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Manufacturing Process Map - 4. Pack Assembly Challenges
surface cleaning; cell-to-current collector bond quality; cell matching
Challenges
damage due to placement (primarily pouch); large machinery required due to module mass & dimensions; avoiding cell damage during assembly; safety at high voltages
CONNECTING BATTERY CELLS Battery cells are placed into the module arrangement and connected to current collectors after surface cleaning
MODULARIZATION The cells are attached to the module case, before or after connection to current collectors
Challenges
ensuring cable flexibility; avoiding cell damage during handling
PACK ASSEMBLY The modules are put in the battery pack and connected, including voltage sense and thermal connections
Design Challenges
i. Ensuring low resistance connections between modules and other connections to prevent fire ii. Maintaining creepage and clearance distances for high voltage elements iii. Preventing arcing due to contact with metallic objects during assembly
FINAL INTEGRATION The battery packs are then used in Electrical Vehicle (EV) and Battery Energy Storage System (BESS)
APPLYING BMS A Battery Management System is applied to battery pack; modules typically interface with the pack BMS
CHALLENGES
difficult & time consuming to test in a high-throughput environment
FINAL TEST A series of electrical tests are performed to ensure the highest quality, including verification of cell connections, isolation, and BMS function
*Graphics courtesy of LG Energy Solution. Reproduced with permission. Source: LG Energy, RWTH PEM, Mondragon, internal expertise
Extracted from the PDF; charts and images may read imperfectly.
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