Introduction

Lithium-ion battery packs are the core of energy storage systems. Performance, safety, and longevity depend on careful design and precise manufacturing.

Step 1: Cell Selection

• High-quality cells selected based on capacity, voltage, and chemistry

• Cells are tested for voltage, capacity, and internal resistance

• Only uniform cells are used in a pack

Step 2: Module Assembly

• Cells connected in series and parallel to achieve desired voltage and capacity

• Connections made using laser welding, spot welding, or mechanical methods

• Modules enclosed in protective casing

Step 3: BMS Integration

• BMS monitors voltage, current, temperature, and state of charge

• Protects against overcharge, over-discharge, overcurrent, and overheating

• Balances charging and discharging across cells

Step 4: Thermal Management and Safety

• Heat sinks, cooling plates, or phase change materials used

• Fuses, circuit breakers, and fire-resistant casings installed

Step 5: Final Testing and Quality Control

• Charge/discharge cycles, voltage and current stability, and safety tests performed

• Only packs meeting standards are shipped

Conclusion

Battery pack production requires careful cell selection, assembly, BMS integration, thermal management, and rigorous testing for safe, reliable, and long-lasting packs.