How is a battery pack assembled?
The Assembly Process of Custom Lithium Battery Packs
07 Feb | By: José González
If you want to learn more, please visit our website HUIYAO.
In this article, we will delve into the detailed process of assembling custom lithium battery packs, addressing everything from the initial reception of customer requirements to the shipment of the final product. Every vital phase in the manufacturing of these packs will be meticulously explored. These components are fundamental in a variety of industrial and commercial applications, highlighting the importance of thoroughly understanding their production process. From material selection to quality controls, each step will be examined to reveal its contribution to the final outcome.
Introduction
Custom lithium battery packs represent an innovative energy solution that has revolutionized a wide range of industries and applications. In the modern era, where mobility, electrification and energy efficiency are key imperatives, these personalized packs have emerged as a fundamental piece in the convergence towards a more sustainable and technologically advanced future. Their versatility and adaptability make them indispensable in sectors ranging from automotive and consumer electronics to renewable energy and aerospace.
These battery packs are distinguished by their ability to be designed and configured according to the specific requirements of each client. From power capacity to voltage to physical form, these packs can be tailored to meet a wide variety of needs and applications. This flexibility makes them the preferred choice for a variety of projects, from energy storage systems for homes and businesses to electric mobility solutions for land, sea and air vehicles.
In the field of mobility, custom lithium battery packs have played a fundamental role in accelerating the transition to electric vehicles. From cars to electric bicycles and scooters, these packs offer a unique combination of energy density, light weight and fast charging capabilities, making them the ideal choice to power the next generation of clean and efficient vehicles.
In the industrial sector, these custom packs are essential for powering a variety of equipment and devices, from power tools to telecommunications equipment and power backup systems. Their ability to be engineered to exact customer specifications makes them ideal for a wide range of applications, from demanding environments to critical applications where reliability and durability are paramount.
In addition to their terrestrial applications, custom lithium battery packs also play an important role in aerospace and space exploration. Their ability to deliver high energy density and long life makes them the preferred choice for powering satellites, space probes and other devices in deep space, where reliability and performance are critical.
In short, custom lithium battery packs represent an innovative energy solution that is transforming the way we live, work and move. With their ability to adapt to a wide range of needs and applications, these customized packs are paving the way to a cleaner, more efficient and more sustainable future for everyone.
Reception of Client Requirements
The process begins with receipt of the client&#;s specific requirements. This may include data such as desired power capacity, voltage, physical pack size, safety requirements and more. It is crucial to fully understand the customer&#;s needs to ensure that the resulting battery pack meets all of their expectations and requirements. Clear and effective communication between the client and our team is essential in this initial stage of the assembly process.
During this phase, we strive to establish a strong relationship with the client, encouraging an open dialogue to fully understand their needs. We focus on asking the right questions to get a clear view of the project requirements. Additionally, we take every opportunity to offer expert guidance and suggestions that may improve the final battery pack design.
By fully understanding the client&#;s requirements from the beginning, we can avoid misunderstandings and ensure the end result meets your expectations. Continuous feedback and close collaboration with the client are key aspects of our approach, allowing us to adapt and adjust the design as necessary to achieve maximum client satisfaction.
Design and Planning of the Battery Pack
Once the requirements are received, our design and planning team works on creating a custom design for the battery pack. Aspects such as cell layout, electrical connection, thermal management and safety are considered.
During this phase, we use software specialized in battery design to model and visualize the proposed pack. Various configurations are examined to optimize energy efficiency and pack performance based on customer requirements.
In addition, we pay special attention to the safety of the design. Protection measures against overloads, short circuits and overheating are implemented to ensure user safety and prolong the life of the battery pack.
Our goal at this stage is to create a design that maximizes the capacity, durability and reliability of the battery pack, while meeting customer specifications and internal quality standards. Close collaboration between our design team and the client ensures that the final design meets all expectations and requirements.
