![]() This is a specimen unit that verifies that the seal testing apparatus is working properly. From time to time, a different-looking unit appears among the tested batteries. The first is the seal test, with separate checks of the tightness of the cooling circuit and the battery as a whole. The lid is screwed on by a robot.Īssembly is followed by a series of tests. The lid on the case is secured with a double seal: rubber and a special glue. All that’s left to do after that is to connect the module to the control unit, and the battery is ready to be sealed. “This requirement forces the employee to actually look at the connection,” Mašek says. “The screws for attaching braces are on a special trolley with scales, which can tell whether the worker used the right number of screws and didn’t take one more that fell into the case, for example,” says Otakar Mašek.Īt the start of assembly battery modules are paired up the complete battery blocks are made from multiples of these pairs.Īnother control practice might seem unexpected as well: after all the connectors have been attached inside the battery, the employee at the next station uses a felt-tip pen to make a dot on the place of the given connection to show that he performed a second visual check of the connection. One smart solution is applied when these are screwed together on the line. The installation of the low-voltage cabling is completed and the case is given filler material and support braces. ![]() Once the case and modules have been put together, other components are fitted, primarily the cooling circuit. ![]() The complexity lies in the fact that the screw and the mount are automatically connected first. Another robot takes care of the fairly complicated process of screwing bath and module together. While in automobile manufacture this has traditionally meant the phase when the body is joined together with the chassis and engine, here it means putting the assembled battery modules into the case, which is done by a robot. After being vacuumed, the case is ready for what is known as the “marriage”. When the case is fully assembled, it is the turn of a perhaps unexpected assistant to do its bit: a robot that uses a vacuum cleaner to make sure that the case is free from any impurities that might cause problems during operation. This shield protects the entire battery from the heat from the exhaust that runs beneath it.Īssembled batteries head off for rigorous testing. Here on the line it is fitted with all the necessary components such as various connectors, seals, stops and screw bushes, but also the external heat shield that passes through the centre of the case. The massive aluminium case also comes from a supplier. Most of the handling work here is done by robots, but at some stations they have a manual backup in case the robot is unable to do the job for some reason. While the battery modules and e-boxes are being assembled, in another part the aluminium can forming the body of the battery is prepared. A cooler is inserted between the modules – once connected, coolant liquid flows through the cooler. The first step is to fit the module with special heat-conducting foil that helps improve the cooling of the entire battery set. Each module comes from the supplier charged to roughly 20% capacity, so safety precautions are necessary right from the start of the production process. ![]() These modules proceed along the first part of the line in two parallel streams: for the left and right parts of the battery separately. When assembling the four battery modules, ŠKODA uses modules from an external supplier that are actually finished small battery cells. The battery’s electronics are put together in the third, smaller branch. In another branch there is the fully equipped case that houses the battery modules and is perfectly sealed at the end of the assembly process to protect the battery from external influences. The battery modules are being put together into the assembly of four in one branch. But it has three main branches, and the finished batteries come off it roughly in the middle. In the brightly lit, airy and spacious factory shed, the battery production line looks like a single, neat line at first sight.
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