How are Lithium Batteries Made Step By Step With Pictures Lithium Battery Manufacturing Process Lithium battery making process,lithium ion battery manufacturing company in india,lithium ion battery recycling process
The use of lithium batteries is done in various devices such as energy storage systems, electric vehicles, toys, cameras, etc. Different devices require batteries of different shapes and sizes, so we find these batteries in various shapes and sizes.
Whether lithium batteries are used in any device anywhere, the process of making all lithium batteries is the same. So today we are going to tell you which components are used to make lithium batteries and how lithium batteries are made.
Components for Lithium battery
First of all, you should know which components are used to make lithium batteries.
Different types of cells are used to make lithium batteries. Various sheets are used to make the body of the lithium battery. Various type holders are used to connect the cells together. The complete list is given below.
- Lithium Cells such as nickel-magnesium-cobalt lithium-ion cells, or NMC cells,
- Lithium iron phosphate, or LFP cells,
- Prismatic cells,
- Cell holders,
- Nickel strips,
- Battery management system, or BMS,
- Wires such as DC wires, sensor wires, etc.
- barley paper, tapes such as FEP tape, Kapton tape, filament tape, double-sided tape, etc.
Different types of bodies such as stainless steel, mild steel, plastic containers, epoxy fiberglass bodies, FEP sheet bodies, heat shrink sheet bodies, etc.
Out of all the components used in lithium batteries, only lithium cells are imported from outside, the rest are manufactured in India.
Machines for making lithium battery
Various types of machines are used to make lithium batteries because different machines are used for different processes from testing the cells used in lithium batteries to welding. The list of all these machines is given below.
- Cell Grading Machine
- Cell Sorting Machine
- Auto-insulating Sticker Pasting Machine
- CCD Inspection Machine
- Automatic Spot Welding Machine
- Automatic Laser Welding Machine
- Battery Testing Machine
How Lithium Batteries Are Made
So now you know about the equipment and processes used to make lithium batteries. Let’s talk about how a complete lithium battery is made using these.
1. Cell Grading
First, the cells used in the lithium battery are graded. In this machine, the cell is fully charged and discharged to test it.
Afterward, the cells are categorized based on their capacity. For example, if we have cells with a voltage of 3.2v, the voltage is checked up to the decimal point, and cells are categorized accordingly. For instance, cells with voltages like 3.23v, 3.25v, and 3.28v are categorized separately.
The reason for separating these cells is that if different voltage cells are used in a lithium battery, it significantly affects the battery’s lifespan. That’s why the voltage of all cells used in the battery is kept the same.
2. Cell Sorting
This process is similar to cell grading. However, in this process, cells are sorted based on their voltage and internal resistance. This ensures that all cells used in the lithium battery have the same voltage and internal resistance.
3. Applying Barley Paper for Insulation
This is a type of insulation paper used to prevent internal short circuits in cells. This process can be done both automatically and manually. Once this paper is applied, the cell is ready to be placed inside the battery.
4. Placing Cells in Cell Holder
Cell holders are used to place cells together. Small square-shaped boxes are made, which are interconnected. Cells are placed inside these and the cell holder is placed above and below the cell. Using the cell holder, any number of cells can be placed in the battery. The larger the battery, the more cells can be placed inside.
5. Inspection of the Cells
After placing the cells in the cell holder, they are inspected to ensure that the positive and negative terminals are correctly placed. If even one cell is incorrectly placed, the entire battery won’t function. A CCD machine is used to check this.
6. Soldering or Welding The Cells
After passing the CCD machine, all cells are connected using support welding. Nickel strips are used for this. This work can be done manually and with the help of machines. Different machines are required for this, which are explained below.
- Manual Spot Welding
In this machine, the operator has to manually weld the battery using a foot pedal, adjusting the manual battery pack and welding each cell one by one. This process takes quite a long time.
- Automatic Spot Welding
In this machine, after attaching the battery pack once, the computer analyzes the automatic battery pack, and all cells are automatically welded. This process is much faster and multiple battery packs can be closed in a short amount of time.
- Automatic Laser Welding
This type of welding is used to connect larger cells. The battery pack is placed in the machine, and after analyzing it on the computer, it is welded automatically using lasers. This entire process is also displayed on the computer, showing which cell is being welded.
Each type of welding method has its advantages and disadvantages. However, it depends on which cell requires which type of welding, and the welding method is selected based on this.
7. Arrange the Lithium Cell Strings
After welding, the battery pack is joined using epoxy sheet insulator paper and different tapes.
However, the battery is not yet complete because lithium batteries cannot be used directly like lead-acid batteries. For this, you need to install a Battery Management System (BMS).
8.Connecting a BMS
Battery Management System (BMS): A Crucial Component of Lithium Batteries, BMS stands for Battery Management System. It is a type of computer circuit that is connected with different strings of batteries. This enables monitoring of cell charging, discharging, heat, etc., ensuring cell safety and enhancing battery life.
It functions like the brain of the entire battery, optimizing and protecting it, as well as monitoring its health.
Currently, there are two types of BMS available in the market:
Normal BMS: This is a basic Battery Management System used in lithium batteries. It automatically optimizes the battery and helps in enhancing its health and lifespan.
Smart BMS: In Smart Battery Management Systems, various sensors are included, and a Bluetooth transmitter device is attached. This allows all the battery data to be viewed on your phone.
9. Lithium Battery Testing
Once the Battery Management System is installed, the lithium battery is fully prepared for use. It undergoes a thorough test to ensure it is functioning correctly.
A machine is used for battery testing, where the battery is charged and discharged, and its computerized report is generated. If the battery passes this test, it is ready for use.
10. Lithium Battery Body
After passing the battery test, it is placed inside a casing. This casing can be made of stainless steel, mild carbon steel, or plastic, depending on the battery’s size and weight. Larger and heavier lithium batteries are placed in stainless steel casings, while smaller ones might use plastic containers.
Conclusion
So, this was the information about making lithium batteries. Hopefully, you now understand how lithium batteries are created and which components are used.
If you want to use lithium batteries at home, you can, as they offer numerous advantages. Lithium batteries are significantly lighter in weight. Their lifespan is much longer compared to lead-acid batteries. They require almost no maintenance; you just need to install them once and put them to use.
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