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Views: 0 Author: Site Editor Publish Time: 2024-12-09 Origin: Site
With the widespread adoption of new energy vehicles, power batteries, as their core components, have garnered increasing attention. A single cell's energy is often limited, making it insufficient to meet the demands of large-scale equipment. However, through proper arrangement and coordination, multiple cells can be connected and combined to form a battery module, unleashing more powerful energy. The process of assembling individual cells into a battery module constitutes the production process of a battery pack.
The production and manufacturing of battery packs is a complex process involving installation and connections, casing, and testing. During the installation and connection phase, the housing is first cleaned and sealed with adhesive. Next, connectors and thermal management system components are installed. Finally, the modules or cell units are securely fixed within the housing.
Lithium battery pack sorting aims to ensure performance consistency and enhance safety. By selecting cells or modules with similar performance, it guarantees stable power output under various operating conditions and accurately predicts range. Through rigorous testing of protection circuits and cell uniformity, it prevents overcharging, over-discharging, and reduces short-circuit risks. This process avoids safety incidents or performance fluctuations caused by abnormal cells, laying a solid foundation for the stable and efficient operation of new energy devices.
Plasma cleaning plays a crucial role in power battery pack production by removing surface contaminants from cells, increasing surface energy to enhance adhesion, improving electrochemical performance, reducing safety risks, preparing for the gluing process, ensuring an eco-friendly and pollution-free operation, and improving the uniformity and consistency of cleaning. This process enhances the overall performance and reliability of the battery.
The main purpose of adhesive application in power battery pack production is to secure the cells to each other, the cells to the module structure, and the module to the battery pack casing. This enhances the structural stability of the battery pack, prevents cell displacement under vibration or impact, provides essential electrical insulation, and offers waterproof and dustproof protection. These measures significantly improve the overall safety and reliability of the battery pack.
The purpose of stacking in power battery pack production is to layer multiple cells or modules in a specific arrangement to achieve the required voltage and capacity. This process optimizes space utilization, enhances overall energy density, and ensures structural stability and thermal management efficiency of the battery pack, meeting the performance and safety requirements of new energy vehicles.
The primary purpose of steel banding in power battery pack modules is to enhance structural strength and stability, protect the cells from damage, and extend their service life. Steel bands also assist in thermal management by maintaining uniform battery temperature, shielding against electromagnetic interference to ensure normal operation of electronic equipment, and offering insulation and flame-retardant functions to improve safety.
At lower temperatures, the curing speed of adhesive slows down, requiring additional time to achieve the desired strength. After steel banding, adhesive curing ovens may be necessary to cure the adhesive in low-temperature climates.
The purpose of adhesive curing in power battery packs is to ensure a firm bond between internal components, providing the required structural strength and stability. This prevents cell displacement during vibration or impact. Additionally, the cured adhesive layer acts as a seal, offering water resistance, dustproofing, and thermal insulation, enhancing the overall protection and ensuring the safety and reliability of the battery in various environments.
The primary purpose of terminal addressing and laser cleaning is to ensure welding quality and improve production efficiency. Terminal addressing uses a visual system to accurately identify the terminal positions, providing precise alignment for laser cleaning and welding. Laser cleaning removes oxidation layers, residual electrolyte, and other contaminants from the terminal surfaces, creating optimal conditions for welding.
This process enhances welding strength and the overall performance of the battery module while reducing production costs and supporting green, environmentally friendly manufacturing.
Installing the CCS (Cell Contact System) is essential for establishing electrical connections between the cells and the Battery Management System (BMS). This ensures efficient current transmission while providing structural support to stabilize the cells within the PACK, ensuring safety and reliability during charging and discharging processes.
CCS components typically include busbars and contact elements, serving as critical electrical and mechanical interfaces within the battery PACK.
The purpose of laser welding is to achieve precise, efficient, and stable electrical connections between components within cells, modules, or PACKs. This welding method provides high-strength weld spots, ensuring the structural integrity and electrical safety of the battery pack.
Additionally, it reduces contact resistance, enhancing the conductivity of the battery pack. Its non-contact nature prevents damage to sensitive components, further improving production efficiency and product quality.
The purpose of post-weld inspection and cleaning is to ensure that the welding quality meets standards. This process involves checking for defects in the welds, such as cold joints, weak welds, or burn-through. It also includes the removal of residual materials like welding slag and metal debris generated during the welding process.
These steps prevent such residues from affecting battery performance and safety, and provide a clean surface for subsequent assembly and testing, ensuring the overall performance and reliability of the battery pack.
The purpose of the EOL (End-of-Line) comprehensive testing before the module is offline is to verify the performance and safety of the battery module. It ensures that the module meets the design standards in terms of electrochemical parameters, electrical connections, thermal management, protection functions, and more.
This step guarantees that the battery module has high quality and reliability before being integrated into the final battery pack, reducing rework and maintenance costs in subsequent production stages, and improving overall production efficiency.
After the comprehensive testing, the module can be taken offline and moved to the PACK assembly line. The assembly line includes the following processes:
Aging batteries can pose safety risks, such as overheating or leaking. Monitoring aging parameters allows for early detection of these hazards, reducing the likelihood of accidents and ensuring the safety of users and equipment. For example, many modern battery systems come equipped with safety features that monitor temperature and voltage, shutting down the system in case of anomalies.
Prepare all necessary PACK components, including BMS, cooling systems, enclosures, connectors, etc..
On an automated or semi-automated assembly line, the battery modules are combined with other components to form a complete battery pack.
Ensure all electrical connections are correct, including connections between modules and with the BMS.
Install seals to ensure the battery pack's waterproof and dustproof performance, and install the cooling system to manage the battery temperature.
Conduct a series of performance tests, including voltage, internal resistance, insulation resistance, charging and discharging performance, etc.
Perform safety tests, such as overcharge, over-discharge, short circuit, and temperature tests, to ensure the safety of the battery pack.
Record all test data for quality traceability and subsequent analysis.
Conduct a final visual and functional inspection to ensure the appearance and functionality of the battery pack meet the required standards.
Package the battery packs that passed the final inspection and prepare them for shipment.
This concludes the in-depth analysis of the lithium-ion battery PACK production process. Through this series of introductions, we have gained a detailed understanding of every critical step, from cell preparation, module assembly, to the final integration and testing of the battery PACK. Each stage reflects the precision and complexity of modern battery manufacturing technology, as well as the relentless pursuit of safety, performance, and efficiency.
