PFD

PROCESS FLOW DIAGRAM
Model Part Number Drg Stage/Rev/Date Part Description Rev. ST. Date
UP.467F KE242080 C2 1B 10.10.2023 BATTERY PACK ASSY 00 CR 12.12.2023
Op Operation Description Machine Process Product Characteristics Process Characteristics

No Flow
0005 BTM CELL HOLDER INSERT BATTERY ORIENTATION OF INSERTS(BIGGER SIDE IN) SENSORS INTERLOCK & ALARM AGAINST
ASSLY AND LOADING ASSY PART T
CONVYR-LINE
2 (5065248)
NO OF INSERTS ON BOTTOM CELL HOLDER BOTTOM CELL HOLDER REVERSE LOADING
USE OF CORRECT INSERTS BOTOM COVER PROPER SEATING
RESTING BLOCK CHA.OVER-MODEL TYPE

SELECT
RFID - OK STATUS IN HMI
ANTI-BACK PRESENCE
PNEUMATIC AIR PRESSURE
REPLACEMENT OF MATERIAL DURING MODEL

C/O
0010 BTM CELL HOLDER - LASER LASER QR CODE AS PER TSES 859 NO OF CHARACTERS IN QR 2D
MARKING MARKING-
5065232
SIZE OF THE QR (8*8mm)
SENSING OF SERVO ZEROING PIN (X & Z AXI
OVER TRAVEL SENSOR FUNCTIONING
QR CODE SCANNER FUNCTIONING
HOME POSITION PRECONDITIONS
POWER ON PRECONDITIONS
SAFETY LIGHT CURTAIN FUNCTIONING
PART PRESENCE SENSOR IN GRIPPER
WORKING OF FUME KILLER
FUME KILLER FILTER CLEANING FREQUENCY
FUME KILLER FILTER REPLACEMENT

FREQUENCY
PREPARED BY: BCP CHECKED BY: SA APPROVED BY: MRS
OPERATION INSPECTION TRANSPORT DELAY STORAGE OPERATION & INSPECTON
Page: 1 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
FUNCTIONING OF SAFETY DOOR INTERLOCK
MARKING POSITION (Y-AXIS)
MARKING POSITION (Z-AXIS)
SCANNING POSITION (Y-AXIS)
SCANNING POSITION (Z-AXIS)
PICKING POSITION (Y) LH STATION
PICKING POSITION (Z) LH STATION
GRIPPING POSITIION (Y -AXIS)
GRIPPING POSITION (Z-AXIS)
GRIPPER OPEN SENSOR
GRIPPER CLOSE SENSOR
PART PRESENCE SENSOR IN PALLET-14S7P
SCANNER COVER FORWARD PRESENCE
SCANNER COVER REVERSE PRESENCE
IOT PARAMETERS TRANSFER TO DATA

LOGGER
LASER HEAD DISTANCE TO MARKING

POSITION
FUNCTION OF ENTRY SIDE DOOR
FUNCTION OF EXIT SIDE DOOR
0020 CELL SORTING & CELL CELL SCANNING OF QR CODE CELLS GRADING <5mV G1
SCANNING SORTING-
5065231
CELL OCV RANGE WITHIN MODULE CELLS GRADING <5mV G2
CELL IR RANGE WITHNIN MODULE CELLS GRADING <5mV G3
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
CELL 2D DATA VALIDATION CELLS GRADING <5mV G4
NO DAMAGE ON CELLS CELLS GRADING <5mV G5
NO CELL SHORTCIRCUIT CELLS GRADING <5mV G6
CELLS GRADING <5mV G7
CELL IR SETTING
BOX PRESNECE SENSOR AT LOADING

POSITION
BOX TRAVEL SENSOR OK/NOK ALARM
BOX STOPPER UP DURING TRAVEL
BOX STOPPER DOWN DURING PREVIOUS BOX

AUT
AREA CLEAR SENSOR OK/NOK - INFEED ZONE
AREA CLEAR SENSOR OK/NOK - OP30A ZONE
AREA CLEAR SENSOR OK/NOK - OP30B ZONE
BOX PRESENCE SENSOR AT THE PICKING

POSIT
WORKING OF CAMERA BAR LIGHT DURING

CYCLE
CONVEYOR DIRECTION DURING EMPTY BOX

DISP
UNLOADING CONVEYOR ALIGNMENT SENSOR

STAT
Page: 3 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
REMOVAL OF PERFORATED SHEET FROM THE
BOX
EMPTY BOX PRESENCE FOR UNLOADING
UNLOADING OF EMPTY BOX
ENSURE NO CELLS PRESENT DURING

DISPOSAL
LOADING OF TEMPLATE ON INPUT CELL BOX
CLAMPING OF COTTON BOX
LH INFEED CONVEYOR SPEED
RH INFEED CONVEYOR SPEED
LH LIFTER CONVEYOR SPEED
RH LIFTER CONVEYOR SPEED
LH RETURN CONVEYOR SPEED
RH RETURN CONVEYOR SPEED
WORKING OF LH CONVEYOR STOPPER

CYLINDER
WORKING OF LH CONVEYOR SINGLING

CYLINDE
WORKING OF LH CONVEYOR CLAMP

CYLINDER 1&
WORKING OF LH TILT CONVEYOR TILTER

CYLIN
WORKING OF RH CONVEYOR STOPPER

CYLINDER
WORKING OF RH CONVEYOR SINGLING

CYLINDE
WORKING OF RH CONVEYOR CLAMP

CYLINDER 1&
WORKING OF RH TILT CONVEYOR TILTER

CYLIN
CELL PRESENT AT ROBOT GRIPPER
Page: 4 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
CELL NOT PRESENT AT ROBOT GRIPPER
CAMERA LIGHT INTENSITY
CAMERA CALIBRATION FREQUENCY
ZEROING OF INSPECTION CONVEYOR
WORKING OF MAGNETIC CYLINDER
WORKING OF TILTER CYCLINDER (90 DEG)
WORKING OF BUFFER STATION CYLINDER
WORKING OF 2D STATION LIFTER
WORKING OF 2D STATION LH CYLINDER
WORKING OF 2D STATION RH CYLINDER
WORKING OF HIOKI STATION CELL LEVEL

