Original Article

Research on the intelligent control system for lithium-ion aluminium shell power battery module stacking

¹ Rajamangala University of Technology Krungthep, Bangkok, Thailand
² Henan Polytechnic Institute, Nanyang, PR China

^* e-mail: adisorn.s@mail.rmutk.ac.th

Received: 27 May 2025
Accepted: 23 July 2025

Abstract

During the stacking and welding process of lithium-ion aluminium shell power battery modules, the accumulation of cell size errors can easily cause the module length to exceed the tolerance range, affecting the module length qualification rate and the stability of welding quality, thereby reducing production efficiency and product reliability. Aiming at solving the problems, this paper proposes an intelligent control system based on a length and pressure dual control strategy for the automatic stacking and welding process of power battery modules. The system adopts a closed-loop feedback mechanism of detection-control-execution, and monitors and dynamically adjusts the module length and welding pressure in real time through the Beckhoff control system (Beckhoff), Siemens PLC (S7-1500) and HMI human-computer interaction system. The experiment takes the D173F120 lithium iron phosphate aluminium shell 9-cell module as the research object to evaluate the influence of the dual control strategy on the stacking accuracy and weld quality. The results show that the system can effectively improve the first-time qualification rate of module stacking, make the weld quality more stable, and reduce the production loss caused by length and pressure deviations. The system reduces the mean time between failures (MTBF) of equipment, shortens the mean time to repair (MTTR), improves the overall equipment efficiency (OEE), and has high application value for the automated production of power battery modules.