Lithium battery module design and production process flow and key points. The power lithium battery module connects several single cells in series and parallel through conductive connectors to form a power supply. It is fixed at the designed position through technology and structure, and collaboratively performs the function of charging, discharging and storing electric energy. It can be said that the basic functions of the module are connection, fixation and safety protection. The connection method between the battery cells and the module busbar not only affects the manufacturing efficiency and whether automation can be achieved, it also has an impact on the performance of the battery after it is installed in the vehicle that cannot be ignored.

　　Introduction to lithium battery modules

　　A lithium battery module can be understood as an intermediate product between a battery cell and a pack formed by combining lithium-ion batteries in series and parallel and adding a single battery monitoring and management device. Its structure must support, fix and protect the battery core, which can be summarized into three major items: mechanical strength, electrical performance, thermal performance and fault handling capabilities.

　　Whether the position of the battery core can be fixed intact and protected from deformation that damages performance, how to meet the current carrying performance requirements, how to control the temperature of the battery core, whether the power can be cut off in case of serious abnormalities, and whether thermal runaway can be avoided. Communication, etc., will be the standard for judging the quality of lithium battery modules. For lithium battery modules with high performance requirements, thermal management solutions have turned to liquid cooling or phase change materials.

　　There are many internal connection wires in the lithium battery pack, and there are too many manual welding steps, which can lead to problems such as welding and assembly. There are many parts, which makes assembly difficult, causing high failure rates and high costs.

　　Lithium battery module design and production process

　　The entire lithium battery module design process actually involves defining the goals of the entire module design, integrating the details of the module design, and having a complete module design verification process, including structural, electrical, and cooling safety parts. , must be implemented in it.

　　The first part is divided into several design levels

　　To meet the demand characteristics of the vehicle equivalent product, it is mainly divided into structure, electrical design, thermal design, and safety. Sufficient compression force is given according to the requirements of the battery core. This compression will be discussed later. The entire battery core, whether it is a soft package or a hard shell , through certain measures, the expansion of the battery core can be effectively prevented and the life span can be given certain support.

　　There is also a fixation between the module and the tray in the entire lithium battery pack. The module and the tray are effectively fixed through pressure strips. The above is mainly about the sampling line inside, and to prevent the battery core from moving inside. The entire battery core does not generate serious heat under normal NETT working conditions. We also have to consider that there may be some extreme situations, that is, the user Maybe it's on the highway, which is equivalent to entering the fast charging state when driving long distances, and the continuous limit is met. There may be a strong heat transfer requirement here. There is a strong connection between safety and the battery core insulation requirements in module design.

　　Part 2, Manufacturing Process

　　The most important thing is to move the cells from single cells to stacking to welding, sampling line layout, and CMU layout. The entire process and equipment have requirements for distance and process assembly. This part needs to be followed by the equipment, especially when measuring. Especially when it comes to automated production lines, there is a strong demand connection.

　　Part Three, Maintenance Considerations

　　Because when we are doing it now, the first step is to make the product. Later, as the vehicle is used, the maintenance of the entire lithium battery module, especially the damage to the sub-components, how to repair the module, This needs to be combined with manufacturing technology and maintenance technology, and there is relatively little talk here.

　　Part 4, module echelon utilization

　　Generally speaking, after we sort out the requirements for the lithium battery pack, we will design a module block diagram, which mainly connects the various parts, including electrical aspects, structural aspects, vehicle coupling aspects, and mechanical fixation aspects, and all the electrical structure requirements. Enter it into it so that the design goals of each part of ours can be clarified.

　　Key points of lithium battery module structural design

　　The lithium battery pack has a reliable structure: anti-vibration and anti-fatigue; the process is controllable: no over-welding or false welding, ensuring 100% no damage to the battery core;

　　Low cost: PACK production line automation has low cost, including production equipment and production losses;

　　Easy to disassemble: The lithium battery pack is easy to maintain and repair, low cost, and the cells can be used step by step;

　　To achieve the necessary heat transfer isolation to avoid the rapid spread of thermal runaway, this step can also be considered in the pack design.

　　It is understood that at present, the module assembly efficiency of cylindrical cells in the industry is about 87%, and the system assembly efficiency is about 65%; the module assembly efficiency of soft-packed cells is about 85%, and the system assembly efficiency is about 60%. ;The module assembly efficiency of square battery cells is about 89%, and the system assembly efficiency is about 70%. The single energy density of soft-packed cells has higher room for improvement than that of cylindrical and square cells, but the design requirements for lithium battery modules are higher and safety is difficult to control. These are all problems that need to be solved by structural design.

　　General lithium battery pack module optimization approach. Improving space utilization is also an important way to optimize modules. Power lithium battery pack PACK companies can improve the utilization of the space inside the battery box by improving the design of modules and thermal management systems and reducing the distance between cells. Another solution is to use new materials. For example, the busbars in the power battery system are replaced from copper to aluminum, and the module fixing parts are replaced from sheet metal materials to high-strength steel and aluminum, which can also reduce the weight of the power battery.

　　The power lithium battery module connects several single cells in series and parallel through conductive connectors to form a power supply. It is fixed at the designed position through technology and structure, and collaboratively exerts the function of charging, discharging and storing electric energy.

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