CYLI
WORKING OF HIOKI STATION LH SLIDE
WORKING OF HIOKI STATION RH SLIDE
WORKING OF CELL ROTATION AT 2D READ

STAT
RFID SENSOR POSITION AT LOADING STATION
RFID SENSOR POSITION AT BUFFER STATION
RFID SENSOR POSITION AT 2D SCAN STATION
RFID SENSOR POSITION AT HIOKI TEST STATI
RFID SENSOR POSITION AT UNLOADING STATI
WORKING OF 2D SCANNER
SCANNER LIGHT INTENSITY
Page: 5 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
FUNCTIONING OF LIGHTS IN 2D STATION
NO DAMAGES IN THE PROBE
HIOKI CALIBRATION
HIOKI PROBE LIFE
NO DAMAGES IN THE CLAMPING PU PADS
PAD LIFE
HIOKI IR OFFSET CORRECTION
HIOKI UNIT CALIBRATION
HIOKI ZERO ADJUSTMENT FREQUENCY
CELL PRESENT AT GANTRY GRIPPER
CELL NOT PRESENT AT GANTRY GRIPPER
GANTRY SPEED
UNLOADING GANTRY FINGER LIFE
FINGER PU COAT CHECK
FUNCTIONING OF AREA SCANNER
GRADING CONVEYOR SPEED
2D SCAN STEPPER MOTOR SPEED
SPACING IN GRADING CONVEYOR
INSPECTION CONV UNLOAD POSITION X AIXS
INSPECTION CONV UNLOAD POSITION Z AIXS
A GRADE CONV1 LOAD POSITION IN X AXIS
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
B GRADE CONV1 LOAD POSITION IN X AXIS
C GRADE CONV1 LOAD POSITION IN X AXIS
TEMP REJECTION CONV LOAD POSITION X

AXIS
PERM REJECTION CONV LOAD POSITION X

AXIS
A GRADE CONV1 LOAD POSITION IN Z AXIS
B GRADE CONV1 LOAD POSITION IN Z AXIS
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
C GRADE CONV1 LOAD POSITION IN Z AXIS
TEMP REJECTION CONV LOAD POSITION X

AXIS
PERM REJECTION CONV LOAD POSITION X

AXIS
PU COATING ON THE CELL PICKING FINGER
0030 CELL LOADING IN BOTTOM CELL POLARITY OF FIRST ROW CELLS (-VE SYMBOL) ROBOT IN SAFE ZONE
CELL HOLDER SORTING-
5065231
PRESENCE OF ALL CELLS ROBOT SPEED
POLARITY SEQUENCE CHANGING
POLARITY SERVO SPEED
FINGER WITH PU COAT
ALL SERVO ZERO PIN IN POSITION
30A: HOME POSITION IN X-AXIS
30A: A GRADE CONV1 UNLOAD POSITION IN X
30A: A GRADE CONV2 UNLOAD POSITION IN X
30A:B GRADE CONV1 UNLOAD POSITION IN X A
30A: B GRADE CONV2 UNLOAD POSITION IN X
30A:C GRADE CONV1 UNLOAD POSITION IN X A
30A: C GRADE CONV2 UNLOAD POSITION IN X
30A: GANTRY LOADING POSITION 1 IN X AXIS
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
30A: GANTRY LOADING POSITION 2 IN X AXIS
30A: HOME POSITION IN Z-AXIS
30A: A GRADE CONV1 UNLOAD POSITION IN ZA
30A: A GRADE CONV2 UNLOAD POSITION IN Z
30A:B GRADE CONV1 UNLOAD POSITION IN Z A
30A: B GRADE CONV2 UNLOAD POSITION IN Z
30A:C GRADE CONV1 UNLOAD POSITION IN Z A
30A: C GRADE CONV2 UNLOAD POSITION IN Z
30A: TILTING AXIS HOME POSITION
30A: TILTING AXIS PLUS 90 DEG POSITION
30A: TILTING AXIS MINUS 90 DEG POSITION
30B: HOME POSITION IN X-AXIS
30B: A GRADE CONV1 UNLOAD POSITION IN X
30B: A GRADE CONV2 UNLOAD POSITION IN X
30B:B GRADE CONV1 UNLOAD POSITION IN X A
30B: B GRADE CONV2 UNLOAD POSITION IN X
30B:C GRADE CONV1 UNLOAD POSITION IN X A
30B: C GRADE CONV2 UNLOAD POSITION IN X
30B: GANTRY LOADING POSITION 1 IN X AXIS
30B: GANTRY LOADING POSITION 2 IN X AXIS
30B: HOME POSITION IN Z-AXIS
Page: 9 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
30B: A GRADE CONV1 UNLOAD POSITION IN ZA
30B: A GRADE CONV2 UNLOAD POSITION IN Z
30B: B GRADE CONV1 UNLOAD POSITION IN Z
30B: B GRADE CONV2 UNLOAD POSITION IN Z
30B: C GRADE CONV1 UNLOAD POSITION IN Z
30B: C GRADE CONV2 UNLOAD POSITION IN Z
30A: TILTING AXIS HOME POSITION
30A: TILTING AXIS PLUS 90 DEG POSITION
30A: TILTING AXIS MINUS 90 DEG POSITION
AREA CLEAR SENSOR POS

ALIGNMENT&FUNCTION
0040 THERMISTOR PASTING-1,2,3& Thermistor PULL OF STRENGTH FUNCTIONING OF SAFETY LIGHT CURTAIN
INSERT ASSY pasting
stations-
5065233
THERMISTOR POSITION ON CELLS FUNCTIONING OF LASER SENSOR AS PER
SEQUE
ORIENTATION OF CABLE STOPPER UP AND DOWN SIGNAL
PASTING OF THERMISTOR STICKER -1 ON CELL PNEUMATIC AIR PRESSURE
PASTING OF THERMISTOR STICKER-2 ON OPERATOR SKILL LEVEL

CABLE
THERMISTOR CABLE BLACK LOCATION PUSH PULL GAUGE CALIBRATION

(X7,Y4)
THERMISTOR CABLE WHITE LOCATION FIXTURE LOCK CONDITION

(X14,Y4
THERMISTOR CABLE RED LOCATION(X8,Y1) RFID - OK STATUS IN HMI
ORIENTATION OF INSERTS( BIGGER SIDE IN)
NO OF INSERTS ON TOP CELL HOLDER
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0050 THERMISTOR PASTING-4 & Thermistor PULL OF STRENGTH FUNCTIONING OF SAFETY LIGHT CURTAIN
ROUTING pasting
stations-
5065233
THERMISTOR POSITION ON CELLS FUNCTIONING OF LASER SENSOR AS PER
SEQUE
ORIENTATION OF CABLE STOPPER UP AND DOWN SIGNAL
PASTING OF THERMISTOR STICKER -1 ON CELL PNEUMATIC AIR PRESSURE
PASTING OF THERMISTOR STICKER-2 ON OPERATOR SKILL LEVEL

CABLE
THERMISTOR CABLE BLUE LOCATION(X1,Y4) PUSH PULL GAUGE CALIBRATION
ROUTING OF THERMISTOR CABLES FIXTURE LOCK CONDITION
0060 TOP CELL HOLDER CLOSING BATTERY NO THERMISTOR BULGE TOP COVER PROPER SEATING
ASSY
CONVYR-LINE
2 (5065248)
FUNCTIONING OF TOP COVER PRESENCE

