New Energy Battery Module Assembly and Testing Guide

This document provides a comprehensive guide for assembling and testing a new energy battery module, specifically a 1P13S configuration using 280Ah cells. The process begins with module stacking, where 52 cells are grouped into four modules of 13 cells each. Key steps include attaching end plate insulation sheets, positioning end plates, applying foam tape between cells, and securing the stack with steel straps. After stacking, output terminal bases and connector support bases are installed, followed by CCS (Cell Connection System) installation using integrated busbars A and B. Laser welding is performed with specified parameters. The module then undergoes rigorous testing, including appearance, dimension, weight, air tightness (battery pack and liquid cooling plate), high voltage short circuit, insulation resistance, dielectric withstand, potential equalization, DCR, and capacity tests. Finally, the module is prepared for enclosure by attaching bottom insulation sheets and applying thermal conductive structural adhesive. This guide ensures proper assembly, safety, and performance validation for new energy battery systems.