The e-bike battery packs are mainly composed of battery cells, battery spacers, nickel strips, a PCBA board, battery insulation papers and an outer shell.

In this solution, the battery cells are cylindrical cells. The main process flow of the e-bike battery pack assembly line is as follows:

1) Barcode scanning and OCV/IR sorting of battery cells

Manually put the battery cell carton or plastic box into the feeding area, the cells will be automatically loaded, scan the barcode of the cells, battery cell OCV/IR testing and sorting, and enter the buffer channels.

2) Automatically paste highland barley paper

After sorting, the battery cells enter the process of automatically pasting highland barley paper to automatically complete the pasting of battery insulation paper.

3) Insert the battery cells into the bottom battery spacer

The bottom battery spacer enters the battery pack assembly line after laser coding and barcode scanning, and the battery cells are automatically installed in the bottom battery spacer.

4) Automatic optical inspection to check battery cell polarity

After the battery cells are installed in the bottom battery holder, the battery automatic optical inspection system checks the polarity of the battery cells, and an alarm will be issued if a battery cell is installed reversely.

5) Manually install the top battery holder & Automatically lock screw

After checking by the battery pack CCD tester, manually install the top battery holder, the e-bike battery pack assembly will automatically lock screws.

6) Manually install the nickel strips and welding fixture

Manually install the nickel strips and welding fixture, ready to enter the welding process.

7) Nickel strip spot welding & CCD inspection

The battery module with the nickel strips and welding fixture installed enters the spot-welding process, and the spot welding of the nickel strips is automatically completed and CCD inspection is performed.

8) Manually remove the welding fixture and install the battery module into the shell

Manually remove the welding fixture and install the battery module into the shell, then install the other components.

Advantages of the e-bike battery pack assembly line:

1) Flexibility

The e-bike battery pack assembly line can be operated as a whole line, or it can be switched to single machines to run independently.

2) Strong compatibility

The e-bike battery pack production line can be compatible with 18650, 21700 and 32650 cylindrical cells, and one production line can produce multiple specifications and models of e-bike battery packs.

3) Fast model switching

The e-bike battery pack assembly line is equipped with intelligent software, which can set and save the parameters according to the product model, so as to realize the rapid switching of models.

4) Smart manufacturing

The e-bike battery pack assembly production line is equipped with MES system and ESOP to realize the monitoring of the entire production line and grasp the production quality and production data in real time.

WinAck Group can provide production solutions for cylindrical cell battery modules and packs, pouch cell battery modules and packs, and prismatic cell battery modules and packs, which are based on the customer's technical requirements. Come by, contact us for a solution that can help you succeed. For better batteries, Win & Ack!