BATTERY INTERCONNECT AND SENSING ASSEMBLIES: A DFM CHECKLIST
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Project / company:
Contact:
Application:
Drawing / model revision:
Sample quantity / pilot quantity / estimated production demand:
Target date:

Fill in what is known and mark open questions. This brief supports an engineering discussion;
the sample configuration, test conditions, and acceptance limits need separate agreement.

WHAT IS INCLUDED IN THE BATTERY ASSEMBLY?
Notes / decisions:
Open items / owner / due date:

BEGIN WITH THE CELL LAYOUT AND JOINING INTERFACES
[ ] Identify the datums used to locate cells, current collectors, and sensing parts.
[ ] Show terminal materials, finishes, joining zones, and prohibited areas.
[ ] Check access for positioning, clamping, joining, inspection, and any agreed rework.
[ ] Define which sample joints represent the intended production process and how joint acceptance will be assessed.
Open items / owner / due date:

DEFINE SENSING CONNECTIONS BY NODE AND PIN
Voltage sensing: Node names, polarity, connector pins, joining points, and the required continuity and isolation checks.
Your input:

Temperature sensing: Sensor type, location, attachment, routing, and the customer's check method and acceptance limits.
Your input:

Mechanical integration: Retention, bend space, handling, assembly sequence, and access to inspect the connections.
Your input:

Monitoring interface: The mating BMS connection and agreed division of responsibility for harnesses, connectors, hardware, and software.
Your input:

Open items / owner / due date:

CHECK INSULATION AND THE ASSEMBLY SEQUENCE
Notes / decisions:
Open items / owner / due date:

AGREE SAMPLE ACCEPTANCE AND PRODUCTION HANDOVER
[ ] Dimensional and assembly checks against the agreed datums and mating interfaces.
[ ] Connection and joint checks using the specified method and limits.
[ ] Continuity, pin assignment, sensing, and insulation checks required for the assembly.
[ ] Any agreed environmental or mechanical checks, plus a separate plan for complete module or pack qualification.
Open items / owner / due date:

Reference guide: https://www.ampnera.com/en/resources/battery-interconnect-sensing-dfm/

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