Especially in the e-mobility sector, end-of-line tests are crucial from a safety perspective.
In our technical news series Module Assembly, we have already presented the challenges and optimization possibilities in the pre-assembly processes, stacking and welding, and the preparation and integration of the cell contacting system. In the last part, we will look at the final steps of assembly: the process is completed with end-of-line tests and module finishing.

Module Assembly - PART 4 | End of Line Testing Guarantees Flawless Processing in Battery Module Production

First, the CMC (Cell Monitoring Circuit) must be installed in the final plant section. This component monitors and controls various battery parameters such as temperature, cell charge and voltage values.

Various EOL tests subsequently ensure the correct assembly of the complete battery module and the integrity of the installed elements. The following tests, for example, are integrated in the last part of the system:

• Insulation tests and breakdown tests
• Verification of cell temperatures
• Acquisition of voltage values in the cells and in the module
• Measurement of discharge and resistance

Finally, during module finishing, a data matrix code for traceability and a product label are applied.

The data of all integrated test processes of the entire system are collected, assigned to the component, evaluated and transferred to a higher-level production control system. Thus, the following data is stored in the customer's system:

• Batch numbers of the individual parts
• Joining forces and joining paths
• Parameters of the adhesive and gap filler application
• Parameters of the laser welds
• Camera evaluations
• Test results from the electrical tests (pre-test of the individual cells and modules up to the end-of-line test of the entire battery system)
• General information on the battery system such as individual part number, production time, product variants, etc.

Safe storage and processing of energy sources - know-how beyond mechanical engineering required

The assembly of battery modules represents the supreme discipline in the e-mobility sector. Here, not only mechanical engineering know-how is crucial. With AKE technologies, our customers have a partner at their side who can demonstrate in-depth experience in the handling and processing of battery cells. In the safe storage and processing of energy carriers, emergency concepts as well as associated safety zones are of particular importance. In addition, we ensure 100 percent traceability - so that our customers can concentrate on what is crucial for them: the efficient manufacture of their products!

Further parts from the series "Module assembly":

• Module assembly - PART 1 | Preparation processes for the assembly of battery systems with prismatic cells
• Module assembly - PART 2 | Stacking and Welding: High demands on process reliability and quality
• Module assembly - PART 3 | The cell contacting system: from the pre-assembly process to integration into the battery module