Automatic Energy Storage Battery Module and PACK Assembly Line

Automatic Energy Storage Battery Module and PACK Assembly Line

Product Overview
ACEY-APAL-ESS Automatic Energy Storage Battery Pack Production Line is designed for the production of prismatic lithium battery modules and energy storage battery packs. The complete line combines automated cell handling, OCV testing, sorting, stacking, compression, laser cleaning, laser welding, module testing, PACK assembly, EOL testing, and traceability management.

The production line consists of two main sections: the battery module assembly line and the battery pack assembly line. It can be configured for both liquid-cooled and air-cooled energy storage battery designs and adapted to different cell sizes, module structures, production capacities, and automation requirements.

The reference configuration is based on a liquid-cooled 1P13S module using prismatic cells, while tooling and fixtures can be adjusted for other module formats.

Applications

This energy storage battery production line is suitable for:

• Commercial and industrial energy storage systems
• Containerized battery energy storage systems
• Residential energy storage battery packs
• Liquid-cooled energy storage battery packs
• Air-cooled energy storage battery packs
• Prismatic LiFePO₄ battery modules
• High-capacity lithium battery PACK production
• Customized ESS module and PACK assembly projects

Main Features

• Compatible with liquid-cooled and air-cooled energy storage battery packs.
• Supports prismatic aluminum-shell cells from approximately 100Ah to 314Ah.
• Configurable for 1P8S, 1P12S, 1P13S, and selected double-row module structures.
• Automated cell loading, sorting, stacking, polarity inspection, laser cleaning, and laser welding.
• Adjustable module compression force from 10 to 1,500 kgf.
• Integrated barcode scanning and MES data traceability.
• Automatic recording of OCV, internal resistance, welding, compression, and EOL test data.
• Modular line design supports product changeover and future capacity expansion.
• Compatible with customized tooling for different cell, module, and PACK dimensions.
• Manual PACK assembly stations can be adjusted according to the customer’s production process.

Full-Line Process Flowchart

*Battery Module Assembly Process

*Battery Pack Assembly Process

Whole Line Layout

*2D Layout

*Full-Line Size Diagram

Overall size of the line: 56x8.5x3.5m(L*W*H m) (the final size is subject to the actual design). 
The whole line is divided into: cell processing section, module stacking section, module pre/welding/after processing section, PACK box on-line processing section, module into box assembly section, PACK finished product testing and offline section. 

*3D Layout

Battery Module Assembly Line

1. Robotic Cell Loading
Prismatic cells are supplied in foam trays or boxes and manually transferred to the loading area. A robot equipped with a vision system identifies the cell position, grips the cells, and places them onto the OCV infeed conveyor.
After all cells have been removed, the robot transfers the empty box to the designated empty-box placement station. Safety fencing is installed around the robotic loading area.

Main functions

• Automatic cell position recognition
• CCD-guided robotic loading
• Multiple-cell gripping capability
• Automatic empty-box handling
• Cell loading onto the OCV conveyor
• Safety fencing and interlock protection

2. Battery OCV Sorting
Each cell is automatically scanned before testing. The system measures open-circuit voltage and internal resistance and can calculate the K value according to the configured process requirements.Each cell is automatically scanned and tested for open-circuit voltage and internal resistance. The system calculates the K value, sorts qualified cells into four channels according to the module recipe, and transfers non-conforming cells to the NG conveyor or rework station.

After sorting, the cells are automatically flipped when required and transferred to the processing conveyor. A servo-driven plasma cleaning head cleans the cell insulation film before adhesive or insulating pads are manually applied. The finished cells are then positioned upright by an automatic mechanism and transferred to the module stacking station.
The cells are divided into four sorting channels according to the test results and module recipe. Non-conforming cells are automatically transferred to the NG conveyor or rework cart.

