Semi-Automatic Battery Pack Assembly Line Solutions For 18650 21700 26650 32700

Solution Introduction

This semi-automatic assembly line is used for assembling cylindrical battery packs such as 18650, 21700, 26650, 32650 and 32700 used in electric bicycles, power tools, electric scooters, drones, etc. The equipment includes Cell Grading Machine, Insulation Paper Sticking Machine, Battery Voltage & IR Sorting Machine, CCD tester, Manual/Automatic Spot Welding Machine, BMS Tester, Battery Comprehensive Tester and Battery Aging Machine.

Assembly Process
Cell capacity grading → Insulation paper pasting → Cell voltage & IR sorting → CCD testing → Battery pack spot welding → BMS testing → Battery pack comprehensive testing → Shrink film packaging → Inkjet code printing → Battery pack aging testing

Advantages

• Modular & Flexible Design
  The production line consists of standalone machines, allowing customizable configurations to meet diverse process requirements.
• Lower Initial Investment
  Compared to fully automated lines, the semi-automatic solution requires lower capital expenditure, ideal for small-to-medium batch production.
• Easy Operation & Maintenance
  Simple machine structure enables quick troubleshooting, low maintenance costs, and short operator training cycles.
• High Adaptability
  Compatible with various cylindrical cells (18650/21700/26650, etc.), enabling quick model changeover, ideal for multi-model and low-volume orders.
• Scalable & Upgradable
  Supports phased capacity expansion and future upgrades to full automation, reducing initial investment risks.

Key Equipment

1. Battery Cell Capacity Grading Machine

Product Description

Cell Grading Machine is used to test and classify the voltage, capacity and other parameters of the cells through cyclic charge and discharge tests, which can ensure the consistency and reliability of subsequent battery pack assembly.

Key Features

• Multi-channel Operation: Simultaneously tests and grades multiple cells, improving production efficiency.
• Safe and Reliable: Independent channel control prevents overcharge, over-discharge, and short circuits, ensuring cell safety.
• Data Traceability: Real-time recording of each cell’s parameters enables full production traceability.
• Energy-efficient: Equipped with energy feedback functionality to reduce power consumption and enhance overall efficiency.

2. Insulation Paper Pasting Machine

Product Description

Insulation Paper Pasting Machine is designed for the automatic application of barley paper insulation pads or PVC insulation materials onto the positive or negative electrodes of cylindrical lithium-ion batteries.

Key Features

• Automated Operation: Fully automatic sticking process reduces manual labor and improves production efficiency.
• High Positioning Accuracy: Ensures precise and consistent placement of insulation pads on battery electrodes.
• Stable and Reliable Performance: Designed for continuous operation with low failure rates.
• Wide Compatibility: Suitable for cylindrical lithium-ion batteries such as 18650, 21700, 26650, 32650 and 32700.
• Enhanced Safety: Provides reliable insulation to reduce the risk of short circuits during battery pack assembly.

3. Battery Sorting Machine

Product Description

Battery Sorting Machine is used to test and automatically sort cylindrical lithium-ion cells based on voltage and internal resistance. By grading cells with similar performance into the same group, it ensures consistency and reliability for battery pack assembly. 

Key Features

• Wide Compatibility: Suitable for cylindrical lithium-ion batteries such as 18650, 21700, 26650, 32650 and 32700.
• High Throughput: Supports continuous operation, suitable for mass production environments.
• Line Integration: Can be integrated and operated in-line with an automatic insulation paper sticking machine.
• MES Connectivity: Supports MES system integration for data acquisition and data upload.
• Code Scanning Function: Supports barcode scanning.
• Accurate Testing: Measures cell voltage and internal resistance with high precision to ensure reliable sorting results.

4. CCD Tester

Product Description

CCD Tester is used for the automatic inspection of the positive and negative electrodes of cylindrical lithium-ion battery cells. Using an industrial camera, the system captures electrode images and compares their quantity and position with reference standards to determine OK or NG results.

Key Features

• Automatic Inspection: Automatically inspects positive and negative electrodes, reducing manual visual checks.
• High Detection Accuracy: Industrial camera ensures precise identification of electrode quantity and position.
• Improved Efficiency: Supports continuous, high-speed inspection for mass production lines.
• Reduced Human Error: Eliminates subjectivity and variability associated with manual inspection.

5. Spot Welding Machine

Product Description

Spot Welding Machine is used for battery pack welding of 14500, 18650, 21700, 26650, 32700, and 33140 cylindrical cells in multi-parallel and multi-series configurations. It is available in three specifications: Manual Gantry Type, Single-Side Automatic Type, and Double-Side Automatic Type, meeting different production capacity and automation requirements.

