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High power for e-cars: IPTE’s assembly and test line enables efficient automated production of high-performance battery packs
GENK, BELGIUM - IPTE Prodel has installed an automated assembly and test line covering the entire process for the efficient manufacture of high-performance batteries  used in newly engineered battery-operated e-cars. The product manufactured, a polymer-ion battery pack, consists of two units weighing 80 kilograms in total that are finally securely placed into an aluminum casing. In additional to the various mechanical assembly steps the line also includes a variety of test stations for quality and reliability assurance. 

The production process starts with pressing together the separate battery plates which results in a sandwich-like battery cell construction. These pressed components are then inserted into the rectangular box together with isolating material and welded using ultrasonic technology (if needed). A high-current cable, screw-fastened to each individual battery cell, provides the electrical connections of the single battery cells. After this, the two units are placed in the common aluminum casing and securely closed in a tightly controlled precise crimping process, followed by a leakage test to examine the seal tightness. Then, a temperature sensor will be put on top of the finished battery pack checking temperature stress and behavior.

Furthermore, each individual battery cell will be checked for short circuit and is subject to additional electrical functional and power tests. Having passed all the tests free of error the battery packs will be packed and shipped.

The layout of the flexible production line forms a lean U-shape. Depending on production orders and volumes needed, the number of staff can easily be adjusted. Every manufacturing station operates independently but is completely integrated in the line control system. The self-explaining and intuitively operating stations guide the staff through every production step, the same is true for occasionally necessary service and maintenance procedures. Cycle time for the manufacture of a complete assembled and verified battery pack is less than ten minutes.

About IPTE

IPTE is a supplier of automated production equipment for the electronics and mechanics industry and one of the market leaders in this segment. The company designs turnkey-automation systems of all kinds for production, test and further processing of printed-circuit boards, as well as of board assemblies and final products. IPTE runs nine engineering and production sites, so in Belgium, Germany, France, Spain, Portugal, Mexico, Estonia, Romania and China.

The headquarters of IPTE are located in Genk, Belgium. IPTE supplies global sales and services to its customers from 15 facilities in Europe, America and Asia. IPTE currently employs 600 people.

The IPTE Group's client list includes companies such as Autoliv, Bosch, Continental, Delphi, Ericsson, Hella, Johnson Controls, Lear, Leoni, Schrader, Siemens, TechniSat, TP Vision, TRW, Vaillant, Valeo, Visteon und Yazaki.

Further information about IPTE at: www.ipte.com

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