Battery Assembly Machines Selection Guide: Types, Features, Applications

 

Types of Battery Assembly Machines

 

1. Cell Assembly Machines

 

Cell assembly machines are designed to assemble individual battery cells. They handle tasks such as stacking electrode layers, inserting separators, and sealing the cell. These machines are crucial in the production of lithium-ion batteries, where precision is essential to ensure the cells' performance and safety.

 

2. Module Assembly Machines

 

Lithium battery module assembly machines focus on the assembly of battery modules, which are groups of cells connected in series or parallel. These machines often involve processes like welding, gluing, and stacking to create the desired configuration. Module assembly is a critical step in constructing battery packs for various applications.

 

3. Pack Assembly Machines

 

Pack assembly machines are responsible for the final assembly of battery packs. These machines integrate the modules into a complete battery pack, including the necessary wiring, thermal management components, and enclosure. The efficiency and accuracy of lithium battery pack assembly machines directly impact the overall quality and performance of the battery pack.

 

Li-ion Battery Production Process

 

1. Mixing

Active materials, conductive auxiliary agents, polymer binders, and organic solvents are mixed together to form an electrode slurry.

2 .Coating, Drying, and Calendering

The electrode slurry is coated to copper and aluminum foil, dried, and calendared.

3. Slitting

The electrode sheets are slit to each battery size.

4. Winding or Stacking

A separator is inserted between the anode and cathode electrode sheets, and the electrode sheets are wound or stacked together.

5. Tab Welding

The tabs of the layered electrode sheets are welded together, and collectors are welded to the tabs.

6. Terminal Welding

The covers and collectors are welded together.

7. Assembly

8. Case Closing

The covers and cases are welded together.

9. Before Filling

10. Electroyte Filling

Electrolyte is filled via the electrolyte port.

11. After Filling

The electrolyte port is closed.

12. Pre-charging

Following electrolyte fill, a charging current is fed to the cells for the first time.

13. Charging and Discharging

The cells are repeatedly charged and discharged.

14. Aging

The cells are stored for a certain period of time.

15. Pre-shipment inspection

Quality is tested prior to shipment.

 

 

Product-Specific Machine Types

 

Battery assembly machines come in various types, each designed for specific battery products. These include machines tailored for alkaline, nickel-metal hydride (NiMH), and nickel-cadmium (NiCad) batteries. Additionally, there are specialized machines for lithium-ion, lead-acid, and zinc air cells.

 

1. Alkaline Batteries:

   - Alkaline batteries are widely used and employ a reaction between zinc and manganese dioxide to generate power. They are the predominant type of batteries manufactured in the US.

 

2. Nickel-Metal Hydride (NiMH) Batteries:

   - NiMH batteries are rechargeable and utilize a hydrogen-absorbing alloy for the negative electrode. Compared to nickel-cadmium batteries, they have similar energy density (by volume) but tend to exhibit higher self-discharge.

 

3. Nickel-Cadmium (NiCad) Batteries:

   - NiCad batteries are rechargeable and use nickel oxide hydroxide and metallic cadmium as electrodes. They are available in sealed or vented types.

 

4. Lithium-Ion Batteries:

   - Lithium-ion batteries are rechargeable and employ lithium as the migrating ion during discharge and charging. They are commonly found in consumer electronics, especially portable devices.

 

5. Lead-Acid Batteries:

   - Lead-acid batteries, the oldest rechargeable type, have relatively low energy density but maintain a high power-to-weight ratio. They are frequently used as car batteries and to power smaller electric motors.

 

6. Zinc Air Batteries and Cells:

   - Zinc air batteries operate by oxidizing zinc with oxygen from the air. They offer high energy densities and are cost-effective to produce. Applications range from hearing aids to electric cars, depending on size requirements.

 

These specialized battery assembly machines cater to the distinct manufacturing processes and components associated with each type of battery.

 

Function-Specific Machine Types

 

Some specific machines associated with battery assemblers are cell winders and tab welders.

 

- Cell winders are capable of winding round or prismatic cells 3-12 parts per minute. It is flexible enough to handle up to 5 tabs per cell at varied distances. Tension controls, web speeds, separator cut lengths, and pack roller pressure are adjustable to optimize cell design parameters.

 

- Tab welders serve the purpose of attaching tabs to cells. In their automatic configurations, these machines are capable of affixing multiple tabs to each cell at varying distances. This design allows for the utilization of thinner substrates, creating additional space within the cell for active materials. The equipment typically features adjustable parameters such as tension controls, the number and placement of tabs, and web speeds, offering flexibility for optimization in the manufacturing process.

 

Applications

 

Battery assembly machines are used to create batteries in the aerospace, automotive, consumer electronics, and medical technology industries, among others

 

Conclusion

In conclusion, selecting the right battery assembly machines is a critical decision for industries involved in battery manufacturing. Understanding the types, features, and applications of these machines is essential for making informed choices that align with production goals and industry requirements.

 

If you're seeking guidance on battery assembly machines or looking for a reliable supplier, don't hesitate to contact us. Our team of experts is ready to assist you in finding the right machines for your specific needs, ensuring a seamless and efficient battery manufacturing process.