SENSOR
ANTI-BACK PRESENCE
STOPPER UP AND DOWN SIGNAL
PNEUMATIC AIR PRESSURE
OPERATOR SKILL LEVEL
0065 POLARITY AND INSERT Vision & POLARITY OF FIRST ROW CELLS (-VE SYMBOL) SENSING OF SERVO ZEROING PIN (X & Z AXI
VISION INSPECTION Polarity
Check-5065234
POLARITY OF EACH ROW CELLS OVER TRAVEL SENSOR FUNCTIONING
PRESENCE OF 8 SIGNAL INSERT @BTM HLDR HOME POSITION PRECONDITIONS
PRESENCE OF 7 SIGNAL INSERT @TOP HLDR POWER ON PRECONDITIONS
Page: 11 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
AUTO CYCLE START SIGNAL FROM SERVER SAFETY LIGHT CURTAIN FUNCTIONING
NO TRACEABILITY BYPASS IN HMI RFID - OK STATUS IN HMI
FUNCTIONING OF SAFETY DOOR INTERLOCK
PART PRESENCE SENSOR IN PALLET
IOT PARAMETERS TRANSFER TO DATA

LOGGER
IOT PARAMETERS USL & LSL LIMITS SETTING
FUNCTIONING OF POLARITY CHECK CAMERA
FUNCTIONING OF INSERT CHECK CAMERA
0070 MODULE TIGHTENING(AUTO Cell Holder top PRESENCE OF 6 SCREWS - M4x60 FLANGE BIT SLIP DETECTION - DISABLE ON
STATION) & Bottom HEAD
Tighte-5065235
VERIFICATION OFTIGHTENING TORQUE THREAD DAMAGE DETECTION -DISABLE ON
6SCREWS
TIGHTENING SEQUENCE SCREWHEAD ENGMNT ANGLE STEP1-CW
MODULE WIDTH AFTER TIGHTENING STEP 1 TIGHTENING TORQUE
AUTO CYCLE START SIGNAL FROM SERVER STEP 1 TIGHTENING SPEED
SCREW DISPENSE FROM BOWL FEEDER STEP 2 TIGHTENING TORQUE
TIGHTENING TORQUE IN CONTROLLER STEP 2 TIGHTENING SPEED
NO SCREW HEAD DAMAGE FINAL TIGHTENING TORQUE ANGLE
NO TRACEABILITY BYPASS IN HMI DC TOOL CALIBRATION
0080 INTERCONNECTOR LOADING - Grippers & PRESENCE OF 7 no DUAL ROW OPERATOR SKILL LEVEL
TOP Fixtures for INTERCONNECTOR
Plasma-5065238
LOADING OF DUAL ROW INTR.CNTRS @ LH RH SIDE ORIENTATION -L BEND TOWARDS
SIDE OPTR
LOADING OF DUAL ROW INTR.CNTRS @ RH LHSIDE ORIENTATION -L BEND AWAYFROM

SIDE OPTR
NO DAMAGE ON INTERCONNECTORS
Page: 12 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0090 PLASMA CLEANING - TOP Top Plasma AIR PRESSURE 1
Cleaning-
5065236
AIR PRESSURE 2
CURRENT ZIP1
CURRENT ZIP2
VOLTAGE
ROTATION 1
ROTATION 2
FREQUENCY OF ZIP1
FREQUENCY OF ZIP2
PCT ZIP 1
PCT ZIP 2
PLASME COVERAGE ON MODULE&INTCNTR
0100 GANTRY- TOP SIDE TOP NO DAMAGE ON MODULE HOME POSITION IN X AXIS
WELDING(GA
NTRY-
1)OP100A-
5065239
NO METAL CONTACT B/W GRIPPER AND PART INFEED PICK POSITION -Z1 RH IN X AXIS
MACHINE 1 DROP POS IN X AXIS (Z1)
MACHINE 1 PICK POS IN X AXIS (Z2)
Page: 13 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
OUTFEED DROP POS- Z2 RH IN X AXIS
INFEED PICK POS IN Z1 AXIS
MACHINE 1 DROP POS IN Z AXIS (Z1)
MACHINE 1 PICK POS IN Z AXIS (Z2)
OUTFEED DROP POS- Z2 RH IN Z AXIS
Z1 GRIPPER OPEN POSTION
Z1 GRIPPER CLOSE POSITION
GANTRY SPEED X AXIS
GANTRY SPEED Z1 AXIS
0101 TOP WELDING-A TOP PULLOFF LOAD-(+ve&-ve LV cells)MIN 6 Kgf Z1 AXIS:SQUEEZE TIME -MDB5000
WELDING(GA
NTRY-
1)OP100A-
5065239
WELD NUGGET DIAMETER Z1 AXIS :UP TIME-MDB5000
Page: 14 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
AUTO CYCLE START SIGNAL FROM SERVER Z1 AXIS:WELD TIME-MDB5000
NO TRACEABILITY BYPASS IN HMI Z1 AXIS: DOWN TIME-MDB5000
NO FLASHES Z1 AXIS:HOLD TIME-MDB5000
NO PEEL OFF OF INTERCONNECTOR Z1 AXIS:WELD CURRENT-MDB5000
NO CUT MARKS ON INTERCONNECTOR Z1 AXIS:WELD VOLTAGE-MDB5000
NO.OF.SPOT PER CELL PER SIDE Z1 AXIS:PRECHECK-MDB5000
NO.OF.WELD SPOT PER MODULE Z1 AXIS:PRECHECK VOLTAGE-MDB5000
Z1 AXIS:PRECHECK TIME-MDB5000
Z1 AXIS:PRECHECK PEAK -MDB5000
Z1 AXIS:PRECHECK AVG-MDB5000
Z1 AXIS:SQUEEZE TIME - MU100
Z1 AXIS:WELD TIME- MU100
Z1 AXIS:HOLD TIME- MU100
Z1 AXIS:BEFORE FORCE- MU100
Z1 AXIS:AFTER FORCE- MU100
Z1 AXIS:BEFORE DISPLACEMENT- MU100
Z1 AXIS:AFTER DISPLACEMENT- MU100
Z1 AXIS:DISPLACEMENT- MU100
Z1 AXIS:SCHEDULE SELECTION +VE TERMINAL
Z1 AXIS:SCHEDULE SELECTION -VE TERMINAL
Z2 AXIS: SQUEEZE TIME -MDB5000
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
Z2 AXIS: UP TIME-MDB5000
Z2 AXIS:WELD TIME-MDB5000
Z2 AXIS: DOWN TIME-MDB5000
Z2 AXIS:HOLD TIME-MDB5000
Z2 AXIS:WELD CURRENT-MDB5000
Z2 AXIS:WELD VOLTAGE-MDB5000
Z2AXIS:PRECHECK-MDB5000
Z2 AXIS:PRECHECK VOLTAGE-MDB5000
Z2AXIS:DISPLACEMENT- MU100
Page: 16 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
ELECTRODE CONDITION (No Nickel Depositio
ELECTRODE CHANGE FREQUENCY
MAIN AIR PRESSURE
WELD HEAD AIR PRESSURE FOR COOLING
PROJECTION ELECTRODE GAP BETWEEN RH &

