Lithium-ion Battery Pack Manufacturing Process
Step-to-step: 9 steps to make a battery pack
Step 1: BMS(Battery Management System) Testing
- Open-Circuit Voltage on Startup
- Balancing Function Test
- Single-Cell Overvoltage Protection Test
- Single-Cell Undervoltage Protection Test
- Static Current Test
The first step tests are designed to ensure that the BMS operates correctly, safeguarding the battery pack’s performance and longevity.
Step 2: Battery Cell Sorting
Step 2: Battery Cell Sorting
- Battery cells are from the same batch
- The voltage difference between battery cells is less than 5 mV, and the internal resistance is less than 2 mΩ
These criteria ensure that the battery cells used in the battery pack are consistent in terms of voltage and resistance, promoting balanced performance and safety.
Step 3: Battery Cells Assembled into Holder
Step 3: Battery Cells Assembled into Holder
- Prepare the A and B holders
- Identify the A and B holders
- Arrange according to the SOP (Standard Operating Procedure) image, then attach the holders
These steps guide the proper cell assembly into their designated holders, ensuring accurate placement and alignment during the battery pack assembly process.
Step 4: Battery Module Resistance Welding
Step 4: Battery Module Resistance Welding
- Automatic welding machine
- Each weld point must have a tensile strength >156 N
- A qualified weld point must retain more than 70% of its material after a tensile test
These requirements ensure the durability and reliability of the welds in the battery pack production process.
Step 5: Laser Welding
Step 5: Laser Welding
- Automatic welding machine
- Each weld point must have a tensile strength greater than 156 N
Step 6: Shell Gluing
Step 6: Shell Gluing
- Automatic gluing machine
Step 7: Battery Aging
Step 7: Battery Aging
- Age the battery packs according to the aging process, and record the aging data by binding it with a barcode
- After aging, randomly inspect battery packs with an "ok" label to check their discharge capacity
These steps ensure that battery packs undergo a controlled aging process and that quality is verified through testing and record-keeping.
Step 8: Air Tightness Testing
Step 8: Air Tightness Testing
- Automated air tightness testing
- The air pressure in the air tightness testing equipment should be between 10 kPa and 15 kPa
The step described is typically used to ensure that the product meets certain Ingress Protection (IP) ratings, such as IP67.
The automated air tightness testing helps confirm that the battery packs are sealed to withstand dust and water infiltration according to the specified IP rating.
This ensures durability and safety in various environmental conditions.
Step 9: PACK Finished Product Testing
Step 9: PACK Final Product Testing
- Communication test
- Function test
- Visual test
- EOL(End-of-Line) test
This final step collectively ensure that the battery packs are fully functional, safe, and ready for use by the end of the battery pack manufacturing process.
Tritek: Premium Battery Solutions
Tritek is a leading manufacturer specializing in light electric vehicle battery packs, portable electronic devices, energy storage systems, consumer electronics, and medical devices. Our battery packs are engineered for high energy density and have a low self-discharge rate (≤30uA in deep sleep mode), ensuring extended life and reliability.
At Tritek, we prioritize quality and safety by adhering to the highest standards of quality control and rigorous safety testing. Our processes ensure that every product we produce meets the strictest requirements for performance and safety, providing our customers with peace of mind and dependable energy solutions. Whether you’re looking for robust batteries for light electric vehicles or reliable energy for your consumer electronics, Tritek delivers quality and innovation in every battery pack we produce.
R&D center
100+ Engineers
15+ years experience
Semi-automatic pack assembly line
20,000+ Battery PACKs per day
Automatic SMT line
20,000+ PCBAs per day
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