- Industry: Automobile
A holistic solution that delivers batteries with long operational lives and frees manual labour from the hazardous task of handling battery charge. The project involved concurrent engineering when the assembly line was built even as a leading two-wheeler OEM finalized product design to substantially cut the turnaround time (TAT).
Customer Requirements
- Concurrent Engineering with development and design proceeding simultaneously.
- Long battery life.
- Capacity of 100,000 units per year.
- Total operational integration from electric testing, stack formation, and welding and welding testing to bus bar and BMS assembly, battery pack insertion in housing, cell and battery pack curing, and end-of-line testing with synchronized dispensing of structural adhesives, thermal paste in between.
- Operational safety against electric shocks and fumes.
Cybernetik Solution
- Long battery life via quality parameter track and trace.
- SOC, DCIR, and ACIR testing.
- Robots for cell stacking and adhesive dispensing.
- Automatic electrode polishing for non-stop welding.
- Servo Gantry precisely locates the welding head.
- Thorough weld checks via purpose-built fixture for checking probe.
- Vision system for accurate bus bar assembly and weld positioning.
- Servo actuator for damage-free insertion of battery pack into housing unit.
- Poka yoke eliminates human errors.
- ESD workbench safeguards against electrostatic current.
- Rapid curing for high throughput.
- Fume extraction flushes out welding fumes.
- Optional overhead installation of some units to optimize floor space utilization.
