To ensure the safety performance and quality of mass-produced lithium-ion battery packs, lithium-ion battery packs in PACK production need to squat to find safety, rigorous production process by step production. Insulation of semi-finished products and the reliability of cell welding will directly affect the quality of the finished battery pack, in addition, the operator must wear a good static hand ring when operating, the next, lithium battery PACK manufacturers to explain the lithium-ion battery pack PACK production and manufacturing process, I hope to give you some help;.
Battery cell distribution and selection group
The first step is the cell sorting group, automatic sorting machine to set the parameters of the group should be: (cylindrical cells, for example, ternary system batteries and lithium iron phosphate ion batteries)
Voltage difference of 5mV (if the number of cells is large and consistency requirements are strict, you can choose to set 3mV as a grade)
Internal resistance difference of 3m (if the consistency requirements are strict, you can set 1-2m).
Capacity difference can not be screened on the automatic sorting machine, to be divided on the capacity aging cabinet for capacity allocation group. Before leaving the factory, the cores will be packed and shipped according to voltage, capacity and internal resistance. When the cores arrive, IQC of PACK department will conduct random inspection, and the capacity difference is recommended within 1%.
The core assembly jig, on the automatic welding machine
When assembling the jig, make sure to follow the order of positive and negative electrodes in the SOP of PE engineer. After setting the automatic welding machine program, put the fixture core in and start automatic spot welding.
After completing automatic spot welding, quality should spot check the automatic spot welding battery pack and make up the welding at the leaky and fried spot.
Welding PCM/BMS
In this step, the employee must have an electrostatic hand ring to prevent the PCM/BMS from being damaged by static electricity.
There are different steps according to different battery pack designs. If it is designed for PCM spot welding on the battery pack, then do not solder, quality also to PCM spot welding to the battery pack for spot welding spot inspection.
If the PCM/BMS is to be soldered and connected to the PACK with screws, the solder joints and screw connection points should also be spot checked. To ensure quality. Voltage collection line, in order B-,B1... In order to B+; or unplug the voltage acquisition line row plug after welding, welding is completed, the acquisition row plug for testing, to confirm that there is no error before connecting the BMS.
Semi-finished insulation
For voltage acquisition line, wire, positive and negative output line, the necessary fixed and insulation. The auxiliary materials are routinely high temperature adhesive tape, barley paper, epoxy board, zip ties, etc. Be safety conscious, do not superimpose pressure on the battery pack voltage collection lines or output wires, which may easily lead to short circuit caused by extrusion breakage.
Semi-finished product testing
After the battery pack is added to the BMS, a semi-finished product test can be conducted. The regular test includes: simple charge/discharge test, whole group internal resistance test, whole group capacity test, whole group overcharge test, whole group over discharge test, short circuit test, over current test. If there are special requirements need to carry out high temperature and low temperature test, pinprick test, drop test, salt spray test, etc., special test, destructive, it is recommended to sample inspection.
Pay attention to the battery pack's ability to withstand, such as whether the BMS can withstand high voltage during the whole group overcharge test; whether the BMS can withstand instantaneous high voltage high current during the short circuit test; whether the BMS can withstand pulse current during the overcurrent test, etc.
PACK packaging
This step also depends on the design. But before packaging, the signal acquisition line must be done, the battery pack positive and negative insulation.
PVC packed battery pack, over the heat shrink machine. Ultrasonic sealing of the battery pack, on ultrasonic machine. The battery pack with metal outer case, assembled on the outer case. In this process, we should pay attention to the battery pack lightly to prevent collision, extrusion, etc. The conductor wire should be insulated well to prevent short circuit.
Whole pack test
The whole group tester set the parameters, the battery pack on the whole group tester for testing.
Important test items: shipping voltage, internal resistance, simple charging and discharging.
Optional test items: overcurrent, short circuit.
Packing and shipping
Packing according to the size of the molded foam, do not randomly placed, the battery pack transport, the most afraid of the internal packaging void. Be sure to ensure that there is enough internal foam for cushioning, to prevent transport crashes. Large battery pack PACK, for safety reasons, we should arrange to ship the wooden frame.
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