge current	10-400A	1mA
	overcurrent delay	0-30S	1mS
Short circuit protection	Short circuit protection delay	0-9999uS	1uS
Charging test	Starting voltage	10-100V	2mV
Charging protection test	End voltage	10-150V	2mV
	Charging current	0.1A-200A	1mA
	Charging time	0-60S	1mS
	Charging overcurrent	4-200A	1mA
Resistance R1/R2	Charging delay	0-20S	0.1mS
	NTC、ID	0-1000KΩ	±0.1KΩ
Sustainable output power	30KW
Sustainable load power		60KW
Online mode		Serial communication (RS232, can be used by multiple online devices)
test data		Generate a data table and automatically save it, which can be exported to Excel
Barcode management		Support barcode startup and binding of test data
Free software upgrade service		Lifetime free upgrade until hardware incompatibility occurs
Heat dissipation		Relying on ventilation system and forced air cooling

Introduction to Offline hoisting

The main purpose of this site is to transfer battery modules to the assembly line and complete them through sliding rail movement. Lifting capacity of 150KG. When the battery pack is relatively heavy, it can be considered for use. It is used for battery pack transfer (after total internal pressure and resistance testing) or finished product production (after EOL testing).

Main Component brands List

SN	Standard part category	Description of function and brand restrictions	Origion
1	Machine rack	Aluminum profile + sheet metal surface paint treatment	China
2	Processed parts	The surface of the aluminum parts is sandblasted and oxidized, and the iron parts are electroplated	China
3	man-machine	verenton
4	PLC	Panasonic/Principal	Japan/China
5	Dispaly	Lenovo
6	Industrial Computer	Advantech
10	Power supply	Omron/Mingwei
11	Sensor	Panasonic, Omron, AirTAC	Japan and Taiwan
12	Electric control accessories	Chint
13	Contactor	Chint
14	Button
15	Ordinary motor	Taijing
16	stepper motor	Yingshida
17	servo motor	Principal/Panasonic
18	I/O board	Lei Sai
19	cylinder, solenoid valve	AirTAC	Taiwan
20	bearing or linear bearing	NSK、FAG	Japan
21	guide rail	HIWIN、TBI	Taiwan
22	Structural standard parts	Yiheda