The production process of automotive power battery packs is designed based on intelligent manufacturing principles, using MES system to manage production plans, combined with fully automatic and semi-automatic processes, to achieve efficient production, controllable quality, and full traceability. The core process can be divided into three stages, with specific process steps and characteristics as follows:

1、 Module production stage

Raw material transportation and pretreatment

The AGV system automatically transports raw materials to the loading area according to the MES production plan and cleans foreign objects in the battery box to ensure a clean initial assembly environment.

Assembly of high-voltage components

At the high-voltage cable and component installation station, the high-voltage cables and components are accurately installed to the designated location of the battery box through automated equipment to ensure the reliability of electrical connections.

BMC/LMC assembly

The semi-automatic workstation completes the installation of BMC (Battery Management System Control Module) and LMC (Low Voltage Management Module), combined with manual verification to ensure accurate module positioning.

2、 Battery pack assembly stage

Module positioning and fixation

The fixed workstation uses an automatic lifting system to lift the battery module to the appropriate position, achieving precise positioning and mechanical fixation, and improving assembly efficiency.

Installation and organization of wiring harness

The wiring harness installation and sorting station completes the wiring harness wiring, fixing, and sorting, ensuring that the electrical path is standardized and avoiding signal interference or short circuit risks.

Semi-finished product inspection

Test key indicators such as pulse charging and discharging performance, equipment functional correctness, etc., identify potential defects in advance, and ensure the quality of semi-finished products.

Sealing and Cover Plate Installation

The adhesive coating process ensures sealing, and the cover plate forms a closed structure after installation to prevent external impurities from entering and protect internal components.

3、 Finished product inspection and traceability

Finished product quality verification

Insulation performance testing and airtightness testing ensure that the battery pack meets safety standards and prevents the risk of electrical or environmental leakage.

Full process data management

The MES system collects real-time team, equipment, raw material batches, production processes, and quality inspection data to achieve dynamic monitoring of production and quality status.

Through raw material batch information, the entire product lifecycle can be traced, including the source of raw materials, production processes, and quality inspection records, supporting quality traceability and problem traceability.

Process characteristics and advantages

Integration of automation and semi automation: Key processes such as AGV conveying and module installation adopt fully automated technology, while auxiliary processes such as BMC/LMC assembly combine manual operation to balance efficiency and flexibility.

Intelligent production management: MES system integrates production planning and scheduling, data collection and analysis, supporting real-time decision-making and process optimization.

Quality and Traceability: The entire process data is automatically summarized and analyzed, combined with batch traceability function, to ensure controllable product quality and traceable problems.

Balance between performance and manufacturability: Automatic plug-in module technology and semi-automatic battery pack technology balance product performance requirements and production feasibility, reducing labor costs while improving manufacturing accuracy.

This process route achieves efficient, reliable, and sustainable production of automotive power battery packs through intelligent, automated, and data-driven design, which is in line with the development trend of intelligent manufacturing and meets the strict requirements of the industry for quality, cost, and traceability.

汽车动力电池包生产流程基于智能制造原则设计，采用MES系统管理生产计划，结合全自动与半自动工艺，实现高效生产、质量可控及全程可追溯。其核心流程可分为三大阶段，具体工艺步骤及特点如下：

一、模组生产阶段

1. 原材料输送与预处理

   • AGV系统根据MES生产计划自动将原材料输送至装车区，并清理电池箱内异物，确保初始装配环境洁净。

   
   

2. 高压部件装配

   • 在高压电缆和组件安装站，通过自动化设备将高压电缆、组件精准安装至电池箱指定位置，保障电气连接可靠性。

   
   

3. BMC/LMC组装

   • 半自动工位完成BMC（电池管理系统控制模块）和LMC（低压管理模块）的安装，结合人工校验确保模块位置精确。

   
   

二、电池包组装阶段

1. 模块定位与固定

   • 固定工位通过自动升降系统将电池模块吊装至合适位置，实现精准定位与机械固定，提升装配效率。

   
   

2. 线束安装与整理

   • 线束安装整理站完成线束布线、固定及整理，确保电气路径规范，避免信号干扰或短路风险。

   
   

3. 半成品检验

   • 检验脉冲充放电性能、设备功能正确性等关键指标，提前识别潜在缺陷，保障半成品质量。

   
   

4. 密封与盖盘安装

   • 涂胶工艺确保密封性，盖盘安装后形成封闭结构，防止外部杂质侵入，保护内部组件。

   
   

三、成品检验与追溯

1. 成品质量验证

   • 绝缘性能测试与气密性检测确保电池包满足安全标准，防止漏电或环境渗漏风险。

   
   

2. 全流程数据管理

   • MES系统实时采集团队、设备、原料批次、生产过程及质检数据，实现生产状态与质量状态的动态监控。

   • 通过原料批次信息可追溯产品全生命周期，包括原材料来源、生产工序及质检记录，支持质量追溯与问题溯源。

   
   

工艺特点与优势

• 自动化与半自动化结合：关键工序（如AGV输送、模块安装）采用全自动技术，辅助工序（如BMC/LMC组装）结合人工操作，平衡效率与灵活性。

• 智能生产管理：MES系统实现生产计划调度、数据采集与分析一体化，支持实时决策与过程优化。

• 质量与可追溯性：全流程数据自动汇总分析，结合批次追溯功能，确保产品质量可控且问题可溯。

• 性能与可制造性平衡：自动插件模组技术与半自动电池组技术兼顾产品性能需求与生产可行性，降低人工成本同时提升制造精度。

该工艺路线通过智能化、自动化及数据驱动的设计，实现了汽车动力电池包生产的高效、可靠与可持续性，符合智能制造发展趋势，并满足行业对质量、成本及可追溯性的严格要求。

AGV系统根据MES中的生产计划，自动将原材料输送到装车区。清理箱内异物；

• 在高压电缆和组件安装站，将高压电缆和组件安装到电池箱的相应位置；

• BMC和LMC组装过程中，将BMC和LMC安装到电池盒相应位置；

• 固定工位，工人借助自动升降系统将模块安装到合适的位置；

• 线束安装整理站，安装相应的线束并整理，在半成品检验过程中，检查脉冲充放电等项目，检查设备的正确性在密封过程中，涂胶并安装盖盘；

• 在成品检验过程中，检验绝缘和气密性。

汽车动力电池包的生产流程主要由模组生产、电池包生产和容量检测三个过程组成。根据装配工艺特点，采用全自动和半自动相结合的工艺，提高生产效率，降低人工成本。该工艺路线采用自动插件模组技术和半自动电池组技术，充分考虑了电池组产品的性能和可制造性。

工艺流程以智能制造为设计原则，采用MES管理生产计划；对团队信息、设备信息、原料批次信息、生产过程数据和质检数据进行全面自动采集汇总分析，实时监控生产状态和质量状态；根据原料批次信息可追溯产品信息，通过产品批次信息可以追溯原材料信息和生产过程信息。