In today’s fast-growing new energy industry, the PACK process has become the key to evaluating the safety and reliability of battery systems. EverExceed, committed to delivering safe and reliable energy storage solutions, continuously optimizes PACK design and processes with years of expertise to ensure outstanding performance in global markets.

Core Objectives of the PACK Process

Safety: EverExceed battery packs undergo multi-layer protection and rigorous testing to ensure no fire or explosion under normal, abusive, or fault conditions.
Consistency: Precision cell sorting and intelligent balancing minimize cell differences, unlocking optimal overall performance.
Reliability: Verified under vibration, impact, and thermal shock conditions to guarantee long cycle life and stability.
Energy Density: Optimized structural and system design improves volumetric and gravimetric energy density for higher economic value.

EverExceed PACK Process Workflow

1. Cell Pre-treatment & Sorting
Starting with incoming inspection, EverExceed strictly controls quality:
- Resting and OCV measurement to remove abnormal cells;
- Full parameter sorting (capacity, resistance, self-discharge rate);
- Precision grouping to ensure high consistency (capacity, voltage, and resistance differences controlled within 0.5%).
2. Module Assembly
After sorting, cells are assembled into modules:
- Stacking with accurate fixture positioning;
- Laser/ultrasonic welding or bolted connections for stable, low-resistance electrical links;
- Installation of sampling wires and BMS for accurate monitoring.
3. Module Testing
Every module must pass 100% testing:
- Insulation testing for electrical safety;
- Voltage/resistance re-test to eliminate assembly damage;
- EOL testing to verify charge-discharge performance.
4. System Assembly
EverExceed adopts standardized, modular design:
- Series/parallel connection to meet voltage and capacity requirements;
- Enclosure assembly with lightweight but strong aluminum or steel structures;
- Harness and sensor wiring routed neatly for durability and anti-interference.
5. Final EOL Testing
The last and most critical step to ensure pack quality:
- BMS functionality test: balancing, relay control, SOC estimation;
- Safety tests: insulation withstand voltage, ground resistance, IP67/IP68 protection level;
- Leak-tightness test for dustproof and waterproof verification;
- Full charge-discharge cycle test for capacity and efficiency validation.

EverExceed Advantages

With advanced production lines, strict quality management, and global delivery experience, EverExceed PACK solutions are widely applied in UPS backup power, data centers, industrial storage, solar and wind systems. We focus not only on single cell consistency, but also on system-level safety and intelligence, ensuring long service life and higher efficiency for customers worldwide.
The PACK process is more than a production workflow — it is EverExceed’s commitment to safety, reliability, and performance. Through continuous innovation and strict control, EverExceed will keep delivering high-quality, highly safe, and highly consistent energy storage systems to global customers.