Sau: Dany Huang, Ph.D.
CEO & R&D Leader, TOB New Energy
Txuas nrog Dr. Huang ntawm LinkedIn
Executive Summary & Key Takeaways
Lub ESS boom khiav ntawm loj prismatic LFP hlwb-280Ah thiab 300Ah hom uas hnyav 5.4-6.0 kg txhua thiab yuav tsum tuav lawv cov foob hermetic rau 15-20 xyoo. Kev sib dhos ceev ceev yog kev qhuab ntuas siab ntev: tuaj yeem tso qhov tshem tawm, lub hau vuam nkag, thiab PPM / cov txiaj ntsig sib npaug txiav txim siab seb kab puas tau nyiaj lossis ua rau seem.
- Muaj peev xwm tshem tawm qhov kev tshem tawm: 0.3-0.8 hli tag nrho, nrog lub kaum sab xis nyob hauv qab 0.2 degree. Ntawm 200 mm qhov tob qhov tob, ib nrab ntawm kev qaij sib npaug sib npaug 1.7 hli ntawm offset- txaus los tuav lub ntug sib cais thiab cog tus kheej - tawm qhov tsis xws luag.
- Sab saum toj hau laser welding: 0.76 m perimeter weld ib 280Ah cell ntawm 80-250 mm / s, 0.5-1.2 hli nkag mus, nrog helium leak rate ntawm qhov kev txiav txim ntawm 10⁻⁷ Pa·m³ / s los yog nruj dua.
- PPM thiab tawm los: semi- cov kab tsis siv neeg khiav 2-5 ntu hauv ib feeb ntawm 92-95% ua ntej- kis tawm los; tag nrho automated kab khiav 10-15 PPM ntawm 97.5-99%.
- Qhov sib txawv ntawm cov txiaj ntsig yog qhov ROI tiag tiag: plaub feem pua cov ntsiab lus thoob plaws 10,000 hlwb hauv ib hnub sib npaug li $ 4 lab toj ib xyoo hauv cov khoom khaws cia ntawm ESS cell nqi.
Lub 280Ah LFP cell yog 5.5 kg siab lub nkoj uas yuav tsum muaj sia nyob ob xyoo caum ntawm thermal cycling hauv ib lub thawv. Nws tseem yog cov khoom lag luam- daim phiaj cia cov neeg yuav khoom yuav ntawm tus nqi ib kWh, thiab cov xov tooj ntawm tes rau feem ntau ntawm tus nqi. Cov kab sib dhos yog li ntawd los ntawm ob qhov kawg: siab dua PPM kom txo cov peev, nruj dua rau kev tiv thaiv tawm los. Phau ntawv thiab ib nrab - cov kab tsis siv neeg tuaj yeem xa ob qho tib si. Qhov ntawd yog qhov kev ua haujlwm tiag tiag tom qab txhua qhov kev txiav txim siab nthuav dav hauv ESS.
Ntawm 280Ah, ib lub xov tooj sib npaug 0.896 kWh. Ib tsob nroj 3 GWh xav tau txog 3.3 lab hlwb hauv ib xyoos. Ua haujlwm 300 hnub ntawm 85% kab muaj, uas ua haujlwm rau kwv yees li 9-10 ntu hauv ib feeb. Txoj kab ceev tsis yog qhov nyiam. Nws yog arithmetic.
Yog vim li cas 280Ah thiab 300Ah Cells tawg Pas Kab Tsim
Cov hlwb me me cylindrical zam tuav kev tsim txom. Cov hlau tuaj yeem nruj, qhov loj yog tsawg, thiab lub davhlau ya nyob twg geometry zam txim rau ib millimeter ntawm misalignment. Loj prismatic hlwb tsis.
- Mass thiab inertia.Ib qho 5.5 kg ntawm tes txav ntawm qhov nrawm ntawm lub conveyor nqa lub zog tiag tiag. Txhua qhov nres hloov kinetic zog rau hauv lub cell thiab mus rau hauv lub fixture. Grippers xav tau kev tswj kom muaj zog thiab cov ntaub qhwv ntsej muag kom tsis txhob muaj qhov dents thiab weld-seam stress.
