Customer:
Bajaj Auto Ltd., Aurangabad, India – A leading manufacturer of electric vehicles, including the Bajaj Chetak electric scooter.
Project Overview:
Design and implementation of a Fully Automated Battery Cell Sorting Machine to streamline the production of battery packs used in electric two-wheelers.
Challenges:
Handling Sensitivity: Need to sort Cylindrical Cell smoothly and precisely to avoid physical damage or alteration in internal chemistry.
High Production Volumes: Assembly lines demanded high-speed sorting to avoid bottlenecks.
Quality Assurance: Ensuring that only qualified cells with specific electrical parameters proceed to assembly.
Cost Efficiency: Reduction in manual labor and minimization of human error.
Solution:
Maestrotech delivered a fully automated cell sorting system equipped with patented technology to meet Bajaj’s production and quality needs.
Key Metrics:
Automated Sorting: Cells are automatically sorted based on parameters such as Voltage, Internal Resistance (IR), and K-value.
Precision Handling: Advanced automated pick & place and sensor-based alignment ensure accurate positioning and smooth movement of cells.
Data Traceability: Every cell tested and sorted is traceable through a complete data logging system.
Multi-Cell Compatibility: Capable of sorting multivariate cell types Cylindrical
Custom Engineering: Tailored to Bajaj’s specific line integration and throughput requirements.
Test Findings & Engineering Insights:
During the development and testing phase in collaboration with Bajaj’s R&D team, several important observations were made:
1) Repeat Testing Behavior (Hioki Tester):
When tested multiple times with a Hioki tester (which operates at 10,000 Hz), it was observed that:
Voltage readings increased, and Resistance values decreased after each test.
Reason: The high-frequency testing current slightly energizes the cells, affecting subsequent readings.
2) Temperature Impact on Testing:
Resistance measurements vary with temperature.
At higher temperatures, cell resistance decreases, which can affect grading if not accounted for.
Advice:
Maintain consistent testing temperatures to ensure reliable and comparable resistance measurements.
3) Importance of Smooth Cell Handling:
If cells are dropped via gravity conveyors or allowed to rotate during sorting, they may suffer:
- Dent marks
- Internal chemistry alterations
Maestrotech’s system ensures non-impact, controlled movement to preserve cell integrity and performance.
Results & Benefits:
- Zero Human Error: Fully automated process ensures consistent and accurate sorting.
- Operational Cost Reduction: Reduced dependence on manual labor, resulting in improved ROI.
- Improved Cell Quality Assurance: Handling precautions and precision testing eliminate cell damage and enhance final battery performance.
Conclusion:
Through patented automation technology, Maestrotech’s advanced automated sorting solution helped Bajaj Auto scale its electric vehicle battery assembly with greater efficiency, accuracy, and cost-effectiveness, while ensuring cell health and consistency.