Key process of power battery assembly

As an important component of electric vehicles, power batteries have very high requirements on temperature, safety and performance. Therefore, the assembly of power batteries has also become the focus of electric vehicle assembly.。

Key process of power battery assembly:

The power battery system is a complex system, which consists of BMS battery management system, multiple battery modules and housings. Among them, the battery pack is composed of multiple modules, and each module is composed of multiple battery cells connected in series and parallel.

The assembly of the power battery pack is mainly to arrange and fasten multiple modules and check the junction box. During the assembly process, many stations are involved in safe connections, and these assembly processes are directly related to the safety of the vehicle and its occupants.

The key assembly process of the power battery pack is as follows:

1.High and low voltage connector assembly:

There are many high and low voltage connectors on the battery pack and BMS. The assembly features of these interfaces include:

> Security parts need to collect data feedback, and sensor tools must be used;

> When tightening, it is usually a hand-held tool and a hand-held tool. It is best to use a gun-type tool for easy grip and tightening;

> The torque range is not wide, so it is best to choose a compact tool.

2.Installation of high voltage wiring harness

There are total positive and total negative high-voltage wire harnesses in the battery pack that need to be connected and assembled. When the module is charged, the voltage connected to this part is as high as hundreds of volts. Usually the ground of the work station will be insulated, which is a high-voltage protection work station.

In addition, insulation treatment is also required in the assembly. The insulation treatment of this part of the work station not only affects the safety of the battery, but also affects the safety of the operator.

3.Connection and installation of high-voltage busbar

The high-voltage busbar is used to connect the conduction between the modules. The current is large and intensively used, and the assembly is complicated. As the key structure of the battery conduction, the safety of assembly is also very important. The negligence of assembly may cause the battery to short circuit.

4.Module Installation

The battery pack is composed of multiple battery modules. The assembly of the battery modules requires moderate tightness, and each structural component has sufficient strength to prevent deformation or damage due to external forces inside the battery.

The battery module is composed of multiple power cells connected in series and parallel. The assembly of the battery module needs to fix the battery module in the aluminum box. Generally, long bolts are used to go through the module and fix it to the nut at the bottom of the box. In order to save space, some battery packs adopt the form of double-layer modules, and there will be mounting module brackets to fix the upper module.

5.Cover installation

In order to meet the needs of light weight and improved efficiency, battery packs usually use aluminum casings. Dozens of bolts are used to connect and assemble the upper cover and the lower box of the battery pack aluminum case. The number of bolts is large and the distribution is regular, and the tightening direction is vertically downward. During assembly, they need to be tightened sequentially to ensure that the tightening stress of the upper cover is evenly distributed.