Manufacturing

High efficiency, Sophisticated technology, and Uncompromising quality control lie at the very heart of Roche Energy's manufacturing philosophy. Whether battery pack or system integration, we create lasting value for our customers through strict IPQC and lean manufacturing.

Production Capacity

As a trusted OEM partner, we understand that each client's needs are distinctive, and that's why we approach every project with a personalized touch. Roche Energy's production factory is equipped with multiple production lines to handle different types of customer purchase orders, ranging from manual lines to fully automatic production.

40GWh 1 Automatic Line (2 sides) : 16.5 GWh 4 Half-Automatic Lines : 23.5 GWh
35PPM Max takt time : 35 PPM
1/10000 Product Defective Rate is 1/10000
90secs Produce one 1P52S pack for every 90 secs

Manufacturing Process

  • Cell Loading
  • Module Handling
  • Module to Pack
  • Automatic Gluing System
  • Automatic Tightening Station
  • Fly Welding

Cell Loading

Distance measurement system with robot arm to insure the cell loading precision, safety, and efficiency.

Module Handling

Module loading and unloading adopts CCD vision system, automatically finds the module mark point, and compensates the position of the manipulator to grab the module.

Module to Pack

Automatic boxing saves manpower, improves the accuracy of module boxing, and reduces the risk of product collision.

Automatic Gluing System

Using the robot to apply glue to improve the accuracy of glue application, and the accuracy range is <0.5mm

Adopt 55 gallon glue supply mode to reduce the time of changing glue.

Automatic Tightening Station

Positioning of the screw position and enable the corresponding torque at the corresponding position.

Fly Welding

Flying welding can customize the weld form, optimize the strength of the weld after welding, increase the flexibility of design and process, and can be applied to any welding form and any welding direction.

Technology

Fly Welding

Most advanced welding technology across the whole industry provides extreme welding speed.

 

Traditional Welding

Fly Welding

LDD

LDD Inline Coherent Imaging (ICI) technology is the only technology which can measure the following items at the same time.

Pre-Welding

 

Weld Position

Problem

  • Weld offset
  • Excessive weld gap
  • Misalignment

Height of Parts

Problem

  • Welding height deviation
  • Clamping/movement mechanism abnormality
  • Deformation of parts

 

Welding Process

 

Weld Depth

Problem

  • Excessive depth of weld / Shallow depth of weld
  • Fluctuations in the depth of welding due to welding instability

 

Post-Welding

 

Surface Height

Problem

  • Excessive margin height
  • Burst holes/Dents

Width of Parts

Problem

  • Welding height deviation
  • Clamping/Movement mechanism abnormality
  • Deformation of parts

Annular Beam Technology

The annular beam technology employs an innovative approach aimed at mitigating the issue of spattering during welding processes. Specifically, it triggers a series of beneficial effects by directing an annular beam of light around the welding keyhole. Firstly, this annular beam rapidly vaporizes the metal liquid, generating metal vapor. As this vapor descends, it exerts a downward counterforce on the welding molten pool. This action helps open up the keyhole in the molten pool, resulting in a "Y"-shaped configuration, effectively suppressing surface fluctuations of the molten pool.

This "Y"-shaped keyhole not only reduces fluctuations but also covers the keyhole, preventing the normal outflow of plasma and thereby decreasing the likelihood of spattering. High-speed photography studies reveal that, in comparison to traditional laser beams, the annular beam successfully reduces the proportion of time and the keyhole remains closed from 24% to approximately 2%. The fewer keyhole closures occur, the lower the chances of spattering. Experimental results demonstrate that, compared to traditional laser beams, the annular beam significantly reduces spattering, lowering the probability by more than 92%, particularly eliminating defects caused by substantial spattering, such as quality loss and pitting.

Intelligent Factory Management

Roche Energy incessant pursuit of quality and efficency are inseparable from its meticulously designed Manufacturing Execution System (MES). The system provides real-time feedback about manufacturing status and all component traceability for in-depth optimization.

Our MES dashboard records and traces every product as it is manufactured in our production process, providing essential information about its material and component makeup, from cell to module to pack. This allows us to track any faults in a product straight back to its origin. It also collects data to support our production optimization efforts and control the production process.

 

Process Engineering Control

Production Information Tracing

Product Quality Control

Production Process Control