Key Features

• Multiple Configurations Available
  Manual Gantry Type: Flexible operation, suitable for R&D, and small-batch production.
  Single-Side Automatic Type: Automated welding on one side, balancing efficiency and cost.
  Double-Side Automatic Type: Simultaneous or sequential welding on both sides, designed for high-output production lines.
• Stable Welding Quality
  Ensures uniform weld strength and consistency, reducing false welding and missed welding.
• Strong Adaptability
  Suitable for various cylindrical cell formats and multi-series, multi-parallel battery pack structures.
• Easy Operation & Maintenance
  User-friendly interface and modular design simplify operation, adjustment, and maintenance.

6. BMS Tester

Product Description

BMS Tester is used for functional testing of battery management systems used in lithium battery packs. It simulates real operating conditions to verify key BMS protection and control functions, ensuring stable performance and reliability before they are integrated into battery packs.

Key Features

• Comprehensive Function Testing
  Tests key BMS functions such as overcharge, overdischarge, overcurrent, short-circuit protection, and balancing performance.

• High Test Accuracy
  Provides precise and repeatable test results to ensure reliable BMS evaluation.

• Wide Compatibility
  Supports various BMS types and specifications used in different lithium battery pack applications.

• Automatic Test Process
  Supports automated test sequences, improving efficiency and reducing manual intervention.

7. Battery Comprehensive Tester

Product Description

Battery Comprehensive Tester is used for overall performance testing of lithium-ion battery packs. The main test items include open-circuit voltage, AC internal resistance, continuous charge and discharge current and voltage, charge and discharge over-current protection, short-circuit protection response time, over-current delay, and post-test voltage verification.

Key Features

• Flexible Test Configuration: Test functions can be freely selected and combined according to different testing requirements.
• Fast Test Program Editing: Test plans can be quickly edited and adjusted to improve testing efficiency.
• Customizable Data Storage: Test data can be saved by day, month, or year, as batch data, single-cell data, or by test program, with flexible storage options based on customer requirements.
• MES System Integration: Supports connection with MES systems for data exchange and management.
• Multiple Battery Model Profiles: Allows saving and managing multiple battery model test programs for quick switching.
• Wide Application: Suitable for various lithium battery pack types used in e-bikes, power tools, energy storage, and other applications.

8. Heat Shrink Wrapping Machine

Product Description

Heat Shrink Wrap Machine is used for the battery heat shrink packaging process. It uses a combination of far-infrared heating and hot air circulation to ensure uniform and consistent shrinkage of the battery plastic sleeve, resulting in a clean appearance and tight wrapping. The machine is suitable for PVC, PP, PE, POF, and other types of shrink films.

Key Features

• Electronic Speed Control: Conveyor speed can be freely adjusted to meet different shrink packaging requirements.
• Double-Layer Thermal Insulation Design: Effectively reduces surface temperature, ensuring safer operation.
• High-Temperature Double-Layer Insulation Curtains: Significantly minimize heat loss and improve energy efficiency.
• Heavy-Duty Conveyor Rollers: The auxiliary conveyor chain uses Ø10 mm rollers covered with high-temperature silicone sleeves, allowing it to carry heavy loads without deformation.
• Wide Film Compatibility: Suitable for PE, PVC, PP, POF, and other common heat shrink films.

9. Inkjet Batch Coding Machine

Product Description

Inkjet Batch Coding Machine is used for high-speed, non-contact coding and marking on various product surfaces. It prints clear and durable information such as text, dates, batch numbers, serial numbers, and barcodes, making it ideal for identification and traceability in automated production lines.

Key Features

• High-Speed Printing
  Supports continuous, high-speed coding to match automated production line requirements.
• Clear and Stable Marking
  Delivers sharp characters with strong adhesion and good readability.
• Non-Contact Printing
  No direct contact with the product, suitable for irregular or curved surfaces.
• Flexible Content Editing
  Supports printing of English, Simplified Chinese, Arabic numerals, serial numbers, barcodes, time, date, trademarks, special fonts, etc.

10. Battery Aging Machine

Product Description

Battery Aging Machine is used for aging and performance testing of finished battery packs. It supports various battery types, including ternary lithium, lithium iron phosphate, lead-acid, and Ni-MH / Ni-Cd batteries. The system is mainly applied for battery pack cycle life testing, capacity testing, charge and discharge performance evaluation, and temperature characteristic testing

Key Features

• CC/CV Charge Control
  Supports constant current and constant voltage charging with smooth transition, ensuring safe and stable aging tests.
• Independent Channel Control
  Each channel operates independently, preventing interference between batteries and improving test safety.
• Accurate Parameter Monitoring
  Real-time monitoring of voltage, current, capacity, and temperature during the aging process.
• High Safety Design
  Equipped with multiple protection functions such as overvoltage, overcurrent, overtemperature, and short-circuit protection.
• Flexible Aging Modes
  Supports various aging test modes to meet different battery types and application requirements.
• Data Recording & Traceability
  Automatically records aging data for quality analysis and traceability.