Main functions

• QR code and barcode recognitionMain Functions
• QR code and barcode recognition
• OCV and internal resistance testing
• K-value calculation
• Four-channel automatic sorting
• Automatic NG rejection
• Recipe-based cell grouping
• Selective cell flipping
• Plasma surface cleaning
• Manual adhesive or insulating pad application
• Automatic cell uprighting
• MES data upload and traceability
• Storage of up to 13 cells per sorting channel

4. Automatic Module Stacking
The automatic stacking system arranges the prepared cells according to the selected series and parallel configuration.

The operator can set the required module recipe through the PLC touchscreen. The stacking grippers transfer the upright cells to the stacking fixture and complete the module arrangement automatically.

Main functions

• Recipe-controlled stacking
• Automatic cell positioning
• Dual stacking stations available
• Adjustable stacking sequence
• Compatible with up to 1P13S 314Ah reference modules
• Customized stacking tooling for different module formats

5. Module Compression and Steel Band Fitting
After stacking, the module is transferred to the compression station. The servo electric cylinder applies controlled pressure through the module end plates.

The compression force and travel can be adjusted according to the module dimensions. After compression, the module can be secured with steel bands or plastic-steel straps.

All cell codes can be scanned and linked to a newly generated module barcode for production traceability.

Main functions

• Adjustable compression force
• Adjustable compression travel
• Reference force range: 10–1,500 kgf
• Dual protection design
• Steel band pre-installation slot
• Compatible with left- and right-side compression
• Module barcode generation
• Compression data uploaded to MES
• Touchscreen parameter setting

6. Polarity Inspection and Terminal Positioning
A CCD vision system scans the module barcode and inspects the position and polarity of each cell terminal.

The inspection coordinates are stored and transferred to the subsequent laser cleaning and laser welding stations. Modules that fail inspection are automatically transferred to the NG workstation with an audible and visual alarm.

Main functions

• Automatic module barcode scanning
• Cell terminal positioning
• Positive and negative polarity inspection
• Vision-based coordinate generation
• NG module rejection
• MES inspection data upload

7. Laser Cleaning
The laser cleaning station removes oxide layers, dust, and surface contamination from the cell terminals before welding.

The system reads the module code and retrieves the corresponding terminal coordinates. A CCD camera, laser distance sensor, and three-axis gantry guide the laser cleaning head to each terminal. After cleaning completed, mechanism resets, pallet flows to next process;

8. Busbar and CCS Placement
The module is transferred to the manual busbar placement station. The operator installs the positioning fixture and places the busbars, positive and negative terminal blocks, or CCS assembly according to the selected module recipe. After placement, the module is released to the laser welding station.

9. Laser Welding
The automatic laser welding station connects the busbars to the cell terminals. The system scans the module code, retrieves the positioning coordinates, identifies the reference points, adjusts the focal distance, clamps the busbars, and completes the welding process automatically.

Main functions

• Automatic barcode scanning
• CCD-assisted positioning
• Galvo laser welding
• Automatic focal-distance adjustment
• Spring-buffered busbar clamping
• Welding parameter recording
• MES data upload
• Emergency stop and safety protection

11. Module EOL Testing
The module EOL station uses independently adjustable probes to contact the module terminals and end-plate positions.

Available test items:

• Total module voltage
• AC internal resistance
• Insulation resistance
• Dielectric withstand voltage
• Leakage testing
• Positive and negative terminal verification

12. Module Transfer
Qualified modules are transferred from the module line to the PACK assembly section using a gantry lifting system.

The reference lifting system provides a maximum load capacity of 500 kg and includes protection against power loss, accidental operation, and hook disengagement.

Module Tooling Pallet
The tooling pallet consists of a 15 mm aluminum base plate and a 5 mm Bakelite insulating surface layer, with overall dimensions of 1,200 × 600 × 20 mm.

Module Conveyor System
A continuous double-speed chain conveyor transfers modules between workstations. Lifts installed at both ends enable automatic tooling pallet return and closed-loop circulation.

