The line combines dedicated processing machines with manual assembly workstations. Operators transfer materials between stations, load fixtures, install the BMS and complete wiring. Cell handling equipment and tooling are configured for 32140 and 33140 cells, while welding and electrical testing equipment are selected according to the pack design and production requirements.

Battery Pack Applications
The solution can be configured for 32140 and 33140 battery packs used in:

• Stationary energy storage systems.
• Portable power stations.
• Electric motorcycles, scooters and tricycles.
• Low-speed electric vehicles.
• UPS and industrial backup power systems.

Assembly Process
Cell Capacity Grading → Insulation Paper Application → OCV/ACIR Sorting → Cell Arrangement → CCD Polarity Inspection → Spot Welding → BMS Testing and Installation → Pack Comprehensive Testing → Heat-Shrink Packaging → Coding → Charge-Discharge Aging

Equipment and Process Stations

How the 32140 and 33140 Battery Pack Assembly Line Works

Step 1 — Battery Cell Capacity Grading
Cells undergo programmed charge-discharge testing to measure capacity before matching. The system records voltage, current, capacity and test time, providing a basis for grouping cells according to the specified acceptance criteria.

ACEY-BCT520-256H lithium battery charge discharge machine provides 256 test channels with flat-head clamps. A 10A or 20A configuration is selected according to the cell specification and grading procedure.

Step 2 — Battery Cell Insulation Paper Application
ACEY-BS02 insulation paper sticking machine is designed for insulation paper application on 32140 and 33140 cylindrical cells.

The machine applies insulating paper to the specified terminal area before pack assembly. The paper shape and placement follow the cell terminal and pack insulation requirements, leaving the welding area accessible.

Step 3 — Battery Cell OCV and ACIR Sorting
After capacity grading, the cells are measured for open-circuit voltage and AC internal resistance. The measured values are compared with preset limits, and the cells are separated into matching groups.

ACEY-AS10S battery cell sorting machine provides 10-channel sorting for 32140 and 33140 cells. An optional scanner reads the cell identification code and associates it with the measured voltage and AC internal resistance. MES integration can be configured according to the customer’s data interface and production management requirements.

Step 4 — Cell Arrangement and CCD Polarity Inspection
Sorted cells are placed into holders or assembly fixtures according to the pack’s series-parallel arrangement.

ACEY-CCD01C conveyor-type CCD tester checks the positive and negative orientation of the cells against the preset polarity pattern before welding. The inspection setup is configured for the cell group dimensions and fixture layout.

Step 5 — Battery Pack Spot Welding
Nickel or nickel-plated connecting strips are welded to the cell terminals to form the pack’s series and parallel connections.

ACEY offers manual, single-sided automatic and double-sided automatic battery pack spot welder options. For 32140 and 33140 cells, automatic machines are supplied with a raised-height design to accommodate the cells and assembly fixtures.

The machine configuration and welding power supply are selected according to the pack dimensions, connecting strip material and thickness, cell terminal structure and welding point layout. Welding parameters are established using the actual cells and connecting strips.

Step 6 — BMS Testing and Installation
Before installation, the BMS is tested to verify its protection thresholds, response times, recovery functions and balancing performance against the pack’s specified requirements.

The test covers:

• Overcharge protection and recovery voltages.
• Overdischarge protection and recovery voltages.
• Charging and discharging overcurrent protection.
• Overcharge, overdischarge and overcurrent protection delay times.
• Short-circuit protection response time.
• Balancing current and balancing voltage.
• Internal resistance and quiescent current.
• Cell sensing wire disconnection detection.
  

ACEY-BP series BMS test equipment verify overcharge, overdischarge and overcurrent protection thresholds, delay times and recovery functions. They also support microsecond-level short-circuit protection response testing, cell sensing wire disconnection detection, quiescent current measurement at each cell input, and balancing current and voltage testing. The series-count range and test-current configuration are selected according to the BMS specification and battery pack requirements.

Step 7 — Battery Pack Comprehensive Testing
After BMS installation and wiring, the assembled pack undergoes comprehensive electrical testing to verify its charge-discharge performance, resistance and protection functions against the pack specification.

The test covers:

• Open-circuit voltage and post-test voltage, including voltage after short-circuit protection testing.
• AC internal resistance measured at 1kHz.
• Charging and discharging DC internal resistance.
• Continuous charging and discharging current, with voltage limit monitoring.
• Charging overcurrent protection current and delay time.
• First- and second-level discharging overcurrent protection currents and delay times.
• Short-circuit protection response time.
• Charging voltage rise and discharging voltage drop.
• ID and NTC resistance.

• Product model.
• Rated voltage and capacity.
• Production date.
• Batch number.
• Serial number.
• Barcode or QR code.

Configure the Line for Your Battery Pack
The solution is configured for 32140 and 33140 large cylindrical battery pack assembly. The final equipment selection, fixtures, welding settings and test ranges follow the customer’s pack design.

Please provide the following information when requesting a proposal:

Request a Line Configuration and Quotation
Send ACEY your 32140 or 33140 cell datasheet, pack drawing, connecting strip specification, BMS requirements and target daily output.

ACEY will prepare a semi-automatic battery pack assembly line proposal covering equipment selection, fixtures, the raised-height automatic welding configuration, electrical testing and aging capacity.

Contact ACEY for 32140 / 33140 cylindrical battery pack assembly line proposal and quotation.