- Taw taw thiab weld ntev.Ib tug qauv 280Ah cell ntsuas roughly 174 × 207 × 72 mm, muab ib tug cap perimeter ntawm txog 760 mm ntawm nruam weld ib cell. Qhov weld no tsuas yog thaiv ntawm cov electrolyte thiab nees nkaum xyoo ntawm ambient ya raws.
- tob tob.Tsev neeg 300Ah ncav cuag lub peev xwm siab dua. A 200 mm qhov tob tob amplifies angular yuam kev raws nws qhov ntev -geometry rau txim me me qaij.
- Life-of-asset defects.ESS hlwb raug muab qhab nia rau 6,000–8,000 cycles. Ib qho kev sib cais los yog ib feem fused weld tsis ua tiav qhov kev ntsuas hluav taws xob. Nws ua tsis tiav hauv xyoo peb, hauv lub thawv uas tus neeg teb xov tooj tau qhib thiab rov ua haujlwm dua.
High-speed sib dhos kab rau cov chav kawm ntawm tes no tsis yog scaled-up cylindrical kab. Lawv yog lawv tus kheej kev qhuab qhia engineering, thiab ob lub chaw nres tsheb uas txhais tau tias nws tuaj yeem nkag thiab sab saum toj welding.
Tau Insertion: Thawj Tolerance Trap
Cov electrode los ua ke- stacked los yog mob electrodes nrog tabs twb welded rau lub hau terminals - yog qis rau hauv lub txhuas tau. Qhov haum yog txhob txwm thiab nruj: tag nrho clearance ntawm lub electrode los ua ke thiab phab ntsa khiav 0.3-0.8 hli, uas yog 0.15-0.4 hli ntawm radial sib txawv ib sab.
Qhov sib txawv ntawd tsis muaj chaw rau kev taw qhia sloppy, yog li automated chaw nres tsheb siv peb txheej tiv thaiv:
- Chamfered daim phiaj qhia thiab ib zaj duab xis qhia.PET lossis Mylar lub tes tsho funnels lub rooj sib txoos rau hauv lub qhov ncauj, noj thawj qhov kev sib cuag yog li cov ntug sib cais tsis. Cov yeeb yaj kiab yog siv rau ib lub xov tooj ntawm tes lossis ib pawg thiab yog cov khoom siv tswj tau, tsis yog qhov yooj yim.
- Force-tsav kos npe saib xyuas.Insertion servo sau lub zog nkhaus tiv thaiv stroke. Kev nce siab nyob rau hauv ib lub hnab ntawv xav tau yog ib qho kev ntxig zoo. Ib qho kev quab yuam, lub toj siab, lossis ib qho kev poob tam sim ntawd txhais tau hais tias ib qho kev sib tw, ib qho kev sib cais, los yog lub tab tsis zoo. Kev kuaj pom ntawm qhov sib txawv ntawm qhov nqaim nqa cov teeb meem ntawm qhov chaw nres tsheb, tsis yog qhov kawg ntawm kab.
- Angular alignment tswj.Kev sib dhos axis yuav tsum nyob hauv 0.2℃ntawm qhov tuaj yeem axis. Tshaj 200 hli ntawm kev mus ncig, 0.5℃ntawm qaij ua rau 1.7 hli ntawm sab nraud offset nyob rau hauv qab ntawm lub peev xwm -ntau tshaj plaub npaug ntawm radial clearance. Qhov tshwm sim yog qhov sib cais ntawm ntug uas tsis muaj hluav taws xob kuaj yuav chij.
Peb puas ampere-teev hom ntawv ntxiv ib qho kev txiav txim siab thib ob: qhov siab dua tuaj yeem ua rau pawg compression xav tau ntawm kev sib tw, thiab cov kev qhia zaj duab xis ntev. Ob qho tib si qeeb qhov chaw nres tsheb yog tsim los rau me me 280Ah geometry. Lub tshuab hluav taws xob tag nrho prismatic cell sib dhos kab rau 280Ah thiab 300Ah ESS hlwb tau teev tseg rau ib hom ntawv raws nraim qhov no yog vim li cas - tuaj yeem ua qhov siab, ntxig stroke, thiab qhia geometry yog hom tshwj xeeb, tsis yog universal.
