E-Motorcycle Power Pack

Unpack materials and sort components.

Full inspection of grouped cells for defects: leakage, scratches, dents, punctures, swelling, etc.

Load into automated equipment; add foam, test, trim, install adapter boards, and align components.

Attach foam between every two cells for protection.

Fold electrode tabs and flatten with a rubber mallet.

Weld tabs using a laser welder; clean residual slag post-welding.

Insert a pry tool sideways at weld points to detect weak bonds; rework if needed.

Wrap module with fiberboard and seal edges with fiber tape.

Secure wiring using a soldering iron.

Lay module flat, slowly slide casing over it, and fully insert into the casing.

Verify cell voltage, temperature, and voltage differentials meet standards.

Cycle batteries to stabilize performance and screen for defects.

Check communication, voltage, temperature sensing, discharge curves, and leakage.

Secure cover with screws and apply sealant evenly for waterproofing.

Inspect for scratches, adhesive residue, stripped screws, and ensure labels are intact/legible.

Repeat functional tests to confirm compliance.

Wrap finished units in PE stretch film and secure pallets with strapping.

Quality-approved units are boxed and dispatched.