With the widespread adoption of CTP (cell – to-pack) and CTC (cell -to- chassis) technologies in new energy vehicles, battery packs are becoming increasingly integrated, often weighing hundreds of kilograms. However, when these vehicles enter the repair or recycling process, a thorny problem arises for industry professionals: how to safely and efficiently handle these heavy and complex integrated battery packs? Traditional methods involving overhead cranes and manual pushing not only struggle to achieve precise posture adjustments but also pose risks of battery pack drops, damage, and even accidents.
As a professional technical service provider with over a decade of experience in the new energy aftermarket, Guheng Energy understands this pain point. Our battery pack flipping and dismantling machine is designed to systematically solve the challenges of lifting, flipping, and precise positioning of heavy battery packs during dismantling, creating optimal working conditions for subsequent processes.
Real-world Challenges of Disassembling Integrated Battery Packs
Heavy-duty Operations Bring Challenges
Currently, mainstream new energy vehicle battery packs typically weigh between 300kg and 500kg or more. During maintenance or disassembly, whether removing the top cover, handling the water-cooling plate, or separating modules, frequent adjustments to the battery pack’s orientation are unavoidable.
Traditionally, operators often need to use a crane to lift the battery pack and then manually push it to rotate. This is not only inefficient but also prone to causing the battery pack to shake and bump due to the difficulty in controlling the center of gravity, resulting in hidden damage to the internal cells and even the risk of short circuits.
Precision Limitations of Traditional Tools
While some simple flipping frames on the market offer limited flipping angles, most use segmented positioning, making it impossible to achieve stable hovering at any angle. When precise removal of high-voltage connectors on one side or cleaning of structural adhesive is required, the shaking of the equipment itself becomes an obstacle to delicate operations.
The Core Technology of Guheng Energy’s Battery Pack Flipping and Disassembly Machine
To address the aforementioned pain points, the battery pack flipping and disassembly machine developed by Guheng Energy is not a simple mechanical replacement, but a systematic solution integrating precision servo control technology. It can safely handle battery packs of various specifications with a weight not exceeding 2.0T and a width ranging from 500 to 2300mm (length not exceeding 2500mm).
Full Servo Drive System: The Foundation For Smooth Lifting and Arbitrary Tilting
We understand that the key to handling heavy battery packs lies in “stability” and “precision.” Therefore, our battery pack flipping and disassembly machine employs servo control systems for its X, Y, and Z axes. The core advantage of this design is:
- Smooth and shock-free lifting: The servo motor can adjust the output torque in real time according to the actual weight of the battery pack. Combined with the high-precision ball screw, it ensures smooth and stable lifting and lowering within a maximum stroke of 1650mm, eliminating the “nodding” or “slipping” phenomenon caused by gravity-induced speed loss, and achieving true battery pack safety handling.
- True arbitrary angle rotation: Unlike devices that can only stop at fixed positions , the closed-loop control characteristics of the servo system allow the operator to suspend the battery pack at any angle in space. Whether it’s to remove the cooling pipes at the bottom or to inspect the BMS module on the side, the most ergonomic “golden working posture” can be found.
Precision Rotation: Providing a Stable Platform for Intricate Disassembly
“Precise stopping” is a core indicator of equipment performance, especially when removing high-pressure bolts or cutting the casing; even the slightest movement can have serious consequences. Guheng Energy’s battery pack flipping and dismantling machine ensures superior stability through the following design:
- Rigid structure and multi-point support: The equipment itself has a large structural redundancy and a high safety factor. Its clamping range covers 500-2300mm , and it can form stable support from all sides of the battery pack through adjustable clamps, effectively suppressing inertial swaying during the flipping process.
- Power failure position holding: The servo system’s built-in braking device can be activated instantly in the event of a sudden power failure, firmly locking the battery pack in the current position, providing a crucial last line of defense for on-site operations.
Multi-functional: Reconstructing and Disassembling Workflow
The value of a battery pack flipping and disassembly machine lies not only in its flipping and lifting capabilities, but also in its high degree of functional integration. It can complete multiple processes from disassembly to module separation in a single step.
- Battery pack securing and lifting: The battery pack to be disassembled is pushed into the equipment and quickly clamped by a wide-range adjustable clamp. Subsequently, servo control smoothly lifts it to the optimal ergonomic operating height.