Selection of Battery Cells and Components
With the design in place, we proceed to the selection of the battery cells and other necessary components. High quality cells are chosen and compatibility with the proposed design is ensured.
At this stage, we draw on our experience and knowledge in the industry to select the most suitable battery cells for the project at hand. There are several types of battery cells available on the market, each with its own characteristics and specific applications. Among the most common types are:
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Lithium-ion (Li-ion) cells: These cells are widely used due to their high energy density, long life and low self-discharge rate. They are ideal for applications that require high energy density, such as portable electronic devices and electric vehicles.
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Lithium polymer (LiPo) cells: These cells are similar to lithium-ion cells, but have a flatter and more flexible shape. They are ideal for devices that require a thin and light design, such as smartphones and tablets.
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Lithium iron phosphate (LiFePO4) cells: These cells are known for their high thermal stability and ability to withstand a high discharge rate. They are ideal for applications that require high security and reliability, such as home energy storage systems and high-power electric vehicles.
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Nickel-metal hydride (NiMH) cells: Although less common than lithium cells, NiMH cells are known for their high capacity and low cost. They are suitable for applications that require high energy storage capacity, such as power tools and medical devices.
We consider factors such as capacity, energy density, lifespan and discharge rate to select the most suitable type of battery cell for the project at hand.
In addition to battery cells, we also carefully select other necessary components, such as battery management system (BMS), connectors, cables and protection systems. We ensure that all components are of high quality and perfectly matched to the design of the battery pack.
Meticulous selection of battery cells and components is critical to the quality and performance of the final pack. We strive to guarantee the reliability and safety of the battery pack, choosing the best components available on the market and ensuring their compatibility with the previously established design.
Assembly and Manufacturing of the Pack
Battery pack assembly involves physically placing the cells in the arrangement specified by the design. Advanced welding and fixing techniques are used to ensure a secure and durable connection between cells and other components.
Our highly trained and experienced team carries out the assembly process with precision and attention to detail. Each battery cell is carefully placed in its designated position, following the previously established design to ensure uniform charge distribution and efficient thermal management.
During the assembly process, intermediate tests are performed to verify the integrity and function of each component. Special attention is paid to soldering and electrical connections to ensure quality and reliability.
Additionally, rigorous safety measures are applied to protect both personnel and product during the assembly process. Appropriate personal protective equipment is used and established safety protocols are followed to minimize the risk of accidents.
Once assembly is completed, the battery pack undergoes final testing to verify its operation and performance. Loading and unloading tests, as well as functional tests under simulated conditions, are performed to ensure that the pack meets all customer specifications and internal quality standards.
The assembly and manufacturing process of the battery pack is crucial to guarantee the quality and reliability of the final product. We are committed to maintaining the highest standards at every stage of the process to offer premium quality lithium battery packs to our customers.
Product Testing and Quality
Once assembled, the battery pack undergoes rigorous quality and performance testing. This includes capacity testing, charge and discharge testing, security testing, and more. Any defects or issues are addressed and corrected at this stage.
Capacity testing is performed to ensure that the battery pack meets the rated capacity specified by the customer. Specialized equipment is used to measure the actual capacity of the pack and ensure it is within acceptable limits.
Charge and discharge tests are essential to evaluate the performance of the battery pack under real use conditions. Repeated loading and unloading cycles are carried out to verify the stability and durability of the pack over time.
In addition to performance testing, safety testing is performed to ensure that the battery pack meets applicable safety standards. Overload resistance, short circuit protection and other potential risks are evaluated to ensure user safety and product integrity.
Any defects or issues identified during testing are addressed immediately. Adjustments and corrections are made as necessary to ensure the battery pack meets the highest quality standards.
Our commitment to quality and excellence drives us to conduct extensive testing on every battery pack we produce. We strive to offer the highest quality products that meet and exceed our customers&#; expectations in terms of performance, reliability and safety.
Packaging and Shipping of the Pack
Finally, the assembled and tested battery pack is carefully packaged for shipment. Robust packaging materials are used and appropriate safety protocols are followed to ensure that the product reaches its final destination in perfect condition.
