Presentation is loading. Please wait.

Presentation is loading. Please wait.

The Smart Battery Assembly Process (Run as a slideshow & click on each process to view the details)

Similar presentations


Presentation on theme: "The Smart Battery Assembly Process (Run as a slideshow & click on each process to view the details)"— Presentation transcript:

1 The Smart Battery Assembly Process (Run as a slideshow & click on each process to view the details)

2 SOLUTIONS FOR PORTABLE POWER The Smart Battery Assembly Process Circuit Board Population + Cleaning Passive component sub-assembly Cell Corepack Gluing Cell Corepack Welding Circuit Board Attach Calibration Case Gluing Ultrasonic Welding Circuit Board Functional Testing Pre Cal Test Post Cal Test End of line test Load Test Date Coding Test Data Central Storage Labeling Packing & Shipping Click on a process to view details

3 SOLUTIONS FOR PORTABLE POWER Corepack Welding The inter-cell links are individually resistance welded to the positive & negative terminals on each cell. Click The light bulb to go back

4 SOLUTIONS FOR PORTABLE POWER Corepack Gluing Each cell is glued to the adjacent cell. Where adjacent cells have differing voltage, an insulating spacer is used. Click The light bulb to go back

5 SOLUTIONS FOR PORTABLE POWER Passive component sub- assembly Sub assemblies of wires, fuses, thermal safety devices heat shrink tubing and nickel straps etc are assembled prior to building the cell corepacks. Click The light bulb to go back

6 SOLUTIONS FOR PORTABLE POWER Circuit Board Population & Cleaning Each 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 Click The light bulb to go back

7 SOLUTIONS FOR PORTABLE POWER Circuit Board Functional Testing Every 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. Click The light bulb to go back

8 SOLUTIONS FOR PORTABLE POWER Circuit Board Attach The 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. Click The light bulb to go back

9 SOLUTIONS FOR PORTABLE POWER Calibration Every 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. Click The light bulb to go back

10 SOLUTIONS FOR PORTABLE POWER Case Gluing Electronics 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 Click The light bulb to go back

11 SOLUTIONS FOR PORTABLE POWER Ultrasonic Welding Electronics 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 Click The light bulb to go back

12 SOLUTIONS FOR PORTABLE POWER Labeling Labels are applied to each battery pack and a visual inspection is carried out. Click The light bulb to go back

13 SOLUTIONS FOR PORTABLE POWER End-of-Line Testing Prior 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. Click The light bulb to go back

14 SOLUTIONS FOR PORTABLE POWER Std. Battery Inline Quality Checks Battery Pack Assembly Circuit Board Assembly Circuit Board Test Pass Fail Core Pack Assembly Visual Inspection Fail MACCOR Pack Calibration Glue Case SMBus Comms test SMBus Comms test Fail SMBus Comms test Fail Label & Date Code Visual Insp. Pack & Ship Fail Inspect/ Repair Inspect/ Repair Inspect & Repair /Replace board Test Data Storage


Download ppt "The Smart Battery Assembly Process (Run as a slideshow & click on each process to view the details)"

Similar presentations


Ads by Google