Language :

English

XIAMEN ACEY NEW ENERGY TECHNOLOGY CO., LTD.

Advanced Lithium Battery Pack Assembly Solutions Provider.

CALL US+8618950009155 Email Usallen@xmacey.com

6S1P 6S2P LiPo Pouch UAV Battery Assembly Line

ACEY-PAL-UAV UAV Battery Assembly Line is designed for LiPo drone battery production. It covers cell grading, sorting, tab cutting, ultrasonic welding, BMS testing, pack testing, and aging, with customizable configurations for different polymer battery specifications.

Brand:
ACEY
Item No.:
ACEY-PAL-UAV
Compliance:
CE Certified
Warranty:
One-year warranty with lifetime support
Order(Moq):
1 set
Payment:
T/T
Product Origin:
China
Lead Time:
7-35 days

INQUIRE now

Product Catalog

New Products

Product Detail

6S1P 6S2P Semi-Automatic LiPo Pouch UAV Battery Assembly Line

Product Overview

ACEY-PAL-UAV Semi-Automatic Pouch UAV Battery Assembly Line is designed for producing high-power lithium polymer battery packs used in drones and UAVs.

The assembly line covers the main production and quality-control processes, including cell capacity grading, voltage and internal resistance sorting, tab cutting, ultrasonic tab welding, BMS testing, comprehensive pack testing, and charge-discharge aging.

Manual loading and material transfer are combined with dedicated processing and testing equipment. Compared with a fully automatic production line, this configuration requires a lower initial investment and provides greater flexibility for different pouch cell sizes, battery pack structures, and production volumes.

The equipment configuration, fixtures, testing range, and line layout can be customized according to the customer’s cell specifications, series-parallel configuration, battery capacity, voltage, and required output.

Main Applications

This production line is suitable for manufacturing pouch battery packs used in:

FPV and racing drones
Agricultural spraying drones
Aerial photography drones
Surveying and mapping UAVs
Industrial inspection drones
Logistics and delivery drones
Emergency and rescue UAVs
Other high-discharge lithium battery applications

Assembly Process

Welding Process

Pouch battery pack welding process

Step 1: Battery Cell Capacity Grading
Each pouch cell is charged and discharged under controlled conditions to measure its actual capacity, voltage characteristics, and charge-discharge performance.

Cells with abnormal capacity or unstable performance can be identified before pack assembly.

Recommended Equipment:
ACEY-PCT Series Pouch Cell Capacity Grading Machine

Step 2: Cell Voltage and Internal Resistance Sorting
The cells are tested and sorted according to voltage and internal resistance.
Cells with similar electrical characteristics are grouped together to improve battery pack consistency, discharge performance, cycle life, and safety.

Recommended Equipment:
ACEY-PCSM Series Pouch Cell Sorting Machine

Step 3: Pouch Cell Tab Cutting
The positive and negative tabs are trimmed to the required width and length before welding.
Consistent tab dimensions help improve positioning accuracy and welding quality during the subsequent assembly process.

Recommended Equipment:
ACEY-PTC560 Pouch Cell Tab Cutter

Step 4: Ultrasonic Tab Welding
The pouch cell tabs are connected by ultrasonic welding.
The machine is suitable for welding aluminum tabs and nickel-coated copper tabs. Ultrasonic welding provides a low-resistance connection without adding excessive heat to the battery cells.

Recommended Equipment:
ACEY-USW-3000 Ultrasonic Metal Welding Machine

Step 5: BMS Testing
The battery management system is tested before final integration with the battery pack.
The tester can evaluate overcharge protection, overdischarge protection, overcurrent protection, short-circuit protection, internal resistance, balancing functions, and communication performance.

Recommended Equipment:
ACEY-BP Series BMS Testing Machine

Step 6: Battery Pack Comprehensive Testing
After battery pack assembly, the finished pack is tested for voltage, internal resistance, charging current, discharging current, protection delay time, NTC resistance, and other electrical parameters.
This process verifies whether the battery pack and BMS operate correctly under simulated working conditions.

Recommended Equipment:
ACEY-BIT Series Battery Pack Comprehensive Testing Machine

Step 7: Shrink Film Heat Shrinking
A heat shrink film is applied around the battery pack and heated to form a tight protective covering. This process improves insulation, appearance, and protection against dust and mechanical damage.

Recommended Equipment:
ACEY-5035C Heat Shrink Packaging Equipment

Step 8: Charge and Discharge Aging
The completed battery packs undergo controlled charging and discharging cycles.
The aging test helps identify packs with unstable capacity, abnormal voltage, excessive temperature rise, poor consistency, or protection-system faults before shipment.