- Posture optimization and precision operation: Based on the current step (such as opening the cover, removing the top cover, removing the water cooling plate), the battery pack is driven to rotate in three-dimensional space through the control panel to find the best operating angle and achieve precise rotation and stopping.
- Water-cooled plate removal and module separation: When separating modules fixed by structural adhesive, maintaining a stable posture is a prerequisite. At this time, the Z-axis jacking function of the equipment (maximum jacking/pulling force ≤1.5T) can be activated, in conjunction with the integrated electric hoist (maximum lifting weight ≤2.0T), to safely and efficiently complete the ejection, pulling out, and hoisting transfer of the module.
This design, which integrates lifting, flipping, module ejection, and hoisting functions, significantly improves the utilization of production line space and the continuity of work processes.
Conclusion
From “can it be disassembled?” to “how to disassemble safely and efficiently”, Guheng Energy is committed to solving practical problems in the new energy aftermarket service with precise and reliable equipment technology. Our battery pack flipping and disassembling machine is not just a piece of equipment, but a key bridge connecting scrapped battery packs with renewable resources, and connecting complex faults with precise repairs.
Through smooth lifting, arbitrary angle flipping, and precise stopping driven by a full servo drive, we are helping more and more battery recycling companies and repair service stations transform the integrated battery pack disassembly process into a safe, controllable, and efficient standardized process. This is not only a commitment to the safety of every operator, but also a solid step in promoting the green, circular, and high-quality development of the new energy industry.
Looking to introduce this safe and efficient solution to your battery repair or recycling line? Contact us now or call our national service hotline 400-105-5198 for more product details and customized solutions!
FAQ
Q: What is a battery pack flipping and disassembly machine? In which scenarios is it mainly used?
A: A battery pack flipping and dismantling machine is a specialized piece of equipment used to process power battery packs for new energy vehicles (especially those with integrated cells and casings). It can safely clamp, lift, and flip heavy-duty battery packs, and is mainly used for lifting, flipping, and stopping battery packs, as well as for removing top covers, water-cooling plates, and ejecting and hoisting battery modules. It is one of the core pieces of equipment for battery repair, secondary use, and recycling companies.
Q: What are the specific safety advantages of using this equipment to handle heavy battery packs?
A: There are four main advantages: 1) It replaces high-risk manual labor, avoiding the risk of work-related injuries caused by manually handling and flipping hundreds of kilograms of heavy objects; 2) It prevents accidental falls, eliminating the risk of battery pack swaying during hanging operations through multi-point stable clamping and servo control; 3) It improves the safety of delicate operations, with precise hovering capabilities ensuring stability when removing high-voltage components and effectively reducing the risk of short circuits; 4) It has power failure protection, with the servo system’s braking device locking the position immediately in the event of a sudden power failure, preventing secondary injuries.
Q: Is this device compatible with battery packs from different car models? For example, those with different widths.
A: Yes, compatibility is a key consideration in our design. The battery pack clamping range (width) of our battery pack flipping and disassembly machine can be adjusted widely between 500mm and 2300mm, effectively accommodating various battery pack specifications from passenger cars to commercial vehicles, as long as the battery pack length does not exceed 2500mm.
Q: How to achieve “precise stopping”? Can the equipment stop at any angle?
A: Absolutely. This relies on the X, Y, and Z axis full servo system used in the equipment. This system can monitor the position in real time and respond to commands. When the operator sets a certain angle through the control panel or releases the control button, the servo system will immediately lock the motor shaft and, in conjunction with the mechanical brake, ensure that the heavy battery pack remains firmly stationary at the required angle. Even if the center of gravity shifts, it can remain stable, truly achieving precise hovering at any angle.
Q: Besides flipping, can this device perform other disassembly tasks?
A: Guheng Energy’s battery pack flipping and dismantling machine emphasizes “complete single-machine functionality.” It integrates a one-stop solution: in addition to basic lifting and flipping functions, it also has the capability to remove water-cooling plates. Its Z-axis system can provide a maximum pushing/pulling force of 1.5T for separating adhered modules; the electric hoist integrated on the top of the equipment (maximum lifting capacity of 2.0T) can easily lift and transfer the separated modules, achieving a high degree of integration in the dismantling process.
