Automated test system for post-bonding battery module quality control, performing 36-point bonding connectivity verification, Open Circuit Voltage (OCV) measurement, and high-current DCIR testing in 20-second production cycles

Key Features

• Automated dual-stage testing verifies post-bonding module quality with 20-second cycle time for high-throughput production integration
• Comprehensive electrical verification tests wire bond connectivity, current collector continuity, and cell interconnections across 8-brick module configurations
• Combined OCV and DCIR measurement in single automated sequence eliminates manual handling and reduces test floor space requirements
• Three-position vertical lift system enables sequential testing without operator intervention or module repositioning between test stages
• Continuous conveyor flow with automated positioning integrates upstream and downstream processes for inline production operation
• Series-wired safety interlock with emergency stop and full guarding meets production safety standards for automated battery manufacturing

System designed for inline integration into battery module assembly lines with 480VAC three-phase power and 5-6 bar compressed air, operational documentation available upon request.

System Architecture

Bonding Probe Test Station

Upper 36-probe array (825 x 160 mm) tests resistance and voltage across wire bonds, current collectors, and cell interconnections. Cell pallet lifts to contact overhead probes for testing. Multi-channel test equipment measures connectivity across 8 individual bricks and full module assembly.

EOL Probe Test Station

Dual 20 mm probes lift to contact module terminals for high-current DCIR testing. Test equipment measures full module internal resistance over 15-second test cycle.

Material Handling System

Belt conveyor with stopper positions cell pallet for testing. Vertical lift platform (docker) raises pallet to bonding probe height, lowers to EOL probe height, then returns to conveyor level for exit.

Control and Safety Systems

PLC-based sequence control coordinates testing operations across all stations. Emergency stop integrates with external interlock in series configuration for immediate shutdown. Complete safety guarding encloses moving components.

Technical Specifications

• Overall Dimensions: 1,400 mm (L) x 1,200 mm (W) x 2,460 mm (H)
• Total Cycle Time: 20 seconds
• Working Height: 900 mm ± 100 mm
• Power Input: 480 VAC, 3-phase, 50/60 Hz
• Compressed Air Requirement: 5-6 bar
• Conveyor Transport Speed: 72 rpm
• Bonding Test Configuration: 36-probe array, 825 x 160 mm
• EOL Probe Diameter: 20 mm (dual probe)
• Module Configuration: 8-brick assembly
• Noise Level: <70 dB