Dongguan ShunXiang Energy Technology Co.,Ltd

1. Assembly Process

   The assembly process for lithium battery packs bears some resemblance to that of traditional internal combustion engine vehicles. Five major systems are interconnected using fasteners such as bolts, nuts, cable ties, clamps, and wire harness rivets to form an integrated assembly.

2. Air Tightness Testing Process

   Air tightness testing during power pouch lithium battery pack manufacturing occurs in two stages: thermal management system-level air tightness testing and pack-level air tightness testing.

3. Software Programming Process

   The software programming process involves writing the BMS control strategy as code into the CMU and BMU within the BMS. This enables the electronic control unit to process and analyze battery status data collected during testing and operation. Based on the analysis results, it issues control commands to relevant functional modules within the system and ultimately transmits information externally.

4. Electrical Performance Testing Process
   • Lithium battery packs require high consistency among cells (capacity, internal resistance, voltage, discharge curve, lifespan).
   • The cycle life of a lithium battery pack is lower than that of individual cells.
   • Operation must occur under specified conditions (including charge/discharge currents, charging methods, temperature, etc.).
   • After assembly, the pack exhibits significantly increased cell voltage and capacity, necessitating protection measures such as charge balancing, temperature monitoring, voltage monitoring, and overcurrent protection.
   • The battery pack must meet the voltage and capacity requirements specified in the design.

Throughout the entire process from individual lithium battery cells to automated modules and finally to PACK production lines, the level of automation in the assembly line is a key factor determining product quality and production efficiency. In the manufacturing of soft-pack lithium batteries, strict control standards exist for parameters such as temperature and airtightness. However, manual operations present significant challenges in meeting these requirements. Adopting an automated production model makes it easier to satisfy product performance metrics while achieving higher yield rates.

• It possesses comprehensive automated integration, combining custom equipment with universal robots.
• It integrates multiple technological processes including laser metal welding, electronic testing, machine vision, and data management.

• Dynamic screening
• Series/parallel connection per quantity requirements
• BMS system outsourced manufacturing
• Parameter calibration, performance testing, cable preparation
• Housing preparation, heat dissipation, shielding, interfaces, battery pack integration with BMS system
• Rapid quality inspection with performance parameter data
• Packaging and certification.

Computer-automated matching for power battery integrated automation typically encompasses fully/semi-automated assembly lines for modules and PACKs. Most manufacturers widely adopt semi-automated PACK assembly lines, primarily handling three key processes: PACK loading, unloading, and packaging.

1. Preparation of Battery Materials

   The preparation of camera batteries first requires gathering various battery materials. Key components for lithium-ion batteries include cathode material, anode material, electrolyte, and separator.

2. Battery Assembly and Encapsulation

   Once materials are ready, battery assembly and encapsulation proceed. Camera battery assembly involves structuring cathode and anode materials into a battery cell. Cell assembly employs two methods: roll-to-roll assembly and stacking assembly. Roll-to-roll assembly involves winding the positive and negative electrode materials into a cylindrical shape through a specific layering process, while stacking assembly involves layering the electrode materials one on top of another. After assembly, the cell must be encapsulated to ensure its safety and stability. Typically, the cell is placed inside a metal casing, secured with separators and adhesive, and then sealed.

3. Battery Charge and Discharge Testing

   After battery assembly and encapsulation, charge and discharge testing is conducted to verify performance compliance and operational readiness.
   Charge testing involves placing the battery in specialized charging equipment to observe parameters like charging speed and capacity. Discharge testing connects the battery to a load device, measuring discharge duration and capacity.
   These tests determine if battery performance meets requirements. Non-compliant batteries may require reassembly or material replacement.

4. Accessory Assembly

   Beyond the battery, cameras require additional components to function. Common accessories include battery compartments and battery connectors.

   Battery compartments house the battery and are typically made of plastic. Battery connectors link the battery to the camera's main board, usually constructed from metal to ensure reliable electrical transfer.

   These accessories undergo assembly processes before being installed alongside the battery within the camera.

5. Production Inspection and Packaging

   Finally, manufacturers subject the produced camera batteries to quality inspections. These tests encompass visual inspections and battery performance evaluations. Only after passing rigorous testing can the camera batteries proceed to the packaging stage.