the smart battery assembly process (run as a slideshow & click on each process to view the...

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

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Corepack Welding

The inter-cell links are individually resistance welded to the positive & negative terminals on each cell.

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Corepack Gluing

Each cell is glued to the adjacent cell.

Where adjacent cells have differing voltage, an insulating spacer is used.

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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.

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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

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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.

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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.

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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.

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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

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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

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Labeling

Labels are applied to each battery pack and a visual inspection is carried out.

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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.

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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

the smart battery assembly process (run as a slideshow & click on each process to view the...

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