Prismatic Lithium Battery Pack Assembly Production Line

The prismatic lithium battery pack assembly production line integrates advanced processes and equipment to manufacture high-quality battery packs. It begins with meticulous material preparation and inspection, followed by cell preprocessing, including voltage and internal resistance testing. Cells are then welded and assembled into modules using automated equipment like welding robots. Modules are encapsulated in casings, sealed, and subjected to rigorous functional and safety testing. Multiple modules are assembled into a complete battery system, integrated with a BMS for monitoring and management. Comprehensive testing ensures the system’s performance and reliability. Finally, the battery pack undergoes appearance inspection, packaging, and quality traceability. The production line features automated equipment, precise testing instruments, and environmental control systems to maintain high standards of quality and efficiency.

Here is a detailed breakdown of the Prismatic Lithium Battery Pack Assembly Production Line, combining the process flow and equipment configuration:

I. Process Flow

1. Material Preparation and Inspection

• Content: Prepare battery cells, PCM boards (Protection Circuit Modules), wires, bus bars, casings, and auxiliary materials (such as tape, foam, insulating sheets, etc.). Inspect all materials to ensure they meet production quality requirements.
• Equipment Configuration: Material storage racks, inspection workbenches, inspection instruments, etc.

2. Cell Preprocessing

• Content: Conduct visual inspections on battery cells to ensure there are no damages or deformations. Measure the voltage and internal resistance of the cells and sort them by capacity to ensure that cells in the same group have similar performance.
• Equipment Configuration: Visual inspection equipment (e.g., vision inspection systems), voltage/internal resistance testers, sorting equipment.

3. Cell Welding and Assembly

• Content: Use ultrasonic welding or laser welding to connect the battery cells with bus bars and wires to form cell modules. Connect the PCM board to the cell module to ensure correct and secure electrical connections.
• Equipment Configuration: Welding robots (laser welding machines or ultrasonic welding machines), welding workbenches, fixtures, etc.

4. Module Encapsulation

• Content: Place the cell module into the casing and use foam, insulating sheets, and other auxiliary materials to secure and protect it. Seal the casing to prevent the module from being affected by external environmental factors.
• Equipment Configuration: Casing assembly machines, sealing equipment (e.g., adhesive dispensing equipment), pressing devices, etc.

5. Functional Testing

• Content: Conduct functional tests on the assembled module, including voltage testing, internal resistance testing, and charge-discharge testing to ensure the module meets design requirements. Check the safety performance of the module, such as overcharge protection, overdischarge protection, and short-circuit protection.
• Equipment Configuration: Test stations, charge-discharge testers, safety performance testing equipment.

6. System Assembly

• Content: Assemble multiple modules into a battery system using wires, connectors, and other components. Install the battery system’s monitoring and management system (such as BMS) to ensure the normal operation and safety of the battery system.
• Equipment Configuration: System assembly workbenches, BMS installation equipment, connector assembly equipment, etc.

7. Comprehensive Testing

• Content: Conduct comprehensive tests on the battery system, including capacity testing, cycle life testing, and temperature cycling tests to ensure the performance and reliability of the battery system. Check the safety performance of the battery system, such as overtemperature protection and overcurrent protection.
• Equipment Configuration: Comprehensive testing equipment, environmental simulation equipment (such as high and low-temperature test chambers).

8. Appearance Inspection and Packaging

• Content: Conduct a visual inspection of the battery system to ensure there are no scratches or stains. Package the battery system using appropriate packaging materials to prevent damage during transportation and storage.
• Equipment Configuration: Visual inspection equipment, packaging equipment (such as automatic packaging machines).

9. Quality Traceability and Final Inspection

• Content: Establish a quality traceability system to record information from each production stage, ensuring product quality is traceable. Conduct final inspections on the battery system to ensure it meets customer requirements.
• Equipment Configuration: Data collection systems, MES systems, inspection equipment.

10. Shipping and After-Sales Service

• Content: Ship the qualified battery system to customers. Provide after-sales service to resolve any issues customers may encounter during use.
• Equipment Configuration: Logistics equipment (such as forklifts, shelving, etc.).

II. Equipment Configuration

1. Testing Equipment

• Function: Used for comprehensive performance testing of battery packs, including cell testing instruments, BMS testing equipment, insulation testing instruments, etc.
• Equipment: Voltage/internal resistance testers, charge-discharge testers, safety performance testing equipment, insulation testers, etc.

2. Assembly Equipment

• Function: Used to assemble battery cells, BMS, heat sinks, and other components into a complete battery pack.
• Equipment: Welding robots (laser welding machines or ultrasonic welding machines), fixtures, conveyors, robots, and other automated equipment.

3. BMS System

• Function: Responsible for monitoring and managing the state of the battery pack, including functions such as charge monitoring, temperature control, and balancing charging.
• Equipment: BMS installation equipment, monitoring systems, etc.

4. Environmental Control Equipment

• Function: Lithium battery production requires strict environmental conditions, including control of temperature, humidity, and other parameters.
• Equipment: Temperature and humidity controllers, air purifiers, etc.

5. Data Acquisition and Analysis System

• Function: Real-time monitoring of various parameters during the production process and analysis and optimization of production data.
• Equipment: Data acquisition systems, MES systems, etc.

By combining the above process flow and equipment configuration, the prismatic lithium battery pack assembly production line can achieve efficient and precise production, ensuring the quality and performance of the battery packs.