Sab saum toj Cap Laser Vuam: Qhov twg Hermeticity txiav txim siab
Lub hau yog muab tso rau ntawm lub kaus poom, tom qab ntawd koom nrog lub laser txuas txuas ntxiv nyob ib ncig ntawm tag nrho ib puag ncig. Rau 280Ah cell uas yog kwv yees li 760 hli ntawm vuam, tua ntawm 80-250 mm / s nrog fiber ntau laser ntawm 1-3 kW. Kev nkag mus rau lub hom phiaj yog 0.5–1.2 hli- txaus rau fuse cap thiab tuaj yeem phab ntsa yam tsis muaj hluav taws kub mus rau hauv pawg electrode.
Peb txheej txheem variables tswj qhov zoo:
Weld hom thiab qhov chaw oscillation. Aluminium cuam tshuam lub teeb ze-infrared ntawm qhov siv qis, tab sis lub qhov tseem ceeb tshwm sim thaum lub zog ceev hla qhov pib. Beam wobble-circular oscillation ntawm qhov chaw ntawm 100–300 Hz- stabilizes lub keyhole, widens fusion cheeb tsam, thiab suppresses porosity thiab kub tawg. Yog tsis muaj wobble, weld zoo ntawm aluminium yog npib npib hla ib txoj hlua ntev.
Shield gas. Argon ntawm 15-25 L / min, xa los ntawm lub taub hau tom qab ntawm 30-45 degree. Gas kev pab cuam tsis ua hauj lwm tshwm sim li tsaus, oxidized weld hlaws thiab porosity. Helium sib tov yog siv qhov chaw vuam ceev thawb qhov txwv ntawm argon kev pab them nqi.
Kev tswj cov fume thiab spatter. Vaporized aluminium thiab txhua qhov chaw paug tawm tau zoo li cov khoom zoo. Ib qho kev sib tsoo dav hlau thiab coaxial rho tawm kom tawg tawm ntawm lub hau thiab lub qhov muag. Ib qho conductive particle tsaws ntawm qhov tsis ncaj ncees lawm ua ib qho luv luv tom qab. Lub tshuab rho tawm yog ib feem ntawm qhov chaw nres tsheb vuam specification, tsis yog ib qho khoom siv.
Inline saib xyuas kaw lub voj. Kev soj ntsuam cov txheej txheem coaxial sau cov thermal emission kos npe ntawm txhua qhov vuam; qhov sib txawv ntawm lub hnab ntawv siv tus chij ntawm tes ua ntej nws nce mus. Lub chaw kuaj dej xau ces txheeb xyuas qhov tshwm sim. Txhua lub xov tooj welded hla lub helium leak kos ntawm qhov tshwj xeeb ntawm qhov kev txiav txim ntawm 10⁻⁷ Pa·m³ / s lossis nruj dua, sivhelium leak test khoom sivrau prismatic cell foob pov thawj kev koom ua ke rau hauv tib txoj kab hloov mus.
Engineering Insight:
Cap welding yog yuav luag txhua txoj kab tsis muaj dab tsi. A 760 mm seam ntawm 150 mm / s siv 5 vib nas this ntawm lub sijhawm arc; ntxiv load, dlhos, clamp, thiab unload, thiab qhov chaw nres tsheb voj voog mus txog 8-10 vib nas this. Qhov chaw nres tsheb ib leeg ua rau txoj kab ntawm 6-7 PPM txawm hais tias txhua qhov chaw nres tsheb khiav ceev npaum li cas. Kev nqa ib txoj kab ntawm 10 mus rau 15 PPM yog li ntawd yog qhov teeb meem vuam-chaw nres tsheb-ob hau, ob txoj kab sib luag, lossis kev sib cais ntawm lub hau tsim- tsis yog teeb meem conveyor. TOB Tshiab Zog cov kab engineers rebalance qhov chaw vuam ua ntej thaum twg tus neeg siv khoom ESS lub hom phiaj nce PPM.
