Semi-Automatic Battery Pack Assembly Line Solutions For Prismatic Batteries

Solution Introduction

This semi-automatic assembly line is used for assembling prismatic battery packs used in ESS/EV/AGV/UPS/electric 2/3 Wheelers etc. The equipment includes Cell capacity grading Machine, Battery voltage&IR sorting machine, Battery stacking and pressing machine, Laser cleaning machine, Laser welding machine, BMS Tester, Battery comprehensive tester and Battery aging machine, etc.

Assembly Process

Cell capacity grading → Cell Voltage & IR sorting → Module stacking & pressing → Terminal laser cleaning → Module laser welding → BMS testing → Battery pack comprehensive testing → Battery pack aging testing

Advantages

• Modular & Flexible Design
  Standardized modular design allows flexible layout adjustment for various cell sizes, ideal for customized pack production.
• Multi-Model Compatibility
  Compatible with prismatic cells of varying thickness and support multiple processes of aluminum shell/steel shell and welding/bolting.
• Cost Efficiency
  40-50% lower capital investment vs full-automation

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. 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

• Applicable Battery Type: Designed for prismatic aluminum-case batteries.
• Wide Size Compatibility: Supports battery lengths from 90–300 mm, widths from 12–85 mm, and heights from 90–300 mm.
• Flexible Sorting Channels: Available with 3, 7, or 9 sorting channels, with custom configurations supported to meet different production requirements.
• PLC Control System: Uses a PLC control system combined with linear modules for stable and accurate operation.
• Integrated Feeding & Inspection: Supports manual loading with automatic testing; internal resistance tester is optional.
• Code Scanning Function: Built-in scanning supports QR codes, barcodes, and other identification codes.
• Fully Automated Sorting Process: Automated sorting workflow reduces manual intervention and improves consistency.
• MES System Interface: Supports MES connection to record battery QR code information and test data, and generate SPC analysis reports in real time.
• High Sorting Efficiency: Single-machine sorting speed up to 1,000 pcs/hour, improving efficiency by more than 3× compared with manual sorting.

3. Battery Module Stacking and Pressing Machine

Product Description

Battery Stacking & Pressing Machine is used for stacking, pressing, and strapping prismatic lithium battery cells. Driven by a servo motor, ball screw module, and planetary reducer, it provides stable pressing force of over 500 kg with precise control of stroke and pressure. The system supports easy model changeover, adapts to different battery sizes, and features triple protection through software limits, hardware limits, and pressure control to prevent over-compression, ensuring safe and consistent stacking accuracy.

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.

4. Laser Cleaning Machine

Product Description

Laser Cleaning Machine is used in prismatic aluminum-case battery pack assembly to remove surface contaminants from aluminum tabs, busbars, and welding areas. By eliminating oxide layers, oil, dust, and residues without damaging the base material, it improves welding consistency and electrical conductivity, ensuring stable and reliable laser or ultrasonic welding results.

Key Features

• Non-Contact Cleaning Process
  Cleans surfaces without physical contact, avoiding mechanical damage to battery components.
• High Cleaning Precision
  Selectively removes oxides and contaminants while maintaining the integrity of the aluminum surface.
• Improved Welding Quality
  Enhances weld strength and consistency by providing clean and uniform welding surfaces.
• No Chemical Consumables
  Does not require chemicals or abrasives, making it environmentally friendly and low-maintenance.

5. Laser Welding Machine

Product Description

Laser Welding Machine is used in prismatic battery pack assembly for welding aluminum tabs, busbars, and structural connections. It provides stable and precise welding with minimal heat input, ensuring strong joints and consistent electrical performance while maintaining the integrity of battery cells.

Key Features

• High-Power Fiber Continuous Laser
  Equipped with a high-power fiber continuous laser source, offering strong output power, high welding speed, high precision, and stable welding quality.

• Up to 6-Axis Motion Control
  Supports up to 6-axis motion control to meet various automation requirements, suitable for both standalone operation and integration into automatic production lines.

• Galvo Welding Head + XY Gantry System
  Configured with a high-power galvo welding head working together with an XY gantry motion platform, enabling flexible welding of complex trajectories and patterns.

• Dedicated Welding Control Software
  Features professional welding control software with complete process management, data storage and recall functions, and powerful graphic drawing and editing capabilities.

• CCD Monitoring System
  Built-in CCD monitoring system allows easy setup and real-time monitoring of welding quality during operation.

• Red Light Positioning System
  Equipped with a red light positioning system for fast and accurate positioning of welding locations and focal distance, making operation simple and efficient.

• Efficient Water Cooling System
  High-performance water circulation cooling system maintains stable operating temperature, improving welding quality and extending machine service life.

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. 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.