During the packaging process, we ensure that the battery pack is adequately protected against any possible damage during transportation. Strong, padded packaging materials are used to prevent shocks, vibrations or impacts that could affect the integrity of the product.
Additionally, applicable safety protocols and transportation regulations for shipping hazardous products, such as lithium batteries, are strictly followed. Packages are labeled correctly and the necessary documentation is provided to comply with all local and international regulations.
Once the battery pack is properly packaged and labeled, it is scheduled for shipment using reliable and safe transportation services. We make sure to coordinate delivery with the customer to ensure timely and smooth arrival.
With this, the custom lithium battery pack assembly process is complete! From receiving customer requirements to shipping the final product, each step is crucial to ensure quality and customer satisfaction. We strive to offer a comprehensive service that guarantees the delivery of the highest quality lithium battery packs to our customers at all times.
Rekoser is a manufacturer of custom lithium pack batteries, do not hesitate to contact us with any requirements you may have.
How To Assembly Cylindrical Battery Pack?
What is the future of the lithium battery market?
Lithium-ion batteries (LIBs) are now ubiquitous in daily life, in increasingly diverse applications including electric cars, power tools, medical devices, smart watches, drones, satellites, and utility-scale storage etc. In the future, as people's demand for clean energy continues to increase, lithium-ion batteries will be more widely used in new energy fields such as solar and wind power. In addition, with the advancement of technology and the continuous improvement of lithium-ion battery technology, the energy density, safety, cycle life, cost and other aspects of lithium-ion batteries will be improved. Future lithium-ion batteries will be lighter, smaller, more portable, efficient, and their application range will be even wider. They are one of the main development directions in the field of energy storage and conversion in the future.
What are the components of a lithium battery pack?
The main materials of the lithium battery pack include batteries, BMS, casing, barley paper, EVA, brackets, high-temperature tape, nickel sheets, wires, output interfaces, labels, safety tubes, etc.
What are the applications of lithium battery packs?
Lithium battery packs are widely used in various applications due to their high energy density, low self-discharge rate, and long cycle life. Here are some common applications of lithium battery packs:
Portable Electronics: Lithium battery packs are commonly used in portable electronic devices such as smartphones, tablets, laptops, and digital cameras.
Electric Vehicles: Lithium battery packs are used in electric vehicles such as cars, bikes, and scooters. They provide high power and energy density, making them ideal for use in electric vehicles.
Energy Storage: Lithium battery packs are used for energy storage in renewable energy systems, such as solar and wind power. They can store excess energy generated during peak hours for use during off-peak hours.
Medical Devices: Lithium battery packs are commonly used in medical devices such as pacemakers, defibrillators, and insulin pumps. They provide reliable and long-lasting power to these critical devices.
Aerospace and Defense: Lithium battery packs are used in aerospace and defense applications due to their high energy density and reliability. They are used in aircraft, satellites, and other military applications.
Robotics: Lithium battery packs are commonly used in robotics applications such as drones, unmanned ground vehicles, and humanoid robots.
Etc
What equipments do you need to assemble a lithium battery pack?
The main equipments of cylindrical battery pack assembly line include battery formation and grading system, battery insulation paper sticking machine, battery sorter, CCD tester, battery pack spot welder, bms tester, comprehensive tester, heat shrink wrap machine, inkjet batch coding machine, battery pack tester.
Option 1- Semi-automatic cylindrical battery pack assembly line
Option 2- Full-automatic cylindrical battery pack assembly line
What is the assembly process of lithium battery packs?
Step 1-Battery Cell Capacity Grading
1) Product Description
Battery cell capacity grading machine is used to test capacity, charging and discharging of single battery, to achieve the consistency of battery cells.
2) Working Principle and Features
The capacity sorting of Li-ion battery is screened by the cell capacity grading cabinet, the function of the cell capacity grading cabinet is similar to the charger, except that it can charge and discharge a large number of batteries at the same time.
