Full process explanation of lithium battery assembly technology

How to assemble a 48V lithium battery pack by yourself? 

The biggest challenge for many people who want to self assemble 48V lithium battery packs but lack experience and professional knowledge is how to assemble them themselves.

A successfully assembled lithium battery pack can also be referred to as a lithium battery pack, 

but a true lithium battery pack requires more materials besides the lithium battery pack before being assembled again. 

The step of assembling a lithium battery pack is already something that most people don't understand but still want to do. How should we do it at this time?

I searched for questions online, but there were numerous answers that left me confused and unsure of what to do. 

For this issue, the editor of Energy Storage Electric has compiled a detailed tutorial on how to assemble a 48V lithium battery pack, hoping to be helpful to everyone.

Tutorial on assembling 48V lithium battery pack

1. Data calculation

Before assembling the 48V lithium battery pack, it is necessary to first calculate the required product size and load capacity of the lithium battery pack, 

and then calculate the capacity of the lithium battery pack to be assembled based on the required capacity of the product. 

Then, select the lithium battery based on the calculation results.

2. Prepare materials

Choose high-quality and reliable lithium batteries, and it is best to purchase lithium batteries with quality assurance from specialty stores or manufacturers, 

rather than from individuals or other unreliable places. 

After all, when assembling lithium batteries, if there are any problems during the assembly process, the lithium batteries are likely to pose a danger.

In addition to reliable lithium batteries, excellent lithium battery balance protection boards are also needed. 

In the current market, the quality of protective boards varies greatly, and there are also simulated batteries that are difficult to distinguish from the appearance.

 If you want to make a selection, it is better to choose digital circuit control.

The container for fixing lithium batteries also needs to be prepared to prevent any changes when the lithium battery pack is arranged and moved. 

The material used to isolate the lithium battery string and to achieve better fixation, every two lithium batteries are bonded together with adhesive such as silicone rubber.

The material for connecting lithium batteries in series, including nickel sheets, also needs to be prepared.

 In addition to the main materials mentioned earlier, other materials can also be prepared for use in assembling lithium battery packs.

3. Specific steps of assembly

First, arrange the lithium batteries in an orderly manner, and then use materials to secure each string of lithium batteries.

After fixing each string of lithium batteries, it is best to use insulation materials such as barley paper to separate each string of lithium batteries, 

and place the damaged outer skin of the lithium batteries to prevent future short circuits.

After arranging and fixing, the nickel strip can be used for the main series connection step.

After the series connection step of the lithium battery is completed, only the subsequent processing is finished.

 Wrap the battery with tape, and cover the positive and negative poles with barley paper first to prevent errors in subsequent operations that may cause short circuits.

The installation of the protective board also needs to be noted. The position of the protective board should be determined, and the wiring of the protective board should be sorted out.

 If the wiring intersects, it should be separated with tape to avoid the risk of short circuit.

After the wiring is sorted out, it needs to be trimmed, and finally the wire solder needs to be included.

 The solder wire must be used properly.

The act of assembling a 48V lithium battery pack by oneself is not recommended for those who are not familiar with this aspect.

 It is still necessary to learn more about the relevant information in order to better cope with unexpected situations during the assembly process

1. Lithium ion battery material processing

Some materials used for secondary batteries, such as lithium-ion, require special treatment. 

The electrode should be processed at high speed without damaging the fragile active material. In electrolytes, 

special consideration should be given to preventing the occurrence of precipitation and corrosive gases.

2. Cam unit operation

If a machine is constructed using cylinders or AC servo actuators with a cycle time of less than 1 second, even if it is in good condition when installing a new machine,

 it is difficult to synchronize or maintain a stable state for a long time. Then, the cylinder reaches the end of its operating distance in a short period of time, so its maintenance cycle is short. 

In the cam mechanism constructed by machines, such problems can be solved because all drives are held by the smallest electric motor.

3. Installation and Base

Establishing a strong installation and foundation for machinery is crucial for maintaining long-term stability. 

The installation and base can shorten the start-up time by minimizing the accuracy deviation of transmission and transmission mechanism.

 Usually, the use of aluminum frames is eliminated. Build a stable foundation using the substantial foundation of thick square logs and can manufacturing processes. 

Regarding various requirements, annealing can be carried out and installation seats with additional precision can be used.

5. Accurate positioning

Must possess the appropriate positioning technology and relevant experience,

 and be able to efficiently process calibration systems based on mechanical positioning and image processing requirements. 

In order to maintain long-term accuracy, it is necessary to achieve control of the camera or positioning station, as well as precise positioning, including installation design.

4. Vacuum treatment of battery assembly

Not only do they have simple vacuum chambers and furnaces, but they also have mechanisms for operating vacuum chambers and liquid application equipment. 

Have rich knowledge of special vacuum equipment and components such as vacuum pumps, pipelines, and valves.