Core beat control for full PACK assembly process

2. Optimize parallel station setting for high-beat processes (e.g., dual-channel EOL test, double-station cell pre-stacking);

3. Compress non-value-added auxiliary time (material handling, tool adjustment) to reduce single-PACK production tact.

Single-PACK production tact: reduced by 15%–30%

Core station beat deviation: ≤5%

Production line capacity utilization improved by 10%–18%;

Eliminates waiting and blocking losses between processes.

Multi-model mixed production efficiency improvement

2. Store 100+ sets of process parameters in the MES system, realize one-click recipe switching for different PACK models;

3. Standardize the changeover process, and split the internal and external work of model switching to realize parallel operation.

Multi-model mixed production capacity: ≥3 product specifications on the same line

Changeover failure rate: ≤0.5%

Avoids capacity idling caused by market demand fluctuation;

No additional capital expenditure for multi-model production expansion.

Unmanned and semi-unmanned production efficiency improvement

2. Adopt collaborative robots for small-batch flexible assembly and auxiliary material loading, realizing human-machine collaborative operation;

3. Automate the full process from material feeding to finished product unloading, and reduce manual intervention in core processes.

Manual operation error rate: reduced by 95%

Labor cost per PACK: reduced by 50%–70%

Unplanned downtime caused by manual operation reduced by 80%;

Solves the problem of low efficiency in high-labor-cost regions.

Rework and scrap loss reduction

2. Establish a closed-loop quality control system, trace the root cause of defects through MES data, and optimize process parameters in time;

3. Add pre-inspection links for incoming cells and materials to avoid defective materials flowing into the production line.

Process rework rate: reduced by 45%–75%

Scrap loss rate: reduced by 60%–80%

After-sales failure rate and warranty compensation risk reduced by 85%;

Shortens the production cycle caused by rework and repair.

Material handling efficiency improvement

2. Build a stereo warehouse for PACK semi-finished products, and realize automatic storage and outbound through WMS system;

3. Realize real-time material demand pulling through MES, and eliminate material shortage waiting.

Material delivery accuracy: 100%

Inventory turnover days: shortened by 30%

Material shortage downtime: reduced by 90%

Manual handling labor cost reduced by 80%;

Warehouse space utilization increased by 40%.

Equipment operation efficiency improvement

2. Deploy a predictive maintenance system to monitor the operating status of core equipment (welding machine, robot, test bench) in real time, and realize early warning of potential failures;

3. Realize closed-loop optimization of process parameters through production big data analysis.

Unplanned downtime: reduced by 50%–70%

New product trial production cycle: shortened by 50%

Maintenance cost reduced by 30%–40%;

Accelerates the mass production verification of new PACK products.

A: Pre-processing (cell sorting & testing), module assembly, PACK final assembly & post-inspection. Preprocessing screens defective single cells; module forms series-parallel cell groups; final assembly integrates BMS, housing, cooling system and completes finished product testing.

A: Classify cells by open-circuit voltage, AC internal resistance, capacity and self-discharge consistency. Cells with large parameter differences will cause uneven charge and discharge, overheating and premature failure of the whole pack. Standard grouping tolerance: voltage difference ≤5mV, internal resistance ≤2mΩ.

A: Cell feeding conveyor, visual positioning platform, automatic code scanning machine, AGV material transfer system. Realize one-to-one traceability of cell QR code information bound to MES production system.

A: Ultrasonic metal spot welding: low heat generation, suitable for aluminum tabs and small power modules; fiber laser continuous welding: high welding strength, low contact resistance, for energy storage and vehicle-grade high-current modules.

A: Apply thermal conductive structural adhesive between cells and modules. It fixes cells to resist vibration, transfers heat to cooling plates, and realizes electrical insulation between adjacent cells to avoid short-circuit risk.

A: Constant temperature and pressure compaction after cell grouping, eliminate assembly gaps, ensure uniform thickness of the module, improve the fitting degree between cells and cooling components, stabilize module overall consistency.

A: Cooling plate positioning installation, water pipe quick plug assembly, coolant vacuum filling, air tightness testing of cooling circuit. Helium leak detection is used to check pipeline micro leakage to prevent liquid short circuit.

A: Automatic PCB pressing, voltage sampling wire laser welding, temperature sensor pasting, wire harness automatic bundling and fixation. Sampling line virtual welding or falling off will cause BMS protection failure.

A: Use megohmmeter to test insulation between high-voltage positive/negative pole and module housing. Insulation resistance ≥500Ω/V is the qualified standard, eliminate insulation damage caused by assembly scratches.

A: Large servo bolt tightening machine (torque closed-loop control), ultrasonic plastic welding, integral structural glue sealing. Bolt torque deviation is controlled within ±5% to prevent loose bolts under long-term vibration.

A: AC withstand voltage test between high-voltage loop and shell, confirm no breakdown or flashover, verify the safety of high-voltage insulation for electric vehicles, energy storage and industrial equipment battery packs.

A: Constant temperature charge-discharge cycle aging, full-capacity calibration, BMS function verification, communication protocol debugging with upper computer. Expose assembly defects such as poor welding and abnormal sampling lines.

A: Each single cell, module and PACK is labeled with a unique QR code. MES records process parameters, test data, equipment parameters, test results of each station, supporting after-sales fault tracing and echelon utilization screening.

A: Flexible line uses modular tooling and programmable positioning, can quickly switch cylindrical, pouch, prismatic cell PACK production; dedicated line has high speed and low cost, only for single specification mass production.

A: Manual/automatic spot welding, plastic shell ultrasonic welding, waterproof glue filling, finished pulse discharge aging, drop vibration simulation test, compact layout for small-batch multi-model production.

A: Insulated workbench, anti-static wrist strap/grounding, high-voltage interlock tool, smoke temperature sensing fire suppression system, emergency power-off button at each station, dry environment anti-static control.

A: Verify BMS over-current short-circuit protection action. Detect wrong wiring of harness, damaged BMS chips, internal virtual welding of modules which will fail to cut off current during accidental short circuit.

A: Adopt segmented parallel assembly, centralized liquid cooling pre-assembly, offline module pre-test to reduce online failure rate, reduce production line downtime caused by large module rework.

A: Classification collection of leftover busbar metal materials, defective cell sealed storage, waste glue and waste harness hazardous waste centralized recovery, static electricity elimination for defective cells to avoid spontaneous combustion risk.

A: AI visual online defect detection, digital twin real-time production simulation, autonomous AMR whole-line material distribution, integrated module-PACK one-step molding, automatic disassembly and repair station for defective battery packs.