LH
ELECTRODE HEIGHT SETTING
CALIBRATION OF LOAD CELLS
X AXIS REPEATABILITY
Y AXIS REPEATABILITY
Z1 AXIS REPEATABILITY
CALIBRATION OF PUSH PULL GAUGE
INSPECTOR SKILL LEVEL
INTERLOCK OF EMERGENCY BUTTON
INTERLOCK OF TEACHPENDANT EMG BUTTON
INTERLOCK OF SIDE SAFETY DOOR RH
INTERLOCK OF BACK SIDE SAFETY DOOR
WORKING OF ENERGY METER
FIXTURE LOCATION PIN DIAMETER
FIXTURE ORIENTION PIN DIAMETER
Page: 17 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
TIP POLISH FREQUENCY
TIP POLISH EMERY CHANGE FREQUENCY
TIP POLISHING TIME - Z1 HEAD
TP Z1 HEAD - X1 AXIS AT ROUGH
TP Z1 HEAD - X1 AXIS AT SMOOTH
TP Z1 HEAD - X1 AXIS AT BRUSHING
TP Z1 HEAD - Z1 AXIS AT ROUGH&SMOOTH
TP Z1 HEAD - Z1 AXIS AT BRUSHING
PART LOADING POSITIN IN FIXTURE(Y AXIS)
TIP POLISHING FORCE FEEDBACK
CALIBRATION OF LOAD CELL &LVDT SENSOR
CALIBRATION OF WELDCHECKER MM400
TIP POLISHING EMERY SHEET GRADE 800
0102 TOP WELDING-B TOP PULLOFF LOAD-(+ve&-ve LV cells)MIN 6 Kgf Z1 AXIS: SQUEEZE TIME -MDB5000
WELDING(GA
NTRY-1)
OP100B-
5065240
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No Flow
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
MAIN AIR PRESSURE

LH
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No Flow
0103 TOP WELDING-C TOP WELDING PULLOFF LOAD-(+ve&-ve LV cells)MIN 6 Kgf Z1 AXIS: SQUEEZE TIME -MDB5000
(GANTRY-1)
OP100C-
5065241
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No Flow
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No Flow
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No Flow
MAIN AIR PRESSURE

LH
Page: 25 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
TIP POLISHING TIME -Z1 HEAD
0110 FLIPPING Flipping Station NO DAMAGE ON MODULE HOME POSITION IN X AXIS SERVO1
-1-5065242
Page: 26 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
NO METAL CONTACT B/W GRIPPER AND PART RH SIDE ABOVE PART1 POSITION IN X-AXIS S
PART GRIPPING POS IN X AXIS SERVO1
PART UNGRIPPING POS IN X AXIS SERVO1
HOME POSITION IN X AXIS SERVO2
RH SIDE ABOVE PART1 POSITION IN X-AXIS S
PART GRIPPING POS IN X AXIS SERVO2
PART UNGRIPPING POS IN X AXIS SERVO2
HOME POSITION IN Z AXIS
DOWN TO PART GRIPPING POS IN Z AXIS
PART UP POS TO ROTATE IN Z AXIS
PART DOWN POS IN Z AXIS
MID POS W/O PART IN Z AXIS
GANTRY SPEED X-AXIS SERVO 1
GANTRY SPEED X-AXIS SERVO 2
GANTRY SPEED Z-AXIS
0120 INTERCONNECTOR LOADING - Grippers & PRESENCE OF DUAL ROW INTERCONNECTORS OPERATOR SKILL LEVEL
BOTTOM Fixtures for
Plasma-5065238
PRESENCE OF SINGLE ROW RH SIDE ORIENTATION -L BEND TOWARDS
INTERCONNECTORS OPTR
LOADING OF DUAL ROW INTR.CNTRS @ LH LHSIDE ORIENTATION -L BEND AWAYFROM

SIDE OPTR
LOADING OF DUAL ROW INTR.CNTRS @ RH

SIDE
LOADING OF SINGLE +VE INTR.CNTRS @ RH SI
LOADING OF SINGLE -VE INTR.CNTRS @ RH SI
Page: 27 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
LOADING OF SINGLE +VE INTR.CNTRS @ LH SI
LOADING OF SINGLE -VE INTR.CNTRS @ LH SI
NO DAMAGE ON INTERCONNECTORS
0130 PLASMA CLEANING - BOTTOM AIR PRESSURE 1

BOTTOM PLASMA
CLEANING-
5065237
AIR PRESSURE 2
CURRENT ZIP1
CURRENT ZIP2
VOLTAGE
ROTATION 1
ROTATION 2
FREQUENCY OF ZIP1
FREQUENCY OF ZIP2
PCT ZIP 1
PCT ZIP 2
PLASME COVERAGE ON MODULE&INTCNTR
0140 GANTRY - BOTTOM SIDE BOTTOM NO DAMAGE ON MODULE HOME POSITION IN X AXIS
WELDING(GA
NTRY-
2)OP140A-
5065243
NO METAL CONTACT B/W GRIPPER AND PART INFEED PICK POSITION -Z1 RH IN X AXIS
Page: 28 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
OUTFEED DROP POS- Z2 RH IN X AXIS
INFEED PICK POS IN Z1 AXIS
OUTFEED DROP POS- Z2 RH IN Z AXIS
GANTRY SPEED X AXIS
Page: 29 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0141 BOTTOM WELDING-A BOTTOM PULLOFF LOAD-SINGLE ROW(+ve&-ve LV cells Z1 AXIS: SQUEEZE TIME -MDB5000
WELDING(GA
NTRY-
2)OP140A-
5065243
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No Flow
Page: 31 of 75
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No Flow
MAIN AIR PRESSURE

LH
Page: 32 of 75
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No Flow
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QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0142 BOTTOM WELDING-B BOTTOM PULLOFF LOAD-SINGLE ROW(+ve&-ve LV cells Z1 AXIS: SQUEEZE TIME -MDB5000
WELDING(GA
NTRY-
2)OP140B-
5065244
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No Flow
Page: 35 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
MAIN AIR PRESSURE

