Complete introduction of battery module PACK automated production line
hit：125 date：2026-06-19
The battery module PACK automation line is an integrated intelligent complete set of equipment that goes from individual battery cells to modules and then to complete battery packs. It is divided into two main sections: the module front-end production line and the PACK back-end whole package production line. It is suitable for square aluminum shells, soft packages, and large cylindrical battery cells, covering scenarios such as new energy vehicles, industrial and commercial energy storage, household energy storage, and engineering machinery batteries.
1、 Standard complete process flow (fully automated line)
First paragraph: Cell pre-processing&module assembly (module line core)
Scanning code for battery cell loading: Robot loads the entire pallet, single scan code binding SN, one item one code traceability
OCV/DCR sorting: automatic measurement of open circuit voltage, internal resistance, thickness, polarity, automatic removal of NG cells, ensuring consistency of cells in the same module
Plasma laser cleaning: remove oxide layer and oil stains from the pole, improve welding strength, and eliminate virtual welding
Battery cell insulation adhesive/end plate coating: automatic application of foam, double-sided adhesive, thermal conductive adhesive, servo precision dispensing
Robot stacking and pressing: Six axis visual stacking, servo pressure monitoring and pressing, accuracy ± 0.2mm, anti cell compression damage
Busbar busbar automatic assembly: automatic feeding and positioning of copper aluminum connectors
Laser/Ultrasonic Welding: Fiber Laser Welding of Pole Columns and Busbars, CCD Real time Weld Seam Detection, Splash Monitoring, and Depth Determination
Module bundling and fixing: steel strip bundling, end plate locking, size correction
Module insulation withstand voltage test: insulation resistance, high voltage Hi pot withstand voltage, polarity conductivity detection, automatic shunt for defects
Module static EOL initial inspection: overall voltage internal resistance retest, module offline cache
Second paragraph: PACK assembly (battery pack wire)
Cleaning of the lower box body and airtight testing of the liquid cooling plate: dust removal of the box body and leak detection of the water cooling pipeline
Automatic application of thermal conductive adhesive on liquid cooled plates
Module automatic box entry and servo locking
Automatic assembly of high-voltage copper bars, sampling harnesses, and temperature probes
BMS/high voltage contactor, fuse assembly, program burning
Sealing and gluing the upper cover, tightening the locking attachment
Whole package air tightness testing (IP67)
Complete EOL comprehensive testing: charge and discharge activation, BMS communication, pre charging, high-voltage interlock, capacity, temperature difference full detection
Finished product coding, packaging offline, AGV warehousing
2、 Classification of the three major configurations of the production line (automation gradient)
1. Semi automatic PACK line (budget of 800000 to 3 million)
Artificial cell feeding, manual stacking, and manual assembly of wiring harnesses; Only welding, airtight, EOL automatic
Beat 3-5 PPM, suitable for small batches, multiple models, and small energy storage factories
Advantages: Low investment and small footprint; Disadvantages: More manual labor, poor consistency, incomplete traceability
2. Standard fully automatic module PACK line (mainstream 2.8-12 million)
Robot automatic loading and unloading, full process automation, automation rate of 90%+
Beats 6-12PPM, compatible with multiple battery cells, can be replaced within 30 minutes
Standard configuration includes visual inspection, automatic NG removal, MES data collection, and energy storage/vehicle enterprise standard selection
3. High flexibility high-speed whole line (12-20 million+)
Multi robot linkage, AGV intelligent logistics, CTP/CTC compatibility, multi category co production
Rhythm of 15-20 PPM, compatible with three-dimensional storage and fully automatic drying rooms, used by head power battery factories
Integrated AI weld quality inspection, digital twin, virtual