Lithium batteries are managed by computer to get the data of each testing point, so as to analyze the size of these batteries' capacity and internal resistance and other data to determine the quality level of the batteries, and this process is capacity sorting.
*Each channel can be started and stopped at a single point, and the response speed is fast
*The operation is simple, convenient and intuitive
*Modular design, easy to maintain
*The digital current and voltage automatic calibration function
*Using network connection and SQL database
*The hardware technology is advanced, stable and durable
3) Product Model
Type
Normal or energy-saving type(can save energy up to 40% )
Energy-saving type
Customized
Cylindrical Battery
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//
Voltage and Current
5V/1A
5V/2A
5V/3A
5V/6A
5V/10A
5V/20A
Channels
256/512
128/256
Products
More
Step 2-Battery Cell Insulation Paper Pasting
1) Product Description
The function of Insulation Paper Pasting Machine is to paste a layer of barley paper outside the positive pole of the cylindrical battery, so that it has good insulation, wear resistance, waterproof and other characteristics, and effectively prevent the positive and negative short circuit of the power battery pack during vibration.
2) Working Principle and Features
The battery sticker machine is controlled by a PLC stepper motor and cylinder to complete the positive electrode pasting of the finished battery cell with barley paper.
Using a cylinder driven cutting knife for stamping, four battery cells are punched and attached at once. The slices are made of high-speed steel material, with high wear resistance, good product quality, and high production efficiency.
It can be used for multiple purposes, and if different cell models need to be pasted with barley paper, simply change the mold and you can switch between them.
*Approximately cylindrical batteries can be completed per hour.
*High consistency of placement and low defect rate.
*Fault information reminder function, fault sound and light alarm, can quickly diagnose faults.
3) Product Model
Mould
Replaceable
Replaceable
Customized
Cylindrical Battery
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/
Products
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Step 3-Battery Cell Sorting
1) Product Description
The lithium-ion battery sorter is used to sort the internal resistance and voltage of cylindrical lithium batteries. The built-in tester adopts HIOKI/HK high-precision internal resistance and voltage testing system, and the test results are analyzed by computer to generate classification data, and the historical test data can be queried, counted and exported. It is also equipped with barcode scanning function, which can analyze and save the battery test data. It adopts precise servo motor control and synchronous belt drive, which greatly improves the testing speed and stability of test data.
2) Working Principle and Features
The battery is manually loaded into the lower slot, then the battery is tested for internal resistance and voltage, the tested battery flows into the belt slot, the QR code or barcode on the battery is automatically scanned, the data is automatically entered into the system, and finally the battery is pushed into the corresponding slot.
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With the integrated industrial control, all parameters of the battery can be traced and tracked, which is convenient for data management and easy to operate. Battery voltage, battery internal resistance, grouping information and other management functions.
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Adapt to various types of batteries, easy to change type and easy to operate.
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Built-in high-precision HIOKI internal resistance tester, high testing accuracy and fast.
3) Product Model
Cylindrical Battery
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/
Customized
Mould
Replaceable
Barcode Scanner
Optional
Tester
HK/HIOKI
Channels
5
6
11
5
Product
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Step 4-Battery Positive And Negative Polarity Detection
1) Product Description
CCD tester is a device for testing whether the battery polarity is correctly placed in the automatic spot welder fixture. It is used in conjunction with automatic spot welding machine to avoid major accidents caused by short circuit of batteries due to manual placement errors.
2) Working Principle and Features
Through the CCD computer system, set the measurement mode and accuracy parameter range, adjust the parameters, and the equipment starts to monitor and enter the working state.
Action process: manual loading of the whole box of batteries &#; start CCD detection button &#;CCD system analysis &#; CCD system discrimination (OK/NG) &#; material receiving personnel to receive materials.
Features:
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The equipment is equipped with sound and light alarm, fault alarm, etc.
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Operating parameters can be freely set according to the actual requirements of customers.
