Overview

The global new energy vehicle market continues to expand rapidly, driving lithium battery manufacturers to pursue higher capacity, stricter safety standards, and smarter production lines. In the core link of the battery industry chain—the PACK assembly line—industrial monitors have become indispensable human-machine interaction (HMI) and data visualization hubs, replacing fragile commercial displays to meet the extreme requirements of 24/7 operation, strong electromagnetic interference, and harsh environments.

Touch Think, a leading provider of industrial display solutions, recently delivered a customized embedded industrial monitor solution for a top-tier lithium battery integrator’s 2GWh EV battery PACK production line. This solution addresses critical pain points in traditional setups—such as unstable data transmission, frequent downtime, and poor environmental adaptability—while enabling full-process visualization, precise parameter control, and seamless MES/SCADA integration.

Project Background & Challenges

The customer’s new 2GWh PACK line is designed for passenger and commercial vehicle battery packs, covering key processes including module loading, high-voltage EOL testing, and charge-discharge aging. The production environment presents multiple challenges for display equipment:

a. Harsh Conditions: Heavy dust, oil contamination, and wide temperature fluctuations (-10°C to 55°C).

b. Strong EMI: Intense electromagnetic interference from welding robots, high-voltage test equipment, and servo motors.

c. 24/7 Operation: Continuous production with zero tolerance for unplanned downtime.

d. Data Precision: Real-time monitoring of high-precision parameters (insulation resistance, voltage, temperature) with no data loss or delay.

e. System Compatibility: Seamless connection to PLC, MES, and SCADA systems for data upload and recipe download.

Traditional commercial monitors failed to withstand these conditions, suffering from screen flickering, data lag, and frequent failures, which severely impacted production efficiency and product quality consistency.

Touch Think Solution

TPC-M2 Series Embedded Industrial Monitor

After on-site evaluation and technical communication, Touch Think recommended the TPC-M2 series industrial monitor (15.6”/17.3”/19” sizes) as the core display terminal, with a tailored installation and configuration plan for different stations.

Product Highlights

a. Industrial-Grade Reliability: IP65-rated front panel for dust and water resistance; wide operating temperature range (-20°C to 60°C); anti-vibration design compliant with GB/T 2423 standards, ensuring stable operation in harsh environments.

b. High Brightness & Clarity: 1080P high-resolution screen with 700 cd/m² high brightness, delivering clear visibility even in strong workshop light.

c. Strong Anti-EMI Performance: Optimized circuit design to resist electromagnetic interference from high-voltage equipment and robots, ensuring stable data display and transmission.

d. Rich Industrial Interfaces: Equipped with HDMI, VGA, USB 2.0/3.0, RS-232/485, and Gigabit Ethernet ports, supporting seamless connection to PLC, industrial cameras, and MES systems.

e. Flexible Installation: Embedded, wall-mounted, and VESA installation options to adapt to control cabinets, test stations, and central monitoring rooms.

Deployment & Application Scenarios

The solution deployed TPC-M2 industrial monitors at three core stations of the PACK line, achieving full coverage of process monitoring and operation control.

1. Module Loading Control Cabinet (17.3” Embedded Mount Industrial Monitor)

Function: Real-time display of module positioning coordinates, tightening torque/angle parameters, and equipment status; parameter adjustment and recipe switching; one-click start/stop of equipment.

Value: Enables precise control of module loading and tightening processes, reducing assembly errors and improving production efficiency by 15%.

2. High-Voltage EOL Test Cabinet (15.6” Embedded Mount Industrial Monitor)

Function: Dynamic display of insulation resistance, withstand voltage, contact resistance, and voltage acquisition data; real-time curve playback and threshold setting; fault code pop-up and alarm prompt.

Value: Ensures 100% testing coverage of battery pack electrical performance, with test accuracy up to 99.9%, effectively preventing defective products from entering the next stage.

3. Charge-Discharge Aging Cabinet (19” Wall-Mounted Industrial Monitor)

Function: Continuous monitoring of battery pack temperature, voltage, and charge-discharge current during aging; real-time data recording and historical curve query; abnormal temperature rise alarm.

Value: Provides data support for battery pack aging performance analysis, ensuring product consistency and safety.

System Integration & Workflow

The TPC-M2 industrial monitor serves as a bridge between on-site equipment and the factory’s digital system.

a. Data Collection: Collects real-time data from PLC, sensors, and test equipment via industrial Ethernet and RS-485.

b. Local Display & Control: Presents data in the form of numbers, curves, and charts; supports on-site parameter setting and equipment operation.

c. Data Upload: Uploads production data, test results, and equipment status to the MES system in real time for production scheduling, quality traceability, and data analysis.

d. Remote Monitoring: Supports remote access via the SCADA system, enabling engineers to monitor production status and troubleshoot faults off-site.

Benefits & Results

Since the deployment of the Touch Think industrial monitor solution, the customer’s 2GWh PACK line has achieved significant improvements in stability, efficiency, and intelligence.

a. Enhanced Stability: The industrial-grade design adapts to harsh environments, achieving 7×24 hours failure-free operation and reducing equipment maintenance by 60%.

b. Improved Production Efficiency: Precise parameter control and real-time monitoring reduce process errors, increasing the line’s overall equipment effectiveness (OEE) by 12%.

c. Guaranteed Product Quality: High-precision data display and test monitoring ensure the consistency and safety of battery packs, with the product defect rate dropping from 0.8% to 0.15%.

d. Accelerated Digital Transformation: Seamless integration with MES/SCADA enables full-process data traceability and intelligent management, laying a foundation for the customer’s smart factory construction.

Conclusion

In the high-standard production scenario of EV battery PACK lines, industrial monitors are no longer just display tools but core components of the production line’s digital and intelligent transformation.

Touch Think’s TPC-M2 series industrial monitors, with industrial-grade reliability, high-precision display, and rich connectivity, provide a stable and efficient HMI solution for lithium battery manufacturers.

This 2GWh PACK line case fully verifies the applicability and value of Touch Think industrial monitors in new energy battery production scenarios. In the future, Touch Think will continue to optimize product performance and customization capabilities, helping more lithium battery enterprises achieve efficient, stable, and intelligent production line upgrades.