The Birth of an Energy Storage Battery
Have you ever wondered how those silent guardians storing clean energy transform from scattered components into “Titans of Energy”? Today, let’s step into EITAI SOLAR‘s battery production line to witness the “full birth process” of an energy storage battery. Every step, from the cell to the finished product, holds intricate “energy-creation codes.”
The Initial Growth of Cells
Just like building a house requires selecting bricks, the “starting point of life” for an energy storage battery is the strict screening and grouping of cells.
Loading
Workers push neatly arranged cells to the loading port, where equipment grabs them and transfers them to the sorting area. These unassuming small blocks are about to begin their “transformation journey.”
Cell Sorting
The OVD test station gives each cell a “health check,” categorizing them into 4 grades based on voltage and resistance. Eight cells of the same grade will form one battery module.
Module Stacking
After polarity flipping and the installation of insulation plates, cameras scan the information again, recording it into the MES system. Then, the cells are automatically stacked into the frame.
Module Fastening
The equipment places the grouped cells into slots, automatically attaches end plates to both sides of the cell stack, and then secures them tightly with steel straps, ensuring the “team” is stable.
Equipping the "Messengers"
Two modules of the same grade form one battery pack. Each cell within the modules is scanned and recorded into the MES system. Then, busbars (the “nerve center” of the module) are installed. If an abnormality occurs, they send a signal to the BMS system to trigger protection mechanisms. After installation, a unique QR code label is affixed to each module, ensuring every module has a “clear identity.”
Laser Cleaning & Welding
The equipment precisely removes dust and contaminants from the cell terminals, preparing them for subsequent welding. Then, it accurately welds the busbars onto the module. The weld points are strong and uniform, like “precise stitching.”
AOI Inspection
Optical equipment checks the welds for defects like missed or weak solder joints. Cameras scan the information of the two modules and upload it to the MES system. This is followed by PQC inspection and DCR testing. Finally, flexible copper busbars and the top cover are installed, completing the module’s “advanced training”!
External Frame Assembly
The assembly line has a U-shaped layout. From processing MOS tubes and heat sinks to installing the mainboard and SPS board, followed by tests like no-cell testing, the “limbs and torso” of the battery pack are built step by step.
Battery Pack Assembly & Testing
The A+B modules are placed into the enclosure, and the positive and negative terminals are connected. Smart electric screwdrivers ensure precise installation. The MES system monitors the assembly process in real-time. After withstand voltage testing and a full QC inspection, the cover is finally locked on, like “closing the body” of the battery pack.
ATE1 Test
The finished battery packs are transported to the test area for the first round of ATE testing. This includes CAN communication detection, parallel cluster addressing detection, cell voltage detection, cell temperature detection, and module voltage detection.
Aging Test
AGVs automatically transport the finished battery packs into aging racks, which can simultaneously accommodate 132 packs for aging tests. They undergo a 5.5-hour charge/discharge cycle (one charge, two discharges) to simulate real-world usage scenarios.
ATE2 Test
After the aging test, a second round of ATE testing is required. This includes capacity testing, cycle life testing, internal resistance testing, charging performance testing, and safety performance testing. Finally, after passing airtightness testing, visual QC, and packaging inspection through multiple layers of screening, the battery packs officially clear all hurdles.
Packing & Warehousing
Having passed all rigorous tests, the qualified battery packs are packed and sent to the warehouse, awaiting deployment to the energy storage front. At this point, the “birth journey” of an energy storage battery is successfully completed!
From battery cell to battery pack, an energy storage battery has to go through dozens of processes, behind which is the full recording of the information system and the precise operation of intelligent equipment. It is this ultimate pursuit of details that makes each battery a reliable “energy guardian”.