In the process of large-scale commercialization of flow batteries such as all-vanadium and zinc-bromine batteries, the assembly precision and consistency of the stack directly determine the efficiency and lifespan of the battery.
Our company's fully automatic flow battery stack assembly line is specifically designed for the mass production of energy storage stacks. This production line integrates four core systems: automatic stacking, servo press-fitting, leak testing, and full-process data traceability, achieving fully automated production from material pre-treatment to finished product palletizing. We are dedicated to assisting clients in manufacturing flow battery stacks characterized by high consistency, low internal leakage, and long service life.
PRODUCT DESCRIPTION
1. Intelligent Material Pre-treatment System
The front end of the production line is equipped with a multi-station automatic feeding and pre-treatment module, ensuring precise control over each incoming material:
●Bipolar Plate Processing: Integrated hot-melting/welding process ensures flow channel sealing; optionally equipped with CCD vision inspection to reject defective plates.
●Multi-functional Material Preparation: For end plates, insulating plates, current collector plates, separators, and gaskets, automatic cleaning/film lamination technology is adopted to prevent separator damage and ensure gasket placement accuracy of ±0.1mm.
●Flexible Compatibility: Supports rapid changeover production for various plate sizes and multi-cell battery configurations.
2. High-Precision Stack Stacking System
Employing a modular design, the "skeleton" of the stack is constructed through precise handling and positioning technology:
●Automatic Stacking: Utilizes rotary conveyors and lifting devices to achieve alternating stacking of bipolar plates, separators, and electrode frames. The equipment features automatic layer counting and verification functions to prevent missing or duplicate layers.
●Recipe Management: An integrated stacking recipe management system automatically calls up stacking sequence, pressure, and torque parameters based on different stack models, enabling one-click product changeover.
3. Servo Hydraulic Press-Fitting and Fastening Unit
This is the critical step to minimize stack ohmic resistance and prevent leakage:
●Precision Press-Fitting: Employs a servo hydraulic press specifically for stack assembly, equipped with high-precision pressure and displacement sensors. It monitors the pressure-displacement curve in real-time during the process, ensuring uniform press-fit force and preventing separator damage or plate deformation.
●Intelligent Fastening: Integrates an isobaric/constant torque fastening system. While the press maintains holding pressure, multi-axis servo tightening spindles perform diagonal synchronous tightening of bolts, ensuring consistent clamping force at each point and avoiding seal failure caused by uneven stress.
4. Online Inspection and Data Traceability
Establishes a "production as inspection" quality control system:
●Vision Inspection: Real-time CCD vision positioning and correction during the stacking process.
●Air Tightness Testing: Equipped with an independent air tightness test module. After press-fitting, the stack cavity undergoes inflation testing to accurately determine internal/external leaks, ensuring zero leakage before shipment.
●Traceability Management: The system automatically collects test results (pressure values, torque values, leak test curves) for each stack, generates a unique ID, and enables full lifecycle traceability from material batch to finished product quality.
1. Stack Stacking Worktable: Utilizes a stack turning mechanism to achieve vertical or horizontal stacking of separators/bipolar plates, meeting fluid pipeline design requirements.
2. Stack Assembly Servo Hydraulic Press: Employs precision servo control with both pressure control and position control modes, ensuring press-fitting repeatability accuracy.
3. Automatic Tightening System: Multi-axis linkage enabling constant compression or constant torque fastening of springs/bolts.
4. Material Handling and Transfer System: Includes rotary conveyors, lifting devices, and stack palletizers to connect upstream and downstream processes. Built-in buffer stations balance the production takt time.
5. Leak Test Station: High-precision mass flow or pressure drop testing with automatic OK/NG judgment.
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