Process Flow of Lithium-Ion Battery Pack Processing Line

Sorting and Grouping Process

Objective: Select cells with consistent parameters (voltage, internal resistance, capacity) to ensure uniformity in the final pack.

Equipment: Capacity testers and cell sorting machines.

Automatic Welding Process

Method: Laser welding (e.g., gantry galvanometer laser welders) or ultrasonic welding connects cells to busbars, ensuring minimal heat impact and high-strength joints.

Equipment: Semi-automatic/automatic spot welders; laser welding machines dominate the market (e.g., Han's Laser, United Winners Laser).

Semi-Finished Product Assembly

Steps: Integrate welded cells with protection boards (PCM/BMS), insulation materials (e.g., fish paper, epoxy boards), and structural supports.

Safety: Operators must wear electrostatic wristbands to prevent PCM/BMS damage.

Aging Detection Process

Purpose: Test semi-finished packs under simulated conditions to identify early failures (e.g., self-discharge, micro-shorts).

Equipment: Aging cabinets for parameter validation.

PACK Testing Process

Tests: Comprehensive checks including capacity, cycle life, temperature cycling, overcharge/discharge, and short-circuit tests.

Tools: Integrated testers (e.g., constant current/voltage chargers, AC resistance testers).

PACK Packaging Process

Methods: PVC heat-shrink wrapping, ultrasonic sealing, or metal casing assembly.

Focus: Insulation of terminals and shockproof packaging (e.g., custom foam padding) to prevent transport damage