Battery Pack Assembly Line

The PACK section uses modular chain-driven roller conveyors and can be divided into three areas:

1. PACK housing preparation
2. Module loading and PACK assembly
3. Final PACK testing and unloading

1. PACK Housing Preparation
The liquid cooling plate or PACK housing is manually loaded onto the production line and tested for air tightness. After the test, the system generates a PACK barcode and uploads the result to the MES traceability system.

The housing is then positioned at the adhesive application station, where the operator applies adhesive according to the production recipe. After adhesive application, battery modules are lifted from the module line and placed into the PACK housing using a gantry lifting system.

Main Processes:
Liquid Cooling Plate Testing → PACK Barcode Generation → Manual Adhesive Application → Module Loading into PACK Housing

2. Module Loading and PACK Assembly
After the modules are loaded into the housing, operators complete module fixing, wiring harness installation, BMS installation, and top cover installation.

At the BMS installation station, the module and BMS barcodes are scanned and linked. The system then integrates the module and BMS information into the PACK barcode and uploads the data to the MES system for production traceability.

Main Processes:
Module Fixing → Wiring Harness Installation → BMS Installation and Barcode Binding → Wiring Arrangement → Top Cover Installation

3. Final Testing and Unloading
The assembled PACK is transferred to the final testing section. The PACK EOL station can test insulation resistance, dielectric withstand voltage, BMS communication, no-load voltage, AC internal resistance, and temperature monitoring.

After EOL testing, the complete PACK undergoes an air-tightness test. All test results are linked to the PACK barcode and uploaded to the MES system. Qualified products are then removed from the line using a gantry lifting system.

Main Processes:
PACK EOL Testing → Air Tightness Testing → Test Data Upload → PACK Unloading

PACK Conveyor System
The PACK assembly line uses a chain-driven roller conveyor with an upper-and-lower tooling return structure. The line is manufactured in modular sections, with each section approximately 2.5 meters long and equipped with lighting, stoppers, and operation switches.

Main Technical Parameters

Production capacity is calculated based on the reference 1P13S liquid-cooled module and excludes manual loading and unloading time. Final parameters are determined by the approved product drawings and line configuration.

MES and Production Traceability
All major machines can be connected to the MES system for centralized production data collection and traceability.

MES communication protocols and a compatible server environment are required for system integration. Depending on the project scope, the system can record:

• Cell barcode information
• OCV and internal resistance results
• Cell sorting grade
• Module recipe
• Module compression force and travel
• Polarity inspection results
• Laser cleaning parameters
• Laser welding parameters
• Module EOL results
• BMS binding information
• PACK EOL results
• Air-tightness results
• NG and rework records

Factory Installation Requirements

FAQ

*What battery cells can the production line handle?
The reference line is designed for prismatic aluminum-shell lithium cells from approximately 100Ah to 314Ah. Other cell dimensions can be supported through customized fixtures and handling mechanisms.

*Is the line fully automatic?
The module section includes automated loading, sorting, stacking, inspection, cleaning, welding, and testing. Several assembly processes, particularly in the PACK section, are completed manually or semi-automatically. The automation level can be increased according to the project requirements.

*Can the line produce both liquid-cooled and air-cooled battery packs?
Yes. The line can be configured for both liquid-cooled and air-cooled energy storage battery designs.

*Does the line support MES integration?
Yes. Cell, module, BMS, welding, testing, and PACK production data can be uploaded to the customer’s MES system. The customer must provide the communication protocol and server interface.

*Can the module size be customized?
Yes. The stacking, compression, conveying, lifting, inspection, and welding fixtures can be customized according to the module dimensions and series-parallel configuration.

*What tests are included?
The line can include OCV and internal resistance testing, polarity inspection, module voltage testing, insulation resistance testing, dielectric withstand testing, BMS communication testing, PACK EOL testing, and air-tightness testing.

*How long does product changeover take?
The reference changeover time is within four hours. Actual time depends on the differences between product models and the number of fixtures or parameters that must be changed.