Automotive Battery Assembly Line

Challenges and Client Requirements

Understanding their social mission and commitment to green energy use for environmental protection, our Client boldly transitioned from gasoline-powered to electric vehicles. This was not only a challenging step but also required a comprehensive transformation in the production process, with the pressure to complete it quickly to launch the new product.

The challenge was even more significant as the Client is one of the pioneers in developing domestic electric vehicles. The lack of specialized documentation and production experience made the task more challenging.

In this journey, ETEK was not just a partner but also a reliable companion, ready to face any difficulties with the Client to realize shared goals and introduce innovative solutions at every development stage.

Technology Leadership – Partnering with Clients

With over 20 years of experience in construction and development, we have applied our in-depth expertise and collaborated with the world’s leading partners in the field. Along with our commitment to closely accompany our Client, we have delivered solutions that fully meet their requirements.

Additionally, we also proactively proposed better alternatives and replacement solutions. All aimed towards our core objectives: COST OPTIMIZATION – QUALITY ASSURANCE – TIMELY PROGRESS.

Core Technologies Enabling Our Success in This Project:

• Cell Sorting Technology: The battery packs are assembled from many individual cells, and the quality of these cells is crucial. Thanks to integrating modern testing technology from reputable units, we ensure strict control of each cell. This helps detect potential early errors and ensures uniformity, preventing any mix-up of cell types during assembly.
• Spot Welding Technology: We use specialized welding robots from a reputable, world-leading brand known for its expertise in automation technology. To ensure optimal quality, our programming engineers worked closely with the brand’s experts to set the most accurate and optimal welding parameters. The result is that each welding point achieves high precision, ensuring stability and superior durability throughout the assembly process.
• End-of-Line (EOL) Testing Technology: We collaborate with a leading EOL testing equipment provider to ensure accurate and reliable measurement results. The testing process is comprehensively designed, including crucial features such as current and voltage measurement, continuity testing, temperature reading, and comparison, among other parameters. This helps us control the quality of products, meeting the highest standards before leaving the factory.
• Production Line Control System: The system is built by combining modern hardware devices (such as computers, PLCs, readers, etc.) with advanced control software. Thanks to its real-time data collection and retrieval capability, the system allows clients to visually and accurately monitor the entire production line. This enables early detection of anomalies and timely adjustments, ensuring efficiency and optimizing production.

Thanks to the synchronized application of these technologies, we delivered a comprehensive production solution, contributing to the project’s success.

Challenges During Implementation

The project was implemented amid the complex developments of the COVID-19 pandemic, which spread across many regions in the country. Pandemic prevention measures were a top priority, causing significant challenges for normal production activities. To ensure the project’s timeline, we quickly introduced a series of flexible solutions to adapt and maintain work efficiency.

Our extensive experience from previous electrical and electronics assembly projects helped us master core technologies, quickly grasp technical requirements, and proactively address any issues, ensuring the project was completed on schedule with the highest quality.

Achieved Success

We successfully built a comprehensive assembly solution with full features, from cell sorting, assembly, gluing, and testing to EOL testing. The line operates continuously and stably. The line helped the Client address labor shortages and enhance production capacity.

The application of vision checks and production tracking software allowed us to control production conditions in real time. This helped the Client avoid human errors and make timely production adjustments.

This success not only demonstrated our solidarity and determination to overcome difficulties but also affirmed our capabilities in the eyes of our clients. This lays a solid foundation for future projects, opening up many sustainable cooperation and development opportunities.

Plans for the Future

Following the successful operation of the automated line, it has demonstrated the superior benefits of this technology. Its effectiveness in production not only reinforced the Client’s confidence in the value of automation but also encouraged them to plan to expand this technology to other production stages quickly.

The line has been expanded to include other client car and motorcycle battery models. Many subsequent solutions allowed the integration of multiple models on one assembly line, helping the Client optimize costs.

In addition to automotive and motorcycle battery assembly, we have proposed many solutions to automate the assembly of various parts, such as glass installation, tire fitting, and seat assembly.