Stacked High Voltage Battery Packs

Open packaging, sort components.

Inspect grouped cells for defects: leakage, scratches, dents, punctures, swelling.

Test cell voltage and internal resistance; rebalance cells with excessive voltage deviations.

Punch holes in cell tabs using a stamping machine.

Mount cells onto adapter boards per specs, secure tightly with fiber tape.

Fold tabs in half with a rubber mallet and align holes with PCB board positions.

Secure aluminum plates to adapter boards with screws; verify torque.

Wrap battery module with fiberboard and seal edges with fiber tape.

Tilt module into lower casing, secure series wiring by loosening screws incrementally, apply silicone adhesive, fix top fiberboard, then fully insert into casing.

Plug sensing wire terminals into sockets and secure with adhesive.

Use a voltage tester to measure the maximum and minimum cell voltage difference of the battery pack (≤15 mV), followed by open-circuit voltage, AC impedance, and charge/discharge (including overcurrent) tests.

Stabilize performance through cycling and screen for defects pre-final assembly.

Attach top cover to casing with screws.

Verify communication, output voltage, temperature sensing, discharge curves, and leakage.

Inspect surface for flaws, check display buttons for smooth operation (no sticking).

Label units, place in foam-lined boxes, seal in PE bags with desiccant, add top foam padding.

Box approved units and dispatch.