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China ADC12 New Energy Storage Battery Pack End Plate ESS Parts - High-Quality Suppliers & Factory Solutions
Process
1. Aluminum Die Casting
Production
Equipment & Material
Equipment: 280T aluminum die casting machine
Material: A380
Material: A380
Process Characteristics
- a. Furnace temperature: 670°±20°, Material handle: 20±2MM;
- b. Secondary materials cannot be used;
- c. Test the material composition to confirm that it is OK and can be produced;
- d. First piece confirmation is required after die-casting.
Precautions
- a. The filling quality of the surface needs to be confirmed. No cold insulation, no bulging, or lack of material for the pillars.
- b. Pay attention to the surface to avoid sticking molds, drawing molds, or poor ejector pin convexity.
- c. The ejector pins are concave by 0-0.2mm for non-machine-added surfaces and 0-0.2mm for machine-added surfaces. The thimble needs to be convex 0-0.2mm.
2. Remove Spout (Saw spout and knock out slag bag)
Production
Equipment & Tools
Wooden Stick / sawing machine / labor protection gloves
Precautions
- a. Pay attention to the surface without crushing or shortage of materials.
- b. Control the appearance and size.
3. IPQC Inspection
Inspection
Test Tools
Caliper, projection, three-dimensional, visual inspection of appearance.
Precautions
Use measuring tools correctly and check dimensions according to drawings.
4. Grinding
Production
Process Description & Equipment
The sharp corners of the product are chamfered, deburred, non-machined ejector pins are sharpened, and polished to smooth the appearance.
Equipment: wind grinder, 120# sandpaper
Equipment: wind grinder, 120# sandpaper
Precautions
No processing should be missed, no sharp corners or burrs should be removed, and the R corners should be connected smoothly.
5. Shaping
Production
Equipment
Knife-edge ruler, shaping fixture
Precautions
Within 0.25mm of the front plane of the product
6. IPQC Inspection
Inspection
Process Description
Visual inspection of appearance
7. CNC (CNC machining + Deburring + cleaning)
Production
Process Description & Equipment
CNC machining + Tapping of 2 through holes for M3 teeth
Equipment: Tapping Machines/M3 Taps, Burr knife/Ultrasonic cleaning tank/Air gun.
Equipment: Tapping Machines/M3 Taps, Burr knife/Ultrasonic cleaning tank/Air gun.
Precautions
- a. Do not over-cut or miss processing;
- b. Be careful not to scratch or burr the surface;
- c. Guaranteed dimensional and form tolerances.
8. Laser Engraving Two O-port Location Planes
Production
Equipment
Laser engraving machine, laser engraving fixture
Note
- a. Check that there can be no burrs, particles, aluminum chips on the edge of the O-shaped orifice;
- b. The plane should be complete laser engraving, and the surface after laser engraving is not allowed to be polluted with oil and black marks!
9. 100% Material Inspection - Appearance Visual Inspection
Inspection
Note
- a. Appearance should be inspected according to the sample, and the surface should be free from dirt, scratches and defects.
- b. The tooth pattern should be in accordance with the checking of through and through rule.
- c. The products are put into the blister tray, covered with white rice paper and then packed into boxes.
10. IPQC Inspection
Inspection
Process Description
Visual inspection of appearance
11. Full Inspection of Appearance + Packaging
Inspection
Description & Equipment
Comprehensive inspection of products and packaging
Equipment: Carton, Knife card, Clapboard, bubble bag
Equipment: Carton, Knife card, Clapboard, bubble bag
Note
- a. The appearance shall be inspected according to the sample. The surface shall be free of dirt, scratches, dents and defects, and the glue dispensing shall be even and without defects!
- b. The tooth pattern must comply with the pass-and-stop inspection.
- c. The product is placed in the knife card, covered with flat cardboard on the upper layer, and then packaged.
12. FQC Inspection
Inspection
Test Tools
Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection
Note
Whether the measuring tool is within the calibration period.
13. Shipping
Shipping
Precautions
- a. Make sure the quantity is the same as order.
- b. Label and stamp on the outer box
- c. Provide a shipping report.
14. OQC Shipping Inspection
Inspection
Test Tools
Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection
Precautions
Whether the measuring tool is within the calibration period. Whether it is consistent with SIP requirements and customer requirements.
Frequently Asked Questions (FAQ)
Q1: What materials and machinery are used during the aluminum die casting process?
During the initial die casting phase, a 280T aluminum die casting machine is utilized with high-quality A380 material. The process requires maintaining a strict furnace temperature of 670°±20° and a material handle of 20±2MM. The use of secondary materials is strictly prohibited to ensure structural integrity.
Q2: How is the quality of the product surface verified during the initial steps?
Surface quality is strictly monitored to ensure there is no cold insulation, bulging, or lack of material for the structural pillars. Additionally, inspections are performed to prevent issues such as sticking molds, drawing molds, or improper ejector pin convexity. Non-machine-added surfaces are kept within 0-0.2mm concavity.
Q3: What precautions are taken during CNC machining and tapping?
For CNC machining and tapping of the two M3 through holes, operators must verify that no over-cutting or missed processing occurs. Special care is taken to avoid surface scratches or burrs while guaranteeing strict dimensional tolerances and form accuracy.
Q4: What are the quality requirements for the laser engraving stage?
During the laser engraving of the two O-port location planes, operators must verify that the edges of the O-shaped orifice are free of burrs, particles, and aluminum chips. The engraving must be complete, and the surface must not be contaminated with oil or black marks.
Q5: How are the finished products packaged and inspected prior to shipping?
Before shipping, products undergo 100% visual inspection and final FQC/OQC checks using calipers, projections, needle gauges, and tooth gauges. The products are packaged using protective knife cards, blister trays, flat cardboard, or bubble bags in sturdy cartons to prevent scratches, dents, and surface defects.