From Cell to Pack: A 7-Step Precision Manufacturing Process
The production of the JazzPower battery pack module is a "millimeter-level" precision battle, with every step embodying technology and rigor - from the loading of battery cells to the final factory delivery, seven core processes are closely linked, all aimed at creating a safe, efficient and consistent energy storage core component.
Visual Mechanical Cell Loading
The high-precision camera and the intelligent robotic arm form a "golden pair", capable of accurately positioning and grasping the battery cells within 0.1 seconds. Compared to traditional manual loading, it not only completely eliminates human operational errors, but also increases efficiency by 300%, laying a solid foundation for subsequent processes.
OCV Automatic Sorting for Cell Consistency
The battery cells enter the fully automatic sorting stage. The equipment can accurately obtain key parameters such as the internal resistance and open-circuit voltage of each battery cell, and conduct comprehensive testing. For those cells that do not meet the standards, the system will automatically mark and exclude (as non-conforming) them, screening out the cells with matching performance from the source, thus laying the first line of defense for the consistency of the modules.
Manual Stacking and System Verification
Experienced technicians manually arrange the battery cells to ensure the accuracy of their physical positions. Meanwhile, the MES system continuously checks the data of each battery cell, achieving a dual guarantee of "manual operation + system verification". The unique QR code of each battery cell will be scanned and recorded by the MES system. All data will be stored in the cloud throughout the process. Even 15 years later, all production records of each battery cell can be queried and traced with just one click.
Module Polarity Laser Detection
The module enters the polarity detection stage, using laser detection technology to accurately identify the positive and negative electrodes, ensuring that there are no errors in the arrangement of the battery cells. Once any abnormalities are detected, the system will automatically reject the defective products, providing comprehensive structural-level protection for the connection safety of the battery cells.
6KW High-Energy Laser Welding
By adopting 6KW high-energy laser welding technology, a welding point accuracy of 0.01mm is achieved. The weld strength is enhanced by 50% compared to traditional processes, ensuring both precise and robust connections between the battery cells, thereby providing a core support for the stable operation of the module.
Fully Automatic Dispensing and Sealing
Imported high-performance glue is combined with a constant temperature control system to form a uniform and strong sealing layer. After testing, its waterproof and shockproof performance exceeds the national standard by twice. Even in extreme environments such as heavy rain and earthquakes, it can provide reliable protection for the battery cells.
EOL Final Inspection & Quality Control
The module enters the final comprehensive inspection stage. It not only needs to pass a series of comprehensive tests including insulation, withstand voltage, AC internal resistance, and air tightness; but also has to undergo a 72-hour high-temperature aging test to simulate the operating conditions in extreme environments. Only the modules that pass all the tests and have stable test values of 100% can proceed to the next stage.
From Pack to Cabinet: Tailored Energy Storage Solutions
Based on the mature pack module production line, we can better "tailor" the processing of commercial and industrial energy storage cabinets according to different customer needs, ensuring that the energy storage equipment perfectly matches the requirements of the scenarios.Based on the mature pack module production line, we can better "tailor" the processing of commercial and industrial energy storage cabinets according to different customer needs, ensuring that the energy storage equipment perfectly matches the requirements of the scenarios.
Customization Dimensions for All Scenarios
Power and capacity customization: Based on the customer's electricity load (such as the peak power of a factory, the emergency power supply duration of a shopping mall), the capacity ranges from 50kWh to 1000kWh+ are matched, along with the corresponding power output (50kW - 500kW), ensuring that the energy storage cabinet can not only meet daily peak shaving requirements but also handle emergency power supply situations. Installation environment adaptation: For different installation scenarios such as indoor (e.g. data center rooms) and outdoor (e.g. rooftops, open areas), customized cabinet structures are designed - outdoor cabinets are enhanced with waterproof, sun-shielding, and anti-corrosion features, while indoor cabinets optimize space occupancy and heat dissipation efficiency; for areas with low temperatures, a heating system can be added to ensure stable operation even at -30℃.
Appearance and Layout Customization
Based on the size of the customer's site and aesthetic requirements, the size, color and layout of the cabinet are customized (such as modular and combined design, which is convenient for later expansion), so that the energy storage cabinet can not only operate efficiently but also integrate into the scene environment.Appearance and layout customization: Based on the size of the customer's site and aesthetic requirements, the size, color and layout of the cabinet are customized (such as modular and combined design, which is convenient for later expansion), so that the energy storage cabinet can not only operate efficiently but also integrate into the scene environment.
The Customization Process: From Demand to Delivery
Demand communication: The professional team thoroughly understands the customer's application scenarios, power requirements, installation conditions, budget and other information, and produces a preliminary demand analysis report. Scheme Design: Based on the performance of the pack module and the characteristics of the scenarios, the electrical scheme, structural scheme, and intelligent scheme of the energy storage cabinet are designed, and simulation tests are conducted for verification. Prototype testing: Build a prototype energy storage cabinet, conduct load tests, extreme environment tests, and linkage operation tests, and optimize the plan based on the test results.Prototype testing: Build a prototype energy storage cabinet, conduct load tests, extreme environment tests, and linkage operation tests. Based on the test results, optimize the plan. Batch production: Based on the confirmed plan, products are mass-produced using standardized production lines, and the MES system tracks the process throughout to ensure product consistency. Post-sale follow-up: Offer installation guidance, debugging services, as well as long-term operation support and data monitoring, ensuring that customers have a worry-free experience throughout the process.Post-sale follow-up: Offer installation guidance, debugging services, as well as long-term operation support and data monitoring, ensuring that customers have a worry-free experience throughout the process.
Empowering Energy Storage with Technology & Customization
The seven-step precise manufacturing process from the battery cell to the pack module is our commitment to quality; the customization capability from the module to the energy storage cabinet is our response to demands.The seven-step precise manufacturing process from the battery cell to the pack module is our commitment to quality; the customization capability from the module to the energy storage cabinet is our response to demands. Whether it is the pursuit of high performance of core components or the need to adapt to special scenarios for energy storage terminals, we rely on technology as the support and detail as the guarantee, providing safe, efficient and demand-aligned energy storage solutions for industrial and commercial customers, helping new energy storage technologies take root in various industries. Whether it is the pursuit of high performance of core components or the need to adapt to special scenarios for energy storage terminals, we rely on technology as the support and detail as the guarantee to provide safe, efficient and demand-aligned energy storage solutions for industrial and commercial customers, helping new energy storage technologies take root in various industries.