Presentation on theme: "The Smart Battery Assembly Process"— Presentation transcript:
1The Smart Battery Assembly Process (Run as a slideshow & click on each process to view the details)
2The Smart Battery Assembly Process Clickon aprocessto viewdetailsThe Smart Battery Assembly ProcessPassivecomponentsub-assemblyCellCorepackWeldingCircuit BoardFunctionalTestingCircuit BoardPopulation +CleaningCellCorepackGluingCircuitBoardAttachPre CalTestCalibrationTest DataCentralStoragePost CalTestCase GluingUltrasonicWeldingPacking&ShippingEnd of line testLoad TestDate CodingLabeling
3ClickThelight bulbto gobackCorepack WeldingThe inter-cell links are individually resistance welded to the positive & negative terminals on each cell.
4Corepack Gluing Each cell is glued to the adjacent cell. ClickThelight bulbto gobackCorepack GluingEach cell is glued to the adjacent cell.Where adjacent cells have differing voltage, an insulating spacer is used.
5Passive component sub-assembly ClickThelight bulbto gobackPassive component sub-assemblySub assemblies of wires, fuses, thermal safety devices heat shrink tubing and nickel straps etc are assembled prior to building the cell corepacks.
6Circuit Board Population & Cleaning ClickThelight bulbto gobackCircuit Board Population & CleaningEach raw board has the solder paste applied by the paste stencil.After a visual inspection, the board passes through the pick & place robot where each component is placed on the board.The populated board is inspected & then passes through the oven to reflow the solder paste.After a visual inspection, the board is placed into the washer to clean any flux or residue from the reflow process
7Circuit Board Functional Testing ClickThelight bulbto gobackCircuit Board Functional TestingEvery board on every panel is fully tested using a computerized system which models the operation of the board and tests the components for performance.The panel is placed on a bed-of-nails fixture & each test point is wired-up to the test rack.The circuit board data is stored in a central database & can be compared to data from battery packs through the work-in-process to the end of line test, to provide full traceability of the test results throughout the process.
8ClickThelight bulbto gobackCircuit Board AttachThe circuit board is soldered to the cell corepack.As the cells are live, this is a skilled operation.The newly-attached board is now a fully functional smart battery.Prior to calibration it is tested for SMBus communications & basic operation.
9Calibration Every battery pack is fully charged & fully discharged. ClickThelight bulbto gobackCalibrationEvery battery pack is fully charged & fully discharged.During the discharge the internal fuel gauge measures the amount of charge present, & this gives the battery its first full calibration.The battery is then given a shipping charge between 30-50% capacity.We do not electronically “write” a calibration to the battery. Every battery must calibrate itself to pass this stage.After calibration the battery data is read and stored.
10ClickThelight bulbto gobackCase GluingElectronics grade RTV is applied to the corepack assembly to unitize it within the case.Adhesive is applied around the perimeter of the case & the case top & bottom are clamped together
11ClickThelight bulbto gobackUltrasonic WeldingElectronics grade RTV is applied to the corepack assembly to unitize it within the case.The case top & bottom are placed into the ultrasonic weld fixture & welded together
12ClickThelight bulbto gobackLabelingLabels are applied to each battery pack and a visual inspection is carried out.
13ClickThelight bulbto gobackEnd-of-Line TestingPrior to packing & shipping, every battery has its SMBus data read by the end of line tester.A load test is also performed to verify the capability of the battery to perform to its discharge specification.As with all other test data, this is stored centrally and can be used to verify the outgoing performance of each individual battery pack.Only if the battery pack passes this test will it receive the date code and serial number embossed into the plastic case adjacent to the connector.Upon completion of a successful test the battery is date coded, packaged & immediately shipped to the customer.