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Suitable for the polarity detection of a variety of batteries, saving labor costs and being able to perform highly repetitive tasks.
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CCD visual inspection can work stably for a long time, with good reliability and high detection accuracy.
3) Product Model
Cylindrical Battery
////// etc
Customized
Camera
HIKVISION 6-12 Million Pixels
Conveyer Belt
Without
With
Product
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FAQ about Briquetting Machine
Step 5-Battery Pack Spot Welding
1) Product Description
Additional resources:8 Major Raw Materials Used for Making Solar Panels
For more private label battery assembly equipmentinformation, please contact us. We will provide professional answers.
Battery pack spot welder is used to weld nickel sheets with many lithium batteries into a group pack, which is suitable for battery pack assembly in the factory for etc multi-parallel multi-series combination. It can be used in electric tool battery, torsion car battery, Energy Storage Battery Pack, Scooter Electric Vehicle Battery, etc.
2) Working Principle and Features
Battery spot welder, also known as resistance welder, is the principle of welding by using the resistance heat generated by the electric current through the welding joint of the workpiece.
When working, two electrodes squeeze the workpiece, so that the two layers of metal form a certain contact resistance under the pressure of the two electrodes. When the welding current flows from one electrode to the other, a transient thermal weld is formed at the two contact resistance points, and the welding current flows instantaneously along the two workpieces from the other electrode, forming a circuit without destroying the internal structure of the workpiece to be welded.
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Support breakpoint start, automatic start, and manual start.
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Cold solder joint and sealing off alarm.
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Easy program, support matrix, array and point program, can store 100 group parameters.
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Welding needle abrasion alarm.
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Build-in welding current monitor, can display real time welding current.
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Can be matched with the production line of lithium battery group.
3) Product Model
Cylindrical Battery
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Customized
Current
A/A/A
Welding Power
DC Inverter/Transistor
Welding Method
Manual
Automatic
Product Type
Gantry
With slide rail
Single side
Double side
With PC
Product
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Step 6-Battery Management System Testing
1) Product Description
BMS tester is used in the safety test of lithium battery protection board, to detect whether the functional indicators of the protection board are within the reasonable parameters.
2) Working Principle and Features
BMS tester uses capacitance to simulate battery charge and discharge, and conducts overcharge test, overcharge recovery test, overdischarge test, overdischarge protection recovery test, standby power consumption test, overcurrent test, etc. for the protection board.
Features:
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The number of series is optional from 1-32;
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Various protection and recovery function tests;
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Can choose the number of sections to be tested according to your own needs;
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Test results can be automatically saved;
3) Product Model
Series
16/20/24/32
Customized
Current
120/150/200/300/400/500/600/800A etc
PC
With
Without
Product
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Step 7-Battery Comprehensive Testing
1) Product Description
The battery comprehensive tester is a device for fast and accurate testing of finished battery performance. The main test items include: open circuit voltage, AC internal resistance, discharge test, discharge over current test, short circuit protection test, charge test and charge protection test.
2) Working Principle and Features
The battery comprehensive tester is to apply a load to the battery or apply a small AC current to measure the open circuit voltage, AC internal resistance, discharge test, discharge overcurrent test, short circuit protection test, charge test and charge protection test and other parameters to quickly screen and judge the performance of the battery and good or bad, by setting the upper and lower limits of the measurement parameters, it is easy to quickly detect the bad battery from a batch of finished batteries.
3) Product Model
Voltage
50/60/100/120V etc
Customized
Current
120/200/300/500/600A etc
Product
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Step 8-Battery Pack PVC Shrinking
1) Product Description
Heat shrink wrap machine is designed for cylindrical and combined battery heat shrink packaging process, using a combination of far-infrared and circulating wind heating technology to ensure uniform heat shrinkage of the battery plastic cover, beautiful deformation and high concentration. Suitable for PVC, PP, PE, POF and other types of shrink film.
2) Working Principle and Features
Heat shrinking machine uses heat shrink films to change the irregular arrangement between the original molecules under heating. Under infrared and other thermal radiation, plastic molecules rearrange tightly, greatly reducing the original area and adhering to the surface of the product to achieve packaging purposes.
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Adopting stainless steel heaters and high-power air supply motors, the shrinkage furnace heats up quickly, has a large air volume, and uniform air flow.
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The conveyor belt speed and furnace chamber temperature can be adjusted according to product size and output to achieve the best shrinkage effect.
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The electronic governor can adjust the conveying speed of the conveyor belt arbitrarily.
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Adopting a double layer insulation device, the machine's exterior will not be too hot.
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High temperature resistant and insulated cord fabric, greatly reducing heat loss.
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The conveyor chain adopts solid rollers and is externally wrapped with high-temperature resistant silicone tubing, which can withstand heavy objects without deformation of the rollers.
3) Product Model
Model
C
C
C
Customized
Shrink film
POF PVC PP
POF PVC PP PE
Tunnel size(mm)
x400x200
x 450 x 250
x 500 x 350
Shrinkable product size(mm)
350*150
400*200
450*300
Product
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Step 9-Battery Pack Code Printing
1) Product Description
Inkjet batch code printing machine is sprayed on the outer surface of the battery with the information of the battery, including the manufacturer, model, Production date, voltage, capacity, Energy, production batch number, etc.
2) Working Principle and Features
The working principle of continue inkjet printer is that ink is continuously ejected from a single nozzle through pressure, and after crystal oscillation, it breaks and forms ink dots; After being charged with ink dots and deflected under high voltage, the moving object surface is scanned into characters.
The products are widely used in the food industry, cosmetics industry, pharmaceutical industry, automotive and other parts processing industries, wire and cable industry, aluminum plastic pipe industry, tobacco and alcohol industry, and other fields. Can be used for printing English, Simplified Chinese, Arabic numerals, serial numbers, barcodes, time, date, trademark patterns, special fonts, and other content.
3) Product Model
Product Type
Drop on Demand(Handheld)
Drop on Demand(with conveyor belt)
Continue ink jet printer
Product
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Step 10-Battery Pack Aging Testing
1) Product Description
The battery pack life cycle tester is a charge/discharge cycle aging test for battery packs with analog motor to calculate the capacity and the number of charge/discharge or working life of the battery pack. The test items include: battery charge protection voltage, discharge protection voltage, capacity, etc.
2) Working Principle and Features
Battery pack life cycle tester system mainly includes PC software, USB hub, router, aging instrument. The core lies in the aging instrument, the main control chip of the aging instrument is 32-bit ARM chip, which is much faster than the traditional microcontroller in execution and has higher accuracy in measuring voltage and current. The device has four test steps: charging, discharging, shelving, and cycling. By editing the corresponding steps, the battery can be tested in accordance with the set process.
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In the network mode, it is connected automatically, without manual connection.
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Use MYSQL database to save data to ensure that data will not be lost, and provide measurement data review function.
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Multiple instruments can use the network to communicate with PC software, which reduces the computer interface. Only one network port is needed to control all instruments, ensuring the real-time and complete communication data.
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The instrument number is displayed through LED lights, and the position of the corresponding instrument can be queried intuitively. The number can be modified by software, which reflects the flexibility of the instrument.
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In addition to the P+ and P- interfaces, the instrument also provides CH+ and CH-, which can test special finished batteries and charge and discharge them on one instrument.
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The battery can be charged as long as the battery is in the test range, avoiding the problem that the charger can only charge a specific type of battery.
3) Product Model
Type
Normal
Energy-Feedback
Customized
Voltage
20V-700V
Current
10A-A
Channels
1/2/3/4/6/7/8/12/16/32
Products
Voltage&Current
30V 10A charge 20A discharge
100V 10A charge 20A discharge
120V 150A charge 150A discharge
150V 200A charge 200A discharge
More 1
More
2
Channels
12
7
4
2
Picture
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