Product classification
The CCS intelligent manufacturing production line of Huiyao Laser is a highly integrated and flexible system, including automated equipment such as wire harness isolation plate feeders and automatic BUSBAR feeders, as well as core process equipment such as single-point/multi-point riveting machines and nickel sheet laser welding machines. The production line is also equipped with precise detection devices such as automatic electrical performance testers and Automatic Optical Inspection (AOI) equipment.
Technical Parameter
| Equipment Yield Rate | First-pass yield rate of laser welding station≥99.5% |
| Final Yield | ≥99.8% (Including rework) |
| The first-pass yield of electrical performance testing | ≥97% |
| The first-pass yield of AOI inspection | ≥97% |
| Equipment Failure | ≤2% (only including the faults caused by equipment) |
| MTBF (Mean Time Between Failures） | ≥4H(Excluding alarms lasting＜2min) |
| Entire Line's OEE | ≥85% |
| *Note: Note: The non-conforming rate statistics only include non-conforming products cause by equipment issues. | |
Line Throughput: Supports up to ~2000+ modules/day, which corresponds to roughly 120–140 modules per hour (depending on shift strategy and configuration).
Cycle Time: Typical single-station cycle time is ~25–30 seconds per module (inferred from throughput and parallel stations).
Scalable Architecture: Dual- or quad-station parallel configuration is available, enabling throughput scaling to 3,000+ modules/day in high-speed setups.
Equipment OEE: ≥ 85%, ensuring stable, high-efficiency operation.
Automation Rate: ~95% automation achievable, depending on features selected (material handling, vision, testing, etc.).
Automated Processes Include:
Auto loading & unloading of components
CCS component (busbar / FPC) positioning & clamping
Multi-point laser welding or riveting
In-line electrical testing
AOI (Automatic Optical Inspection) for welds and parts
Automatic NG (no-good) rejection / sorting
Integration: Fully compatible with upstream module assembly lines and downstream PACK assembly or End-of-Line (EOL) testing lines — enabling seamless, highly automated production flows.
Input Specifications
Supported Cell Types: Cylindrical, prismatic, and pouch cells (customization supported)
Cell Size Range: Approximately 20 × 60 mm up to 80 × 180 mm, customizable per customer design
Material Feed / Tray Types: Plastic trays, blister trays, or custom carriers.
Incoming Quality Checks:
Voltage: 0–5 V / cell (standard QC range)
Internal resistance: ~0.1–20 mΩ (typical for QC)
Visual / optical defect detection: OK / NG by vision system
Output Specifications
Qualified CCS Output: ~120–140 pcs / hour (modules with CCS welded) — based on line throughput of ~2000+ modules/day.
Compatible Pack / Module Size Range:
Length: 200–1,000 mm
Width: 150–800 mm
Height: 50–300 mm (depending on customer structure)
Welding Accuracy:
Laser welding positioning accuracy: ± 0.05–0.1 mm (typical high-precision welding)
Riveting (if used): force accuracy within ± 1%
Weld Reliability: Weld pull strength ≥ 80–120 N (material-dependent, depending on busbar / nickel sheet specs)
Inline AOI inspection ensures visual defects, misalignment, or welding faults are detected in real time.
Closed-loop laser welding energy control for consistent weld quality and repeatable process parameters.
BMS Communication Testing (optional CAN / RS-485) to validate busbar / signal connection integrity.
Comprehensive electrical testing (internal resistance, voltage, load, short-circuit protection) for each module.
Traceability via MES system: full product tracking (QR code or serial number), logging all test data for downstream traceability and quality analytics.
Warranty: Standard 1-year warranty, optionally extendable to 24–36 months.
Technical Support: 24/7 support via remote diagnostics + on-site visits.
Commissioning & Training: We provide full on-site installation, system commissioning, and operator training.
Preventive Maintenance (PM): Available as a scheduled program to minimize downtime.
Spare Parts: Global spare parts supply with 72-hour delivery to major regions (depending on stock).
Remote Diagnostics: Real-time monitoring and troubleshooting for PLC, laser subsystems, vision systems.
Documentation: Full set of SOPs, maintenance manuals, process guides, and standard operation documents.
We offer highly flexible customization tailored to customer needs:
Process Customization:
Welding path programming to suit your CCS design
Hybrid process of laser welding + riveting
Energy / power tuning for weld quality / cycle optimization
Hardware Customization:
Custom fixture and jig design to match your module geometry
Automatic loading modules (robot / feeder) and buffer systems
Choice of laser source (Raycus, IPG, or other) per customer preference
Software Customization:
MES system integration, aligned to your existing factory systems
BMS communication protocol adaptation (CAN, RS-485, custom)
Custom data sampling, analysis, and report generation (production reports, quality reports, traceability)
OEM (Branding):
White-label or customer-branded delivery (external design, UI, HMI, color schemes)
Customized BOM to meet customer-specific branding / cost requirements
ODM (Design + Development):
Turnkey solution: Requirements → Process design → Mechanical design → Software development → Line delivery
Assistance with factory or workshop layout planning for line integration
Line optimization and upgrade options: e.g., later capacity expansion, automation upgrades
