the smart battery assembly process (run as a slideshow & click on each process to view the...
TRANSCRIPT
The Smart Battery Assembly The Smart Battery Assembly ProcessProcess
(Run as a slideshow & click on each process to view the details)
SOLUTIONS FOR PORTABLE POWER
The Smart Battery Assembly The Smart Battery Assembly ProcessProcess
Circuit BoardPopulation +
Cleaning
Passivecomponent
sub-assembly
CellCorepack
Gluing
CellCorepackWelding
CircuitBoardAttach
Calibration
Case GluingUltrasonicWelding
Circuit BoardFunctional
Testing
Pre CalTest
Post CalTest
End of line testLoad Test
Date Coding
Test DataCentralStorage
LabelingPacking
&Shipping
Clickon a
processto viewdetails
SOLUTIONS FOR PORTABLE POWER
Corepack Welding
The inter-cell links are individually resistance welded to the positive & negative terminals on each cell.
ClickThe
light bulbto goback
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.
ClickThe
light bulbto goback
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.
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
Circuit 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
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
Circuit 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.
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
Circuit 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.
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
CalibrationEvery 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.
ClickThe
light bulbto goback
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
ClickThe
light bulbto goback
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
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
Labeling
Labels are applied to each battery pack and a visual inspection is carried out.
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
End-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.
ClickThe
light bulbto goback
SOLUTIONS FOR PORTABLE POWER
Std. Battery Inline Quality Std. Battery Inline Quality ChecksChecks
Battery PackAssembly
Circuit BoardAssembly
Circuit BoardTest
Pass
Fail
Core PackAssembly
Visual Inspection
Fail
MACCORPack
Calibration
GlueCase
SMBusComms
test
SMBusComms
test
Fail
SMBusComms
test
Fail
Label&
DateCode
VisualInsp.
Pack&
Ship
Fail
Inspect/Repair
Inspect/Repair
Inspect & Repair /Replace board
Test DataStorage