Recommended Equipment:
ACEY-BA Series Battery Pack Aging Machine

Auxiliary Equipment: Wire Cutting and Stripping Machine
The wire cutting and stripping machine is used to prepare the power and signal wires required for drone battery pack assembly. It automatically cuts wires to the preset length and removes the insulation from one or both ends, making them ready for soldering and electrical connection.
Wire length, stripping length, and processing parameters can be adjusted according to the battery pack design and wiring requirements.

Main Equipment Specifications

1. ACEY-PCT Series Battery Cell Capacity Grading Machine
Designed for pouch cell charging, discharging, capacity testing, and performance grading.

Parameter	Specification
Number of channels	64 / 128 / 160 / 256 channels
Battery type	Pouch lithium cell
Fixture type	Blue and white clamp
Fixture spacing	Customized according to cell dimensions
Charging voltage range	DC 0–4.5 V
Discharging voltage range	DC 4.5–2 V
Current options	20 A / 30 A / 40 A / 60 A
Power supply	Three-phase five-wire AC 380 V ±10%, 50 Hz
AC current distortion	≤5%
Operating temperature	-10°C to 40°C
Relative humidity	≤80%

2. ACEY-PCSM Series Pouch Cell Sorting Machine
Used for automatic voltage and internal resistance testing, sorting, and cell matching.

Parameter	Specification
Sorting efficiency	8–10 cells per minute
Equipment utilization	≥95%
Sorting channels	7 channels: 6 qualified and 1 unqualified
Optional configurations	5–7 channels
Cell length	50–170 mm
Cell width	20–100 mm
Cell thickness	4–20 mm
Control system	Industrial computer with embedded system
Input power	Approximately 1 kW
Power supply	AC 220 V, 50 Hz
Compressed air	≥0.6 MPa
Display	21.5-inch monitor
Optional functions	Internal resistance tester and barcode scanner
Machine dimensions	Approximately 1800 × 1570 × 1750 mm

3. ACEY-PTC560 Pouch Cell Tab Cutter
Used to trim positive and negative tabs to consistent dimensions before welding.

Parameter	Specification
Applicable battery	Pouch cell
Positive tab width	5–60 mm
Negative tab width	5–60 mm
Tab center distance	12–150 mm
Maximum input power	≤500 W
Power supply	AC 220 V ±10%, 50–60 Hz
Machine dimensions	450 × 310 × 210 mm
Machine weight	Approximately 14 kg

4. ACEY-SWM-20-6000 Ultrasonic Welding Machine
Designed for welding pouch cell aluminum tabs and nickel-coated copper tabs.

Parameter	Specification
Applicable material	Aluminum or nickel-coated copper tabs
Typical tab thickness	Two layers of 0.2 mm
Typical welding area	20 × 4 mm
Ultrasonic frequency	20 kHz ±200 Hz
Maximum input power	6000 VA
Welding time	0.1–0.8 seconds
Welding pressure	0.1–0.6 MPa
Manual welding head stroke	10–15 mm
Welding modes	Time, energy, and segmented modes
Frequency control	Automatic frequency tracking

5. ACEY-BP Series BMS Testing Machine
Used for testing hardware BMS and smart BMS boards before or after battery pack assembly.

Parameter	Specification
Supported cell series	1~52S and customized configurations
Overcharge voltage range	500–5000 mV
Overdischarge voltage range	500–5000 mV
Voltage accuracy	±1 mV
Overdischarge protection current	120–600 A options
Maximum charging current	50–300 A options
Resistance range	0–999 mΩ
Short-circuit protection time	0–5000 μs
Communication options	UART, CAN, RS485
Configuration	Industrial computer and cabinet

6. ACEY-BIT Series Battery Pack Comprehensive Testing Machine
Used for final electrical and protection-function testing of completed drone battery packs.

Parameter	Specification
Voltage options	60 V / 100 V / 120 V / 150 V
Internal resistance range	0–2000 mΩ
Charging current options	30 A / 50 A / 100 A
Discharging current options	120–500 A
Short-circuit time	0–2000 μs
Overcurrent delay time	0–30 seconds
NTC resistance range	0–100 kΩ
R1 resistance range	0–100 kΩ
Power supply	AC 200–240 V
Configuration	Industrial computer and cabinet

7. ACEY-5035C Heat Shrink Film Packaging Machine

Used to wrap assembled drone battery packs with heat-shrink film, providing reliable insulation, surface protection, and a neat, compact finish.

Parameter	Specification
Item No.	ACEY-5035C
Power supply	380V50-60HZ
Power	15KW
Tunnel Dimensions	Shrinking tunnel size: L1800 x W500 x H350mm
Tunnel Dimensions	*Effective size: W400 x H300mm
Transporting velocity	0-15m/min
Conveying material	Mesh
Conveyor loading	25kg max
Machine size	2100mm x750mm x1620mm (L* W * H)
Weight	around 200kg
Shrink film	PE,POF,PVC,PP

8. ACEY-BA Series Battery Pack Aging Machine
Used for charge-discharge cycling, capacity verification, performance aging, and battery pack consistency testing.

Parameter	Specification
Voltage options	60–750 V, depending on configuration
Charge-discharge current	50–1000 A, depending on configuration
Number of channels	1 / 2 / 4 / 8 / 16 / 32 channels
Channel control	Each channel operates independently
Charging modes	CC, CV, and CCCV
Discharging modes	Constant current, constant power, and constant resistance
Test cutoff conditions	Time, voltage, current, capacity, cell voltage, RSOC and others
Accuracy	±0.05% FS + 0.05% RD
Maximum cycle count	9999
Maximum programmable steps	9999
Maximum nested loops	10 levels

*Auxiliary Equipment: ACEY-35XL Wire Cutting and Stripping Machine

Used for automatic cutting and stripping of multi-strand copper wires, sheathed cables, coaxial cables, and other soft or rigid wires.

Parameter	Specification
Display	7-inch color touch screen
Control System	PLC control
Program Storage	Up to 100 processing programs
Applicable Wire Types	Multi-strand copper wire, coaxial cable, sheathed wire, soft wire, and rigid wire
Drive System	Eight-wheel drive with synchronous-belt dual wire feeding
Applicable Wire Cross-Section	BVR 1.5–35 mm²
Blade Material	Imported high-speed steel
Maximum Guide Tube Diameter	Ø16 mm
Cutting Length Range	0–100 m
Front-End Stripping Length	0–250 mm
Rear-End Stripping Length	0–120 mm
Extended Stripping Option	An optional cutting fixture can be added for longer front-end stripping requirements
Minimum Remaining Insulation Length	50 mm
Cutting Accuracy	±(0.002 mm × L), where L is the cutting length
Processing Speed	Up to 1,500 pieces/hour
Rated Power	650 W
Power Supply	AC 220 V, 50 Hz
Machine Dimensions	560 × 520 × 450 mm
Machine Weight	Approx. 70 kg
Optional Accessories	Wire separating fixture, cutting fixture, and inkjet printer

Key Advantages

*Flexible Production Configuration
The line can be configured according to different pouch cell dimensions, battery pack voltages, capacities, discharge currents, and series-parallel structures.

*Lower Initial Investment
The semi-automatic design reduces equipment investment while retaining automated testing, sorting, welding, and aging processes.

*Reliable Ultrasonic Welding
The 20 kHz ultrasonic welding system provides a strong, stable, and low-resistance connection for aluminum and nickel-coated copper tabs.

*Expandable Configuration
Additional equipment for barcode scanning, insulation, heat shrinking, labeling, inkjet marking, and production data management can be added according to project requirements.

Customization Information Required
To prepare an accurate equipment configuration and quotation, please provide:

Pouch cell dimensions: length, width, and thickness
Cell chemistry, voltage, capacity, and maximum discharge current
Positive and negative tab material, width, thickness, and spacing
Battery pack series-parallel configuration
Nominal voltage, maximum charging voltage, and pack capacity
Battery pack drawing or finished-pack dimensions
BMS series number, current rating, and communication protocol
Required production capacity per hour or per shift
Available factory space, power supply, and compressed-air conditions
Required optional processes such as heat shrinking, labeling, coding, or data traceability

FAQ

*What type of battery is this assembly line designed for?
The line is mainly designed for pouch lithium-ion and lithium polymer battery packs used in drones and UAVs. Fixtures and testing parameters can be customized for different pouch cell sizes and pack designs.

*Is this a fully automatic production line?
No. It is a semi-automatic solution. Operators complete loading, unloading, cell stacking, material transfer, BMS installation, insulation, and packaging, while the key testing, cutting, welding, and aging processes are completed by equipment.

*Can the line produce different drone battery models?
Yes. The fixtures, testing ranges, welding tooling, software parameters, and production layout can be customized for different cell sizes, pack voltages, capacities, and series-parallel configurations.

*Can the ultrasonic welding machine weld both aluminum and copper tabs?
The machine can weld aluminum tabs and nickel-coated copper tabs. The welding horn and fixture must be selected according to the material, number of layers, thickness, and required welding area.

*Can smart BMS boards be tested?
Yes. The BMS tester can be configured for hardware BMS and smart BMS boards using communication interfaces such as UART, CAN, and RS485.

*Can barcode scanning and production data recording be added?
Barcode scanners, testing-data recording, and production traceability functions can be added according to the selected equipment configuration.

*Can heat shrinking and inkjet marking equipment be included?
Yes. Heat shrinking, labeling, inkjet marking, insulation processing, and other auxiliary equipment can be added as optional production stations.

*How is the production capacity determined?
The output depends on the number of cells in each battery pack, operator arrangement, tab welding cycle, cell sorting speed, testing time, and aging-channel configuration. ACEY can calculate a recommended configuration based on the customer’s target output.