LH
Page: 36 of 75
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No Flow
Page: 37 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0143 BOTTOM WELDING-C BOTTOM PULLOFF LOAD-SINGLE ROW(+ve&-ve LV cells Z1 AXIS: SQUEEZE TIME -MDB5000
WELDING(GA
NTRY-
2)OP140C-
5065245
AUTO CYCLE START SIGNAL FROM SERVER Z1 AXIS:HOLD TIME-MDB5000
NO TRACEABILITY BYPASS IN HMI Z1 AXIS:WELD CURRENT-MDB5000
NO FLASHES Z1 AXIS:WELD VOLTAGE-MDB5000
NO PEEL OFF OF INTERCONNECTOR Z1 AXIS:PRECHECK-MDB5000
NO CUT MARKS ON INTERCONNECTOR Z1 AXIS:PRECHECK VOLTAGE-MDB5000
NO.OF.SPOT PER CELL PER SIDE Z1 AXIS:PRECHECK TIME-MDB5000
NO.OF.WELD SPOT PER MODULE Z1 AXIS:PRECHECK PEAK -MDB5000
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No Flow
Page: 39 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
MAIN AIR PRESSURE

LH
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No Flow
Page: 41 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0150 WELD VISUAL INSPECTION OVER HEAD NO WELD PEEL OFF ILLUMINATION LEVEL
PALLET
TRANSFER-
5065249
NO DAMAGE ON WELDED MODULE
NO OF NUGGET FORMED PER SPOT
PASTING OF INSULATION ON WELDED

MODULE
0170 BTM DAMPER,THERMAL OVER HEAD CONDITION OF DAMPERS

SHEET&BTM SHELL ASLY PALLET
TRANSFER-
5065249
PRESENCE OF FOUR DAMPERS ON BOTTOM
SIDE
PRESENCE OF BOTTOM SHELL
SEATING OF BOTTOM SHELL ON MODULE
CONDITION OF BOTTOM SHELL
0200 FLIPPING FLIPPING HOME POSITION IN X-AXIS

STATION
-5065250
PICKING POSITION-1(RH) IN X -AXIS
GRIPING POSITION IN X-AXIS
PICKING POSITION-2(LH) IN X -AXIS
HOME POSITION IN Z-AXIS
SAFE POSITION IN Z-AXIS
Page: 42 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PICKING POSITION-1(RH) IN Z -AXIS
GRIPING POSITION IN Z-AXIS
UNGRIPING POSITION IN Z-AXIS
DROP POSITION IN Z-AXIS
ROTARY AXIS HOME POSITION
ROTARY 180 DEG POSITION
0210 RTV DISPENSING RTV SEALANT CURING TIME INTERLOCK IN HMI-10min APPLY OF LIQUID GASKET ON SHELLPER SIDE
DISPENSING-
5065251
PUMP PRESSURE
INTERLOCK OF SAFETY CURTIN DOOR
INLET PRESSURE
0215 TOP SHELL ASSLY SHELL CHECK THE SHELL CLOSING CONDITION STEP 1 TIGHTENING TORQUE
&(TIGHTENING CONTINGENC TIGHTENING-
5065252
PRESENCE OF SCREWS - M4x30 -8 NOS STEP 1 TIGHTENING SPEED
SCREW CONDITION M4x30 STEP 2 TIGHTENING TORQUE
TIGHTENING SEQUENCE STEP 2 TIGHTENING SPEED
TIGHTENING TORQUE OF 8 SCREWS OPERATOR SKILL LEVEL
VERIFICATION OFTIGHTENING TORQUE DC TOOL CALIBRATION

8SCREWS
CONDITION OF DAMPERS
PRESENCE OF FOUR DAMPERS ON TOP SIDE
PRESENCE OF TOP SHELL
SEATING OF TOP SHELL IN MODULE
PRESENCE OF DOWEL PIN 2 NOS
Page: 43 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
CHECK THE SHELL CONDITION
0221 SHELL TIGHTENING (AUTO SHELL CHECK THE SHELL CLOSING CONDITION FRONT SERVO: STEP 1 TIGH.TORQUE
STATION) TIGHTENING-
5065252
PRESENCE OF SCREWS - M4x30 -8 NOS FRONT SERVO: STEP 1 TIGH.SPEED
SCREW CONDITION M4x30 FRONT SERVO: STEP 2 TIGH.TORQUE
TIGHTENING SEQUENCE FRONT SERVO: STEP 2 TIGH.SPEED
VERIFICATION OFTIGHTENING TORQUE REAR SERVO:STEP 1 TIGH.TORQUE

8SCREWS
AUTO CYCLE START SIGNAL FROM SERVER REAR SERVO:STEP 1 TIGH.SPEED
SCREW DISPENSE FROM BOWEL FEEDER REAR SERVO:STEP 2 TIGH.TORQUE
TIGHTENING TORQUE IN CONTROLLER REAR SERVO:STEP 2 TIGH.SPEED
NO SCREW HEAD DAMAGE DC TOOL CALIBRATION
NO TRACEABILITY BYPASS IN HMI
0222 FLIPPING SHELL HOME POSITION IN X AXIS

TIGHTENING-
5065252
PICKING POSITION IN X AXIS
DROPPING POSITION IN X AXIS
HOME POSITION IN Z AXIS
SAFE POSITION IN Z AXIS
PICKING POSITION IN Z AXIS
DROPPING POSITION IN Z AXIS
Page: 44 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0223 BTM GSKT ASSLY& BOTTOM PRESENCE OF BOTTOM GASKET THREAD ENGAGEMENT TRANSISTION TORQUE
LDG&(TIGHTENING COVER
CONTINGE TIGHTENING-
5065253
GASKET SEATING CONDITION ON THREAD ENGAGEMENT RPM
BOTTOMCOVER
BOTTOM COVER CONDITION TIGHTENING TORQUE
PRESENCE OF 16 SCREWS - M4x12 TIGHTENING SPEED
TIGHTENING TORQUE OF 16 SCREWS DC TOOL CALIBRATION
VERIFICATION OFTIGHTENING
TORQUE16SCREWS
TIGHTENING SEQUENCE -16 SCREWS
0230 BOTTOM COVER BOTTOM PRESENCE OF BOTTOM GASKET R1:THREAD ENGAGEMENT TRANSISTION
TIGHTENING(AUTO STATION) COVER TORQUE
TIGHTENING-
5065253
GASKET SEATING CONDITION ON R1:THREAD ENGAGEMENT RPM
BOTTOMCOVER
PRESENCE OF BOTTOM COVER R1:TIGHTENING TORQUE
PRESENCE OF 2 SCREWS(DIAGONAL) M4*12 R1:TIGHTENING SPEED
PRESENCE OF 16 SCREWS - M4x12 R1:SCREWHEAD ENGMNT ANGLE STEP1-CCW
VERIFICATION OFTIGHTENING R2:THREAD ENGAGEMENT TRANSISTION

TORQUE16SCREWS TORQUE
TIGHTENING SEQUENCE -16 SCREWS R2:THREAD ENGAGEMENT RPM
AUTO CYCLE START SIGNAL FROM SERVER R2:TIGHTENING TORQUE
SCREW DISPENSE FROM BOWEL FEEDER R2:TIGHTENING SPEED
TIGHTENING TORQUE IN CONTROLLER R2:SCREWHEAD ENGMNT ANGLE STEP1-CCW
NO SCREW HEAD DAMAGE R3:THREAD ENGAGEMENT TRANSISTION

