Battery pack production
The production of battery packs takes place at ANSMANN headquarters in Assamstadt (Germany). The production started at the beginning of 2012 and changed to flow production mid-2013.
The one-piece-flow system guarantees high efficiency in production and testing. A constant control carried out by quality management ensures a consistent high-quality standard of products in line with German quality standards. Since summer 2013 the production department has been working a two-shift production Rota system.
Cables are prepared by cutting the cables to length, stripping and galvanizing to ensure that there are no errors in the following steps. The welding contacts are prepared to avoid needless welds in production. The safety boards are also prepared for the production at this stage. All cables and components are soldered.
2. Test, isolate and glue cells
Cells are tested by means of a voltmeter and sorted based on voltage. Cells are then glued with isolation tape to protect them from short circuits. A washer is then fitted to the top of the cell. The washer has two functions: Isolation and cutting the positive electrode.
Cells are stuck together with special glue. This process guarantees stability of the battery pack and relieves the welded connectors. If they were not stuck together stress would affect the welded connectors.
3. Weld connectors
Once cells are isolated and glued, they are then welded. The welding process is conducted by means of a resistance welder. The connectors used are made of completely stainless nickel. Due to the bespoke equipment used, the welding process achieves maximum stability.
4. Test PCB (only for Li-Ion battery packs)
The testing of safety boards (PCB) is executed with specially designed testers.
5. Solder on PCB (only for Li-Ion battery packs)
After safety boards have been tested and prepared they are soldered on to the battery pack.
6. Ultrasonic welding/ foil shrinking
There are several ways to protect the electronics against external influences. The battery packs can be integrated into a specially designed housing. This housing is put together and ultrasonically welded in special cases. In many cases, the battery pack has a shrink foil which butts against the battery pack due to the heat of a hot air gun or shrink tunnel.
7. Final inspection and packaging
All devices pass through a final inspection at the end of the production process. The test is conducted by ATE (Automatic Test Equipment). Here, it’s possible to check the communication of the battery pack. Test logs are created and stored automatically. The serial number is registered in the battery pack and a label is generated.
The packaging is the final step in the production chain. Employees ensure that all battery packs have valid UN Transportation certification (UN 38.3) and that the packaging is marked accordingly.