Automatic Lithium Ion Battery Pack Assembly Line For Energy Storage System

Automatic Lithium Ion Battery Pack Assembly Line For Energy Storage System

Product Overview

ACEY-PAL-ESS Automatic Prismatic Battery Pack Assembly Line is designed for the production of prismatic lithium battery modules using 50–314Ah cells. The line combines automatic testing, CCD inspection, laser cleaning, laser welding and conveyor transfer with flexible manual assembly workstations.
It is suitable for 8S1P and 8S2P battery modules and can be customized according to cell dimensions, module structure, busbar design, production capacity and factory layout.

Applications
This prismatic battery pack assembly line can be used for:

• Energy storage battery module production
• Commercial and industrial energy storage systems
• Residential energy storage battery packs
• Communication backup power batteries
• UPS battery systems
• Customized prismatic lithium battery modules

Cell and Pack Information

Production Process

Manual cell loading → Automatic OCV and internal resistance testing →  Automatic cell sorting and NG rejection →  Manual cell transfer and module stacking →  Automatic module pressing and manual steel strip or PET tape installation →  CCD polarity detection → Terminal addressing and laser cleaning → NG discharge → Manual busbar installation → Automatic busbar laser welding → Manual post-weld cleaning and inspection → Finished battery module unloading

Note: The yellow part is the automatic workstation, and the rest is the manual workstation

Workstation Planning

Production Line Specifications

Main Equipment

1. OCV Sorting Workstation

Battery cells are manually placed on the feeding conveyor and automatically transferred to the testing position. The system performs OCV and internal resistance testing before sorting the cells into corresponding channels.
Cells that fail the test are automatically transferred to the NG buffer area. An alarm is activated when the buffer becomes full.

Main functions include:

• Automatic OCV testing
• Automatic internal resistance testing
• Cell parameter classification
• Automatic NG rejection
• Full-buffer alarm
• Multiple sorting channels

2. Stacking and Pressing Workstation
After the cells are manually stacked on the tooling pallet, the module is transferred into the pressing station.
The electric cylinder applies controlled pressure to the battery module. Both pressing force and travel distance can be adjusted according to the module structure.

Main functions include:

• Tooling pallet positioning
• Adjustable pressing pressure
• Adjustable pressing stroke
• Module end-plate positioning
• Steel strip or PET tape installation
• Compatibility with different module sizes

3. Polarity Detection and Laser Cleaning Workstation
The module is transported into the workstation by the conveyor system. Sensors detect and position the incoming pallet before the inspection process begins.
A barcode scanner identifies the module, while the three-axis gantry moves the CCD camera and laser cleaning head across each cell terminal.

Main functions include:

• Module barcode scanning
• CCD polarity detection
• Terminal position inspection
• Pole addressing
• Automatic terminal laser cleaning
• Automatic NG identification and discharge
• Three-axis gantry positioning

4. Automatic Laser Welding Workstation

The module pallet is automatically positioned inside the laser welding station. The barcode scanner reads the module information, and the gantry system moves the camera and welding galvanometer to each welding position.
The ranging system automatically adjusts the working distance, while the vision system identifies reference points before welding.

Main functions include:

• Automatic pallet positioning
• Barcode-based program selection
• Visual mark-point recognition
• Automatic height measurement
• Galvanometer laser welding
• Programmable welding paths
• Automatic transfer after welding

Modular Line Tooling Tray
The tooling tray transports and positions the battery module throughout the production line.
The tray can be customized according to the cell size, module arrangement and busbar dimensions.

1) The tray measures 1200mm x 600mm and is compatible with 280-320AH (2P8S);
2) It uses 20mm bakelite insulation, ensuring durability and preventing stripping of screws during fixture replacement;
3) The busbar fixing plate is designed with fiberglass board, tailored to the busbar dimensions, ensuring the busbar remains stationary while moving on the production line. This allows for fully automated laser welding without operator supervision.

1. Each workstation is equipped with an electronic ESOP touchscreen, accommodating A3 and A4 paper (landscape orientation, adjustable).
2. Each workstation is equipped with LED lighting and an independent switch button.
3. The entire conveyor line is equipped with a single electrical control cabinet, driven by a PLC and featuring a touchscreen, allowing manual selection of any workstation.
4. The conveyor line structure is a vertical circulating system, with two drive units on each level, all equipped with frequency converters and adjustable speeds via the touchscreen.

Factory Installation Requirements

*What Battery Cells Can This Assembly Line Process?
The standard production line is compatible with 50–314Ah prismatic battery cells. The reference configuration is designed around 280Ah and 314Ah cells.

*Is This A Fully Automatic Battery Pack Assembly Line?
This configuration combines automatic and manual workstations. OCV testing, cell sorting, CCD inspection, laser cleaning, NG rejection, conveyor transfer and laser welding are automated. Cell loading, stacking, busbar installation and final unloading are completed manually.
The automation level can be upgraded according to the production requirements.

*What Battery Module Configurations Are Supported?
The reference line supports 8S1P and 8S2P modules. Other module configurations can be developed by adjusting the tooling trays, fixtures and control programs.

*How Is Welding Accuracy Controlled?
The laser welding workstation uses visual positioning, barcode identification, automatic ranging and programmable gantry movement to locate each welding position before welding.

*Can The Line Be Customized For Different Busbars?
Yes. The busbar positioning plate, welding path, laser parameters and tooling fixtures can be customized according to the busbar dimensions, material and module design.

*What Information Is Required For A Customized Solution?
Please provide the cell dimensions, cell capacity, module configuration, busbar drawing, required production capacity, factory layout and preferred automation level.