Product classification
The EV Blade Battery CTP (Cell-to-Pack) Automatic Welding Line is a cutting-edge automated solution tailored for the direct assembly of blade battery cells into robust packs without intermediate modules. This line combines high-precision handling, advanced laser welding, and quality inspection systems to ensure efficient, high-throughput production while meeting the demanding safety and performance requirements of EV batteries.
Key Processes and Modules
1. Automatic Blade Cell Feeding and Positioning Station
· Function: Automatically feeds blade cells into the line and ensures precise alignment for welding.
· Specifications:
o Cell Size Range: Length 400–1,200 mm, Width 80–150 mm, Thickness 10–40 mm.
o Positioning Accuracy: ±0.2 mm.
o Cycle Time: ≤8 seconds per cell.
2. Cell-to-Busbar Laser Welding Station
· Function: Performs high-precision laser welding to connect blade cell terminals to the busbar.
· Specifications:
o Welding Power: 600–1,500 W (fiber laser).
o Welding Accuracy: ±0.05 mm.
o Cycle Time: ≤5 seconds per weld.
o Real-Time Monitoring: Inline monitoring system for weld quality with defect detection.
3. Thermal Management System Installation Station
· Function: Installs cooling plates and applies thermal interface materials (TIM) to ensure efficient heat dissipation.
· Specifications:
o TIM Application Accuracy: ±0.1 mm.
o Cooling Plate Compatibility: Liquid or air-cooling systems.
o Cycle Time: ≤20 seconds per assembly.
4. Structural Bonding and Frame Assembly Station
· Function: Bonds and assembles the structural frame around the blade cells for mechanical stability.
· Specifications:
o Adhesive Type: Epoxy or UV-curable adhesive.
o Bonding Accuracy: ±0.2 mm.
o Frame Material: Aluminum or composite material.
5. High-Voltage Busbar and Connector Welding Station
· Function: Welds high-voltage connectors and busbars to create electrical paths between cells and the pack.
· Specifications:
o Welding Type: Laser or ultrasonic.
o Welding Accuracy: ±0.05 mm.
o Voltage Handling Capacity: Up to 1,000V DC.
o Cycle Time: ≤10 seconds per connection.
6. PACK Assembly and Sealing Station
· Function: Assembles multiple blade modules into the pack housing and seals it to protect against environmental factors.
· Specifications:
o Sealant Material: Silicone or polymer gaskets.
o Assembly Accuracy: ±0.3 mm.
o Cycle Time: ≤3 minutes per PACK.
7. Electrical and Safety Testing Station
· Function: Conducts comprehensive testing for electrical performance, insulation, and leakage.
· Specifications:
o Test Parameters: Voltage, resistance, insulation, short circuit, and leakage current.
o Helium Leak Detection: Sensitivity ≤1x10⁻⁶ Pa·m³/s.
o Testing Speed: ≤2 minutes per PACK.
8. Final Visual Inspection and Quality Assurance Station
· Function: Automated inspection of weld quality, assembly alignment, and surface defects.
· Specifications:
o Vision System Resolution: 8 MP industrial cameras.
o Inspection Speed: ≤1 minute per PACK.
o AI Algorithm Accuracy: ±0.05 mm for defect detection.
Production Line Specifications
· Overall Dimensions:
o Length: 85,000 mm.
o Width: 12,000 mm.
o Height: 4,000 mm.
· Weight: Approximately 55,000 kg.
· Production Capacity: 12–15 PACKs/hour.
· Automation Level: Fully automated with robotic handling and AI-powered monitoring.
Vision and Quality Control Systems
· Defect Detection: AI-driven system for weld and assembly defect detection.
· Data Logging: Centralized database for traceability and production analytics.
· Inspection Accuracy: ±0.05 mm for weld and surface defects.
Control and Interface
· Control System: Distributed PLC and HMI for centralized operation.
· HMI Features:
o 17-inch touchscreen with multilingual support.
o Real-time monitoring and diagnostics.
· IoT Integration: Remote access for predictive maintenance and data analysis.
Safety Features
· Enclosure Design: Fully enclosed with interlocks for safety.
· Emergency Stops: Strategically placed along the line.
· Laser Safety: Class 1 certified enclosures with auto shutdown on fault detection.
· Electrical Protection: Surge and overcurrent protection systems.
Electrical Specifications
· Power Supply: AC 380V ±10%, 50/60 Hz, 3-phase.
· Maximum Power Consumption: 320 kW.
· Control Voltage: 24V DC for auxiliary systems.
Cooling System
· Type: Centralized water cooling for welding and power systems.
· Cooling Capacity: 150 kW.
· Flow Rate: 40–60 L/min.
Environmental Requirements
· Operating Conditions:
o Temperature: 15–30°C.
o Humidity: ≤60% RH (non-condensing).
· Noise Level: ≤75 dB during operation.
· Installation Space: Minimum clearance of 2,000 mm around the line.
Maintenance and Warranty
· Maintenance Schedule:
o Weekly: Check alignment, weld quality, and cooling systems.
o Monthly: Calibrate vision and inspection tools.
o Quarterly: Comprehensive diagnostics and software updates.
· Warranty Period:
o Standard: 12 months.
o Extended: Available upon request.
