VISIT TO BTS – BATTERY TECHNOLOGY SOURCE

Camila Gusmão. Was responsible for international sales for Revista Pb-S.AMÉRICA and FENIBAT, and is currently on sabbatical.

On a recent visit to the Battery Technology Source (BTS) factory in Taichung, Taiwan, Pb-S.America magazine had the opportunity to delve into the innovations and technological advancements that position BTS as a key player in the battery manufacturing machinery sector.

BTS has extensive experience in automating the lead-acid battery manufacturing process and is a pioneer in introducing technologies such as servo-controlled welding and implementing Industry 4.0 solutions.

We were welcomed by Emily Ho, Director of BTS, Alvin Huang, CEO, Daniel Huang, General Manager, and Briaxis Mendes, then the sales manager for the company. We also had the pleasure of meeting several other members of the BTS team.

The visit began with a presentation by Briaxis on the company's history, its pillars, and products. Following the presentation, we toured the factory to witness firsthand the results of many years of dedication. This report details what we learned and saw, offering a comprehensive view of BTS’s capabilities and achievements, providing valuable information for battery manufacturers.

BTS was founded in 2007 when a group of professionals with over 20 years of experience in the lead-acid battery sector came together to create a company focused on automating the battery manufacturing process. Yuan Charm Enterprises Co. Ltd. was established in Taichung, the industrial heart of Taiwan and its second-largest city. In 2008, to facilitate international expansion, the brand Battery Technology Source (BTS) was introduced with the slogan "Source of Innovation," reflecting a philosophy of continuous innovation and customer focus.

Briaxis also spoke of BTS’s pride in its origins, as Taiwan is one of the most important technological hubs in the world, with a highly experienced plastic industry, which is how BTS was founded, through plastic injection.

BTS workshop

BTS has continued to grow, opening an office in Jakarta in 2009 to meet Indonesia’s growing demand for advanced battery technologies. After contributing to the establishment of several battery factories in South and Southeast Asia, international expansion continued with major projects in South America, Africa, and Australia. Today, BTS products are present in more than 20 countries, consolidating its global position in the battery manufacturing market.

BTS primarily worked with production line machinery until 2013 when they launched an advanced line of plate manufacturing equipment, including plates cutting, slitting, and brushing machines.

In 2018, the company introduced one of its most significant innovations: a servo-controlled weld distance control system, which enhances the precision of the cell welding process, thereby improving battery quality and stability.

Controlling weld parameters is a highly complex task, often encountering issues such as air bubbles, splatter, cracks, and channel formation. Motorcycle batteries require even greater welding precision due to their smaller size. Since the primary product for most BTS customers is motorcycle batteries, the company invested significantly in technology and dedicated a lot of time to solve these issues, becoming an expert in welding.

BTS technicians developed various techniques to calculate clamp distance, weld time, and clamp pressure. They focused on modifying clamp regulation and electrode design.

Clamps in the BTS’s semiautomatic car battery intercell welder

Initially, pneumatic cylinder-controlled distance was used, but residual air in the cylinder caused premature stopping or excessive pressure. Later, hydraulic systems were adopted, which were imprecise and had complex maintenance. Servo motors, being more precise and electronically controlled, offered exact positioning and speed control, with simpler configuration and maintenance. In case of problems, they can simply be replaced. BTS also developed formulas to calculate welding parameters, customized for each client.

The industry has evolved significantly, with BTS playing a crucial role.

Taiwanese companies, accessing cutting-edge electronic products, began testing servo motors around six years ago, being the first globally to use this technology in motorcycle battery factories. The second battery manufacturer to adopt this technology was a BTS customer from Brazil.

Beyond quality, technology, and innovation, efficient communication with customers and practical machine control are fundamental at BTS. In 2019, the company launched new "smart" assembly lines incorporating Industry 4.0 functionalities, offering advanced product tracking.

The new smart assembly lines allow:

? Live production reports sent to factory servers, displaying test results and welding parameters;

? Each machine can be accessed via VNC or a dedicated app, providing real-time production information;

? Engineers and programmers can remotely update software and provide technical assistance.

Maintenance and quality control procedures are simplified:

? Production goals can be set, and FPY (first-pass yield) can be calculated in real-time;

? Machines automatically remind operators to replace consumables after a certain number of cycles;

? Batteries identified with a QR or Data Matrix code can be tracked along the assembly line, providing detailed incident information and other useful data;

? Parameters and configurations for each battery type can be saved as recipes for future use, saving time.

Additionally, BTS is developing a maintenance app for reporting incidents with images and videos. Machines can be identified by integrated QR codes, facilitating the management of large equipment quantities. And it offers automated controls in multiple languages, customizable to client needs at no extra cost.

BTS offers a wide range of solutions for battery manufacturing, from plate and grid production equipment to high-speed automatic assembly lines for automotive, industrial, and motorcycle batteries. Their products include acid filling and leveling devices, charging and formation systems, testing equipment, packaging machines, as well as battery parts and consumables.

In 2020, BTS introduced the HM-20AMSX, the world's fastest heat sealing machine for motorcycle batteries, capable of sealing up to 10 batteries per minute, thanks to an innovative servo positioning system.

BTS’s high standards extend to their suppliers, highlighting the stainless-steel SUS 316L used in their filling machines, resistant to acids and ensuring greater durability. BTS developed a vacuum filling system with servo control for precise acid injection, an exclusive technology enhancing filling process control and meeting AGM battery demands. One component of BTS filling machines is made from ultra-resistant ceramic, which takes about two months to produce under high temperatures. This advanced ceramic, produced by only two companies globally, has aerospace and aeronautical applications, demonstrating its exceptional durability and resistance.

BTS excels in automating previously manual processes, such as mold release application, and now offers a new lid placement machine that does not require a technician’s presence.

Each BTS machine is custom-made, ensuring personalization and efficiency. The machine manufacturing process at BTS is so customized and meticulous that the design engineer is also responsible for machine assembly.

In 2024, BTS will use robotic technology in their newest Laser Terminal Burning machine (patent pending). They plan to incorporate AI technologies, a robotic arm system, and a carbon emission monitoring system for SDGs (Sustainable Development Goals) as future standard features in the coming years.

The visit to the BTS factory revealed a company committed to innovation and quality, adapting its technologies to the specific needs of each client. With a focus on automation and precision, BTS remains a prominent player in the global lead-acid and lithium-ion battery production machinery, offering solutions that enhance manufacturing efficiency and quality. For battery manufacturers seeking innovation and excellence, BTS stands out as a strategic partner, ready to help elevate production standards and competitiveness in the global market.

Robot prototype

We would like to express our sincere thanks to BTS for hosting us at their factory in Taiwan. Special thanks to Alvin Huang and Briaxis Mendes for the hospitality and the valuable opportunity to see firsthand the innovations and technologies that make BTS a reference in the sector. The experience was extremely enriching and provided valuable insights that will undoubtedly benefit our readers.