Tus lej: Semi- Tsis Siv Neeg vs. Cov Kab Tsis Siv Neeg Tag Nrho
PPM thiab cov txiaj ntsig sib piv hauv qab no qhia txog 280Ah prismatic sib dhos ntawm cov kab tag nrho -los ntawm electrode los ua ke infeed los ntawm sealing, filling, thiab zaum kawg tu. Qhov tseem ceeb yog qhov sib txawv; txhua tus neeg muag khoom thiab hom hloov cov lej.
| Metric | Semi-Automatic / Phau Ntawv Kab | Fully Automated Kab |
|---|---|---|
| Tso zis | 2-5 PPM | 10-15 ppm (siab ceev tsim rau 20) |
| Thawj-pass yield | 92–95% | 97.5–99% |
| Cov neeg ua haujlwm ncaj qha rau kev ua haujlwm | 18–30 | 3–5 |
| Line OEE | 55–70% | 80–90% |
| Output stability ntawm kev hloov | Declines nrog qaug zog | Flat ntawm daim ntawv teev npe |
| Tsis lees paub rau 10,000 cell | 500–800 | 100–250 |
| Cov khoom poob ntawm USD 35 / cell | USD 17,500–28,000 | USD 3,500–8,750 |
Kev lag luam nyob hauv ob kab kawg. Qhov sib txawv ntawm 95% thiab 99% tawm los yog 400 hlwb ib 10,000-txog USD 14,000 hauv cov khoom ntawm USD 35 ib lub xov tooj. Ib kab uas tsim tau 10,000 lub hlwb ib hnub poob ib qho ntxiv USD 14,000 txhua hnub ntawm qhov qis qis. Thoob plaws 300 hnub tsim khoom, uas yog kwv yees li USD 4.2 lab toj ib xyoo. Muab piv nrog rau lub sijhawm ua haujlwm: hloov 20 tus neeg ua haujlwm ntawm USD 40,000 tus nqi thauj khoom txuag USD 800,000 ib xyoos. Cov khoom seem dwarfs them nyiaj hauv ESS manufacturing. Yield yog ROI.
Yield kuj sib xyaw sib txawv ntawm ESS nplai. 280Ah cell muaj txog 0.9 kWh. 1% yield poob ntawm 3 GWh kab pov tseg cov khoom siv ntawm tes muaj nqis ntau dua li kev siv nyiaj txhua xyoo ntawm tag nrho thaj chaw sib dhos.
Qhov twg Automation tiag them, Chaw nres tsheb los ntawm chaw nres tsheb
Tag nrho automation tsis txhais hais tias ib kab nrog robots bolted mus rau hauv phau ntawv txheej txheem. Nws txhais tau hais tias txhua qhov chaw nres tsheb yog lub voj voog-lub sij hawm sib tw thiab txhua qhov kev hloov pauv yog mechanized.
- Robotic tuav nrog lub zog tswj.Servo grippers nqa 5.5 kg hlwb los ntawm lub cev tuaj yeem nrog lub programmable clamp quab yuam, thiab lub tshuab nqus tsev vacuum txav cov khoom siv hluav taws xob tsis tas kov cov ntug sib cais.
- Indexed los yog pallet hloov.Tsau-pitch indexing rau ib hom ntawv khov; ywj siab pallets qhov chaw nres tsheb khiav ntawm lub sijhawm sib txawv. Ob qho tib si tshem tawm txoj kev taug kev, queuing, thiab phau ntawv qhia ua haujlwm uas siv feem ntau ntawm kev ua haujlwm semi-auto.
- Buffers ntawm chaw nres tsheb.Cov accumulators me me nqus micro-stops yog li 5-second hiccup ntawm qhov chaw nres tsheb vuam tsis nres tag nrho cov kab.
- Inline tshuaj xyuas tom qab txhua kauj ruam tseem ceeb.Cap weld saib xyuas, helium leak test, thiab kos duab ntawm qhov chaw nres nkoj. Cov teeb meem raug tsis lees paub ntawm qhov chaw nres tsheb uas ua rau lawv, tsis pom ntawm qhov kawg ntawm kev xeem.
- Cell-level traceability.Txhua lub xov tooj ntawm tes tsis muaj qhov sib txuas, qhov ntxig quab yuam nkhaus, thiab tus nqi xau yog nkag rau nws qhov barcode. Thaum lub thawv rov qab los rau xyoo plaub, cov ntaub ntawv tsim khoom muaj nyob.