TORQUE
NO TRACEABILITY BYPASS IN HMI R3:THREAD ENGAGEMENT RPM
R3:TIGHTENING TORQUE
Page: 45 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
R3:TIGHTENING SPEED
R3:SCREWHEAD ENGMNT ANGLE STEP1-CCW
R4:THREAD ENGAGEMENT TRANSISTION

TORQUE
R4:THREAD ENGAGEMENT RPM
R4:TIGHTENING TORQUE
R4:TIGHTENING SPEED
R4:SCREWHEAD ENGMNT ANGLE STEP1-CCW
DC TOOL CALIBRATION
0240 SHELL LASER MARKING LASER VISIBILITY OF MARKING MARKING SPEED

MARKING &
FLIPPING -
5065254
CORRECT NUMBERING AS PER DRG MARKING FREQUENCY
MARKING ON THE RIGHT PLACE MARKING POWER
COMPLETE MARKING SIZE OF 2D CODE(8*8mm)
TEXT HEIGHT
SPACING BETWEEN TEXT
TEXT WIDTH
0250 FLIPPING LASER PICKING POSITION IN Z AXIS

MARKING &
FLIPPING -
5065254
SAFE POSITION IN Z AXIS
DROPPING POSITION IN Z AXIS
Page: 46 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0260 PCB LOADING (TIGHTENING PCB AND PRESENCE OF 15 SCREWS - M4x12SP BIT SLIP DETECTION - ENABLE ON
CONTINGENCY) PLASTIC
BASE
TIGHTENING-
5065255
TIGHTENING TORQUE OF 15 SCREWS THREAD DAMAGE DETECTION - ENABLE ON
VERIFICATION OFTIGHTENING THREAD ENGAGEMENT TRANSITION TORQUE

TORQUE15SCREWS
TIGHTENING SEQUENCE -15 SCREWS THREAD ENGAGEMENT TRANSITION SPEED
THERMISTOR CABLE ROUTING ASPER TIGHTENING TORQUE

COLORCODE
PRESENCE OF PCB ON MODULE TIGHTENING SPEED
MODULE NUMBER MAPPING WITH PACK
PCB MAPPING WITH PACK NUMBER
PRESENCE OF PCB ON MODULE
DC TOOL CALIBRATION
0270 PCB TIGHTENING(AUTO PCB AND PRESENCE OF 2 SCREWS(DIAGONAL) M4*12 SP DC TOOL CALIBRATION
STATION) PLASTIC
BASE
TIGHTENING-
5065255
PRESENCE OF 15 SCREWS - M4x12SP BIT SLIP DETECTION - DISABLE ON
VERIFICATION OFTIGHTENING THREAD DAMAGE DETECTION - DISBLE ON

TORQUE15SCREWS
TIGHTENING SEQUENCE -15 SCREWS TIGHTENING RPM (STEP-1)
AUTO CYCLE START SIGNAL FROM SERVER ENGAGEMENT TRANSISTION TORQUE
SCREW DISPENSE FROM BOWEL FEEDER TIGHTENING RPM (STEP-2)
TIGHTENING TORQUE IN CONTROLLER TIGHTENING TORQUE
NO SCREW HEAD DAMAGE DC TOOL CALIBRATION
Page: 47 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0280 INSERT&FUSE TIGHTENING & MANUAL PRESENCE OF COVER HOUSING CAP STEP 1 TIGHTENING TORQUE
THERMISTOR PLUG STATION
-5065256
PRESENCE OF CRR SCREWS M6x8 -2 NOS STEP 1 TIGHTENING SPEED
TIGHTENING TORQUE OF 2 SCREWS STEP 2 TIGHTENING TORQUE
VERIFICATION OFTIGHTENING TORQUE STEP 2 TIGHTENING SPEED

2SCREWS
FUSE CONDITION TOP COVER MAPPING WITH PACK
INSERT FUSE CONDITION DC TOOL CALIBRATION
TIGHTENING SEQUENCE - 2 NOS
0290 +VE & -VE TERMINAL MANUAL PRESENCEOFSCREWS IN -VE STEP 1 TIGHTENING TORQUE
TIGHTENING & CORDSET STATION TERMINAL-M4x12FL
-5065256
NEGATIVE TERMINAL TT (2 SCREWS) STEP 1 TIGHTENING SPEED
VERIFICATION OF +VE 2 SCREWS TT STEP 2 TIGHTENING TORQUE
PRESENCEOFSCREWS IN +VE STEP 2 TIGHTENING SPEED

TERMINAL-M4x12FL
POSITIVE TERMINAL TT (2 SCREWS) DC TOOL CALIBRATION
VERIFICATION OF -VE 2 SCREWS TT
CHECKTHERETIGHTENINGOFSCREWSHEAD
DAMAGE
SIGNAL COUPLERCONNECTION ASSY BMS TO

PCB
DOWSIL 7091 RTV APPLICATION FOR 4SCERWS
DOWSIL7091 RTV APPLICATION FOR

CONNECTOR
0300 TOP COVER LOOSE ASSY MANUAL PRESENCE OF TOP COVER WITH SUB STEP 1 TIGHTENING TORQUE
STATION ASSEMBLED
-5065256
PRESENCE OF 16 SCREWS - M4x30 STEP 1 TIGHTENING SPEED
CHECKTHERETIGHTENINGOFSCREWSHEAD STEP 2 TIGHTENING TORQUE

DAMAGE
Page: 48 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
TIGHTENING TORQUE OF 16 SCREWS STEP 2 TIGHTENING SPEED
VERIFICATION OFTIGHTENING TORQUE 16 DC TOOL CALIBRATION

SCRE
0310 TOP COVER TIGHTENING TOP COVER PRESENCE OF TOP GASKET THREAD ENGAGEMENT TRANSITION TORQUE
(AUTO STATION) TIGHTENING-
5065257
GASKET SEATING CONDITION ON TOPCOVER THREAD ENGAGEMENT TRANSITION SPEED
PRESENCE OF TOP COVER TIGHTENING TORQUE
PRESENCE OF 2 SCREWS(DIAGONAL) M4*30 TIGHTENING SPEED
PRESENCE OF 16 SCREWS - M4x30 DC TOOL CALIBRATION
VERIFICATION OFTIGHTENING
TORQUE16SCREWS
AUTO CYCLE START SIGNAL FROM SERVER
SCREW DISPENSE FROM BOWEL FEEDER
TIGHTENING TORQUE IN CONTROLLER
NO SCREW HEAD DAMAGE
0320 LEAK TESTING LEAK LEAK ACCEPTANCE AIR PRESSURE

TESTING
STATION A &
B-5065258
ENSURE MASTER BATTERY PACK - OK TESTING PRESSURE
MASTER
ENSURE MASTER BATTERYPACK -NOT OK OPERATOR SKILL LEVEL

MASTER
CHARGING 2 TIME
BALANCING 1 TIME
Page: 49 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
BALANCING 2 TIME
DETECTION TIME
EXHAUST TIME
LEAK TESTING HOSE & PLUG CONDITION
LEAK TESTING UNIT CALIBRATION
MASTER VOLUME
WORK VOLUME
AMBIENT TEMPERATURE
0330 BMS FLASHING PRDN BATTERY PRODUCTION POSTING OF OK PACKS

POSTING & UNLOADING ASSY
CONVYR-LINE
2 (5065248)
BMS FLASHING IN LEAK OK PACKS
BMS FLASHING SOFTWARE VERSION-3.1.1
BMS FLASHING TOOL -MAHLE
POSTING STICKER PASTING ON PACK
0340 THERMALPAD MANUAL VISIBILITY OF MARKING OPERATOR SKILL LEVEL

PASTING&LASERMARK ON STATION
TOPCOVER -5065256
CORRECT NUMBERING AS PER DRG LASER SPEED
MARKING ON THE RIGHT PLACE LASER POWER
COMPLETE MARKING FREQUENCY
PASTING OF THERMAL PAD PROTECTIVE GLASS CLEANLINESS
FONT TYPE
FIXTURE LOCATOR CONDITION
Page: 50 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
TEXT SPACE
LOOP COUNT
DATA MATRIX SIZE
CHARACTER HEIGHT OF TEXT
PY FOR THERMAL PAD PRESENCE
0350 BMS & TOP COVER MAPPING, MANUAL PRESENCE OF BMS OPERATOR SKILL LEVEL
THERMAL PAD STATION
-5065256
PRESENCE OF TOPCOVER WITH LASER BMS MAPPING WITH TOP COVER
MARKING
PRESENCE OF CLAMPCORDSET
PROPER SEATING OF CLAMP CORDSET
0360 BMS TIGHTENING MANUAL PRESENCE OF TOP COVER WITH CLAMP OPERATOR SKILL LEVEL
STATION CORDSET
-5065256
PRESENCE OF ALL SCREWS - M4x12 TOOL DRIVE END CONDITION
TIGHTENING TORQUE OF 6 SCREWS TOOL BIT CONDITION
VERIFICATION OFTIGHTENING TIGHTENING TOOL CALIBRATION

TORQUE6SCREWS
TIGHTENING SEQUENCE -6 SCREWS TT SETTING IN CONTROLLER
DC TOOL CALIBRATION
0370 CHAGORI TIGHTENING MANUAL PRESENCE OF TOP COVER TOOL BIT CONDITION (T20)
STATION
-5065256
PRESENCE OF CONTROLLER BMS TIGHTENING TOOL CALIBRATION
PRESENCE OF CLAMP CORDSET TT SETTING IN CONTROLLER
PRESENCE OF SCREWS - M3x8 TORQUE WRENCH CALIBARATION
Page: 51 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
TIGHTENING TORQUE OF 4 SCREWS DC TOOL CALIBRATION
VERIFICATION OFTIGHTENING TORQUE

4SCREWS
TIGHTENING SEQUENCE
0380 CHAGORI &+VE TERMINAL MANUAL PRESENCE OF TOP COVER WITH GASKET TOOL DRIVE END CONDITION
CABLE TIGHTENING STATION
-5065256
PRESENCE OF ASSEMBLED BMS WITH TOOL BIT CONDITION (T20 -M4)
CLAMPCORD
52VCORDSET PRESENCE OF +VE TERMINAL TIGHTENING TOOL CALIBRATION

CABL
PRESENCE OF SCREWS IN TIGHTENING TORQUE WRENCH CALIBARATION

M4X12Fl
TIGHTENING TORQUE OF +VE 2 SCREWS (FVF) DC TOOL CALIBRATION

2SCREWS
CORDSET PRESENCE OF + VE TERMINAL

CABLE
PRESENCE OF SCREWS IN TIGHTENING

M4X12Fl
TIGHTENING TORQUE OF -VE 2 SCREWS (FVF)

2SCREWS
PRESENCE OF BMS POSITIVE CABLE
0390 RTV APPLICATION MANUAL SEALANT ON +VE TERMINAL 52V- 2 SCREWS MAIN AIR PRESSURE
STATION
-5065256
SEALANT ON +VE TERMINAL- 2 SCREWS PUMP PRESSURE
LUBRICATION OF THE RAM
0400 PCM FILLING BATTERY PCM QUANTITY OPERATOR SKILL LEVEL

