Prismatic Battery Cap Manufacture Line

· Equipment Dimensions:

o Length: 15,000 mm

o Width: 3,000 mm

o Height: 2,200 mm

· Weight: 8,500 kg ± 5%

· Modular Structure: Individual stations interconnected with a conveyor system.

· Frame Material: High-strength steel with powder-coated surface for corrosion resistance.

· Worktable Material: Stainless steel with anti-static properties.

1. Explosion-Proof Valve Welding Station

· Welding Method: Precision laser welding.

· Laser Specifications:

o Wavelength: 1064 nm.

o Power: Spot welding 1500W, full welding 3000W

· Welding Speed: 1–3 seconds per valve.

· Welding Accuracy: ±0.02 mm.

· Material Compatibility: Aluminum, stainless steel.

· Vision System:

o High-resolution CCD camera for precise valve alignment.

o Real-time monitoring of weld quality.

2. Cover Plate Assembly Welding Station

· Welding Method: Resistance or ultrasonic welding.

· Welding Current: 50–500 A (programmable).

· Welding Speed: 8–12 welds per minute.

· Alignment Accuracy: ±0.03 mm.

· Cover Plate Size Compatibility:

o Length: 50–200 mm

o Width: 30–100 mm

· Material Compatibility: Aluminum, nickel-coated steel.

· Pre-Welding Verification: Sensor-based detection of proper plate placement.

3. Air Tightness Testing Station

· Testing Method: Helium leak detection.

· Detection Range:

o Minimum Leak Rate: 1*10-⁹ mbar·L/s.

o Maximum Leak Rate: 1 × 10⁻² mbar·L/s.

· Cycle Time: ≤20 seconds per cell.

· Vacuum Chamber Dimensions:

o Length: 50–300 mm

o Width: 50–200 mm

o Height: 5–100 mm

· Helium Recovery Efficiency: ≥98%.

· Pass/Fail Criteria: Configurable based on customer specifications.

4. Impedance and Performance Testing Station

· Testing Parameters:

o Internal Resistance (Impedance): 0.01–100 mΩ (accuracy: ±0.001 mΩ).

o Voltage Range: 0–100 V (accuracy: ±0.01 V).

o Current Range: 0–200 A (accuracy: ±0.1 A).

· Testing Speed: Up to 30 cells per minute.

· Performance Metrics: Conducts charge/discharge cycle simulation and resistance measurements.

· Data Storage:

o Internal Storage: 2 TB SSD for test results.

o Export Formats: CSV, PDF via USB, Ethernet, or cloud.

· Transport Speed: Adjustable, up to 12 m/min.

· Conveyor Material: ESD-safe belt with wear-resistant coating.

· Load Capacity: 10–15 kg per cell.

· Positioning Accuracy: ±0.05 mm with servo-driven indexing.

· Control System: PLC-based centralized system with integrated monitoring.

· HMI:

o 15-inch capacitive touchscreen with multi-language support.

o Intuitive GUI for station control and monitoring.

· Data Management:

o Recipe storage for different battery models.

o Real-time analytics for production and quality metrics.

· Communication Protocols: Modbus, Ethernet/IP, and OPC UA for factory integration.

· Power Supply: AC 380V ± 10%, 50/60 Hz, 3-phase.

· Maximum Power Consumption: 20 kW (entire line).

· Control Voltage: 24V DC for auxiliary systems.

· Emergency Stop: Multiple emergency stop buttons at each station.

· Overload Protection: Integrated sensors for load monitoring in conveyors and welding stations.

· Laser Safety: Class 1 laser enclosures with interlocks and safety curtains.

· Helium Leak Detection Alarms: Audible and visual alerts for excessive leak rates.

· Protective Barriers: Transparent enclosures with interlocks for operator safety.

· Operating Environment:

o Temperature: 15–30°C

o Humidity: ≤60% RH (non-condensing).

· Noise Level: ≤75 dB during operation.

· Installation Requirements:

o Flat, vibration-free surface.

o Minimum clearance: 1,000 mm around the equipment.

· Dual Welding Heads: For higher throughput at welding stations.

· Advanced Vision System: AI-based defect detection for welding and assembly processes.

· Automated Loading/Unloading: Robotic integration for material handling.

· IoT Connectivity: Cloud-based monitoring and remote diagnostics.

· Maintenance Schedule:

o Weekly: Inspect welding heads, check conveyor alignment, and clean vacuum chambers.

o Monthly: Calibrate test stations and verify alignment systems.

o Quarterly: Comprehensive diagnostics of electrical and mechanical systems.

· Warranty Period:

o Standard: 12 months.

o Extended: Up to 36 months available upon request.