Qhov chaw nres tsheb-los ntawm-chaw nres tsheb kev sib koom ua ke yog qhov chaw muab kev pabcuam turnkey muab raws li ib qho kev ua haujlwm: fiber ntaulaser vuam automation rau prismatic cellsab saum toj cap sealing engineered nrog rau kev ntxig, hloov chaw, thiab tshuaj xyuas chaw nres tsheb tsis yog muab cais thiab sib cuam tshuam ntawm qhov chaw.
Npaj kom npaj ib txoj kab ESS los ua ke?
ESS margins tawm tsis muaj chaw rau ib kab uas khiav ntawm 60% ntawm daim ntawv teev npe. TOB Tshiab Zog, raws li lub Hoobkas ncaj qha, engineers ua tiav prismatic cell sib dhos kab rau 280Ah, 300Ah, thiab cov qauv loj dua - tuaj yeem ntxig, cap laser vuam, xau kuaj, hloov mus, thiab kev taug qab nyob rau hauv ib qho. Xa cov duab ntawm tes, lub hom phiaj GWh, thiab xav tau PPM mus rau pab pawg engineering rau qhov chaw nres tsheb-los-chaw nres tsheb-lub sij hawm tsom xam thiab lub Hoobkas ncaj qha hais.
FAQ: ESS Prismatic Cell Assembly
Dab tsi PPM yuav tsum 280Ah xov tooj sib dhos kab khiav ntawm?
10-15 qhov chaw ib feeb rau ib txoj kab uas siv tag nrho, nrog rau kev teeb tsa kev kub ceev mus txog 20 PPM. Semi-automatic kab feem ntau khiav 2-5 PPM. Qhov xav tau PPM ua raws ncaj qha los ntawm lub hom phiaj GWh: 1 GWh ntawm 280Ah sib npaug li 1.1 lab hlwb hauv ib xyoos.
Cov txiaj ntsig dab tsi tuaj yeem xav tau los ntawm kev siv tshuab ESS los ua ke?
97.5-99% first-pass yield yog ua tiav ntawm kev tswj cov kab hluav taws xob, piv rau 92-95% ntawm cov khoom siv semi-automatic. Cov khoom siv tus nqi sib txawv ntawm cov kab ntim siab tau sau rau ntau lab USD toj xyoo.
Dab tsi yog cov txheej txheem nyuaj tshaj plaws hauv 280Ah prismatic sib dhos?
Sab saum toj cap laser welding feem ntau yog ob qho tib si qhov zoo thiab qhov chaw hla dhau. Ib tug 760 hli nruam weld ntawm 0.5-1.2 hli nkag mus yuav tsum tau tua nyob rau hauv ob peb vib nas this nrog xoom porosity, thiab lub voj voog chaw nres tsheb feem ntau caps kab PPM.
Lub cell hermeticity tau txheeb xyuas li cas?
Helium leak test ntawm qhov kev qhia tshwj xeeb ntawm qhov kev txiav txim ntawm 10⁻⁷ Pa·m³ / s lossis nruj dua, ua tiav hauv kab tom qab lub hau vuam. X-ray lossis CT sampling yog siv los tshuaj xyuas qhov kev nkag mus rau hauv cov khoom siv.
Puas muaj ib nrab - tsis siv neeg kab uas twb muaj lawm tuaj yeem hloov kho kom siab dua PPM?
Ib nrab. Ntxiv qhov chaw nres tsheb welding, kev xeem xau, thiab traceability rau ib phau ntawv kab nce yield, tab sis PPM nyob twj ywm txwv los ntawm phau ntawv hloov. Tshaj li kwv yees li 5 PPM, ib txoj kab tshiab tsim nyob ib ncig ntawm kev siv lub tshuab nqus tsev thiab vuam yog qhov qis dua.
Kev siv cov ntaub ntawv sau los ntawm TOB Tshiab Zog txheej txheem engineering pab pawg los ntawm prismatic cell sib dhos kab xa mus rau ESS cell hom. Rau lub voj voog-lub sij hawm thiab cov qauv tsim tawm ntawm koj qhov tshwj xeeb 280Ah lossis 300Ah lub hom phiaj tsim khoom, txuas nrog Dr. Dany Huang ntawm LinkedIn lossis xa cov lus qhia ntawm tes mus rau Xiamen engineering rooj.