ASSY
CONVYR-LINE
2 (5065248)
PACK WEIGHT BEFORE PCM FILLING NOZZLE TEMPERATURE
PACK WEIGHT AFTER PCM FILLING BOTTOM HEATER TEMPERATURE
Page: 52 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PASTING OF 3 SAFETY STICKER (2+1) PUMP FLANGE TEMPERATURE
PUMP OUTLET TEMPERATURE
LEVEL OF THE HEATED TANK
WEIGHING SCALE CALIBRATION
0410 PCM PORT TIGHTENING & BATTERY PRESENCE OF SCREWS HEX BOLT M10X12 OPERATOR SKILL LEVEL
VALVE ASSLY ASSY
CONVYR-LINE
2 (5065248)
TIGHTENING TORQUE OF SCREW TOOL DRIVE END CONDITION
VERIFICATION OF TIGHTENED SCREWS TOOL BIT CONDITION
PRESENCE OF TRITON VALVE TIGHTENING TOOL CALIBRATION
TIGHTENING TORQUE OF TRITON VALVE TT SETTING IN CONTROLLER
VERIFICATION OF TIGHTENED TRITON VALVE
AFTER FILLING THE BP SHOULDBE IN UPRIGHT
0420 PCM COOLING Battery Assy COOLING TIME AFTER PCM FILLING (Forced) FIFO WITH GREEN LIGHT PRESENCE
Work station - 7
COOLING TIME AFTER PCM FILLING (Natural)
0430 HRD & EOL - CAPACITY Chroma EOL DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-1(40CH) testing m/c -
HRD- 5000432
NO FLAG ERROR HIGH RATE DISCHARGE TIME
DISCHARGE OPERATING TEMPERATURE REST BEFORE CAN WRITE DATA
NO FLAG ERROR CAN WRITE DATA () time
RATED CAPACITY OF PACK @ 1C REST AFTER CAN WRITE DATA
RATED ENERGY OF PACK @ 1C REST TIME AFTER HRD
UPDATE SOFTWARE VERSION OPERATOR SKILL LEVEL
Page: 53 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
COUPLER CONDITION
OVER CURRENT PROTECTION SETTING
OVER TEMPERATURE PROTECTION SETTING
ROOM TEMPERATURE
CALIBRATION OF TESTER UNIT
POSITIVE TERMINAL LOAD TEMP. - HRD
NEGATIVE TERMINAL TEMP.- - HRD
POSITIVE TERMINAL TEMP.- - HRD
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CC-CV CHARGE 1-20A TEMPERATURE
CHARGING VOLTAGE
REST AFTER CC-CV CHARGE 1-20A
CHARGING CUT-OFF SOC
POSITIVE TERMINAL LOAD TEMP. - CHRG
NEGATIVE TERMINAL TEMP.- CHRG
POSITIVE TERMINAL TEMP.- CHRG
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
Page: 54 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
DISCHARGE CURRENT
REST TIME AFTER DISCHARGE
COUPLER CONDITION FOR EOL TROLLEY
HIGH CURRENT PROTECTION SETTING
ROOM TEMPERATURE
POSITIVE TERMINAL LOAD TEMP.-DSCHRG
NEGATIVE TERMINAL TEMP.-DSCHRG
POSITIVE TERMINAL TEMP.-DSCHRG
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
DISCHARGE CUT OFF SOC
0431 HRD & EOL - CAPACITY Battery Pack DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-2(40CH) EOL Tester-
5000365
COUPLER CONDITION
Page: 55 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
Page: 56 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
0432 HRD & EOL - CAPACITY Battery Pack DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-3(40CH) EOL Tester -
5000366
COUPLER CONDITION
ROOM TEMPERATURE
Page: 57 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
Page: 58 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
TESTING ST-4(40CH) testing m/c -
5000429
COUPLER CONDITION
ROOM TEMPERATURE
Page: 59 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
Page: 60 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
TESTING ST-5(40CH) Capacity testing
m/c- 5000433
COUPLER CONDITION
ROOM TEMPERATURE
Page: 61 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
Page: 62 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
TESTING ST-6(40CH) Capacity testing
m/c- 5000434
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
Page: 63 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
Page: 64 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0436 HRD & EOL - CAPACITY Chroma Eol DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-7(40CH) Testing M/c
-5065098
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
Page: 65 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
Page: 66 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
0437 HRD & EOL - CAPACITY Chroma Eol DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-8(40CH) Testing M/c -
5065099/640462
8
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
Page: 67 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
TESTING ST-9(40CH testing m/c -
HRD- 5000431
Page: 68 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
Page: 69 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
TESTING ST-10(40CH testing m/c -
5000428
Page: 70 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
Page: 71 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
0440 HRD & EOL - CAPACITY CHROMA EOL DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-11(12CH TESTING
-11-5000435
Page: 72 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
COUPLER CONDITION
ROOM TEMPERATURE
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
Page: 73 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
0441 HRD & EOL - CAPACITY CHROMA EOL DISCHARGE OPERATING TEMPERATURE HIGH RATE DISCHARGE CURRENT
TESTING ST-12(12CH TESTING
-12-5000434
COUPLER CONDITION
ROOM TEMPERATURE
Page: 74 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

No Flow
PCB TEMP.- - HRD
MOSFET TEMP.- - HRD
CHARGING VOLTAGE
PCB TEMP.- CHRG
MOSFET TEMP.- CHRG
DISCHARGE CURRENT
ROOM TEMPERATURE
PCB TEMP.-DSCHRG
MOSFET TEMP.-DSCHRG
Page: 75 of 75
QSF PED 02 03 001 Rev '1' Dated 04.12.2007

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PROCESS FLOW DIAGRAM

Op Operation Description Machine Process Product Characteristics Process Characteristics

USE OF CORRECT INSERTS BOTOM COVER PROPER SEATING

RESTING BLOCK CHA.OVER-MODEL TYPE

RFID - OK STATUS IN HMI

PNEUMATIC AIR PRESSURE

REPLACEMENT OF MATERIAL DURING MODEL

SENSING OF SERVO ZEROING PIN (X & Z AXI

OVER TRAVEL SENSOR FUNCTIONING

QR CODE SCANNER FUNCTIONING

HOME POSITION PRECONDITIONS

SAFETY LIGHT CURTAIN FUNCTIONING

PART PRESENCE SENSOR IN GRIPPER

WORKING OF FUME KILLER

FUME KILLER FILTER CLEANING FREQUENCY

FUME KILLER FILTER REPLACEMENT

PREPARED BY: BCP CHECKED BY: SA APPROVED BY: MRS

OPERATION INSPECTION TRANSPORT DELAY STORAGE OPERATION & INSPECTON

Op Operation Description Machine Process Product Characteristics Process Characteristics

MARKING POSITION (Y-AXIS)

MARKING POSITION (Z-AXIS)

SCANNING POSITION (Y-AXIS)

SCANNING POSITION (Z-AXIS)

PICKING POSITION (Y) LH STATION

PICKING POSITION (Z) LH STATION

GRIPPING POSITIION (Y -AXIS)

GRIPPING POSITION (Z-AXIS)

GRIPPER OPEN SENSOR

GRIPPER CLOSE SENSOR

PART PRESENCE SENSOR IN PALLET-14S7P

SCANNER COVER FORWARD PRESENCE

SCANNER COVER REVERSE PRESENCE

IOT PARAMETERS TRANSFER TO DATA

LASER HEAD DISTANCE TO MARKING

FUNCTION OF ENTRY SIDE DOOR

FUNCTION OF EXIT SIDE DOOR

CELL IR RANGE WITHNIN MODULE CELLS GRADING <5mV G3

PREPARED BY: BCP CHECKED BY: SA APPROVED BY: MRS

OPERATION INSPECTION TRANSPORT DELAY STORAGE OPERATION & INSPECTON

Op Operation Description Machine Process Product Characteristics Process Characteristics

NO DAMAGE ON CELLS CELLS GRADING <5mV G5

NO CELL SHORTCIRCUIT CELLS GRADING <5mV G6

CELLS GRADING <5mV G7

CELLS GRADING <5mV G8

CELLS GRADING <5mV G9

CELLS GRADING <5mV G10

CELLS GRADING <5mV G11

CELLS GRADING <5mV G12

BOX PRESNECE SENSOR AT LOADING

BOX TRAVEL SENSOR OK/NOK ALARM

BOX STOPPER UP DURING TRAVEL

BOX STOPPER DOWN DURING PREVIOUS BOX

AREA CLEAR SENSOR OK/NOK - INFEED ZONE

AREA CLEAR SENSOR OK/NOK - OP30A ZONE

AREA CLEAR SENSOR OK/NOK - OP30B ZONE

BOX PRESENCE SENSOR AT THE PICKING

WORKING OF CAMERA BAR LIGHT DURING

CONVEYOR DIRECTION DURING EMPTY BOX

UNLOADING CONVEYOR ALIGNMENT SENSOR

PREPARED BY: BCP CHECKED BY: SA APPROVED BY: MRS