1. Li-Ion Polymer Production Line Capability Enhancement
Powering Up Your Mobility
Li-Ion Polymer Production Line
Capability Enhancement
TWS (Technology with Spirit)
Aug 2012

2. Semi-Auto Machine Investment
Background
In 2012, TWS invested resources to significantly improve and enhance its Lithium Polymer pack production lines.
Goals
Eliminate inconsistency and minimize quality issues from manual process.
Assure repeatable and consistency.
Increase production through-put.
Reduce pack conversion cost.

3. Semi-Automation Line Polymer Assembly Line Laser Welding PCM Bending
Functional
Tester
Auto Dimension
Measuring
Hot Bar
Semi-auto Line

4. Semi-Auto Machine Investment
Hot Bar Soldering Machine
Purpose
For soldering FPC/connector to PCM
Capacity
pcs/hour
Quality Goals
Eliminates inconsistency from manual soldering process.
Minimizes or eliminates cold solder joints & solder bridge defects.
Improvement Schedule
4 sets AVIO & Miyachi online
2 sets Miyachi ETA end of August
Video Hot Bar

5. Semi-Auto Machine Investment
Laser Welding Machine
Purpose
Welding PCM to cell.
Capacity
900 pcs/hour
Quality Goals
Avoids quality issues caused by operator(s) handling bare cells & PCMs in manual process.
Eliminates targeting inconsistency from manual welding process.
Minimizes or eliminates welding defects such as blown weld.
Improvement Schedule
2 sets online
Video Laser 1
Video Laser 2

6. Semi-Auto Machine Investment
PCM Auto Folding Machine
Purpose
Folding PCM after assembly of PCM & cell.
Capacity
500 pcs/hour
Quality Goals
Avoids quality issues caused by operator(s) handling bare cells & PCMs in manual process.
Assures repeatable folds and allows tighter pack dimensional tolerance.
Video PCM Fold

7. Semi-Auto Machine Investment
Auto Dimension Measuring & Testing
Purpose
Automated pack dimension measurement & testing.
Capacity
1000 pcs/hour
Quality Goals
Automated process assures repeatability & consistency.
Eliminates quality issues caused by operator(s) touch bare cell pack during the manual operation.
Video Testing
Video Dimension

8. Semi-Auto Machine Investment
Automatic Label Wrapping Machine
Purpose
Label wrapping LiP pack.
Quality Goals
Assures label placement accuracy, minimizes wrinkles & blisters that can occur in the manual process.
Avoids quality issues caused by operator(s) handling core pack in manual process.
Assures repeatable folds and allows tighter pack dimensional tolerance.
Improvement Schedule
1 set ETA mid Aug

9. Next Stage of Automation
Minimize human touching for safety, quality and consistency
Significantly increase output rate
Maximize efficiency of equipment

10. Battery Solutions Roadmap
Softpack
Ultra thin Softpack
(2.5mm )
Polymer Cells
Multi-cell/pack >108
Cell Varieties
Prismatic Cells
Ultra-High Multi- cells/pack >300
Wireless Charging - Qi
Cyclindrical Cells
BMS
w/communication
CAN bus, EnergyBus
Multi-level & Precise protection
BMS
w/communication
SPI/SMbus/RS
BMS
Cell Balancing
Active Cell Balancing
Fuel Gauging
Battery Pack Mfg
High-Auto Assembly
Traditional Assembly
Semi-Auto Assembly
High Multi-cells Assembly
2011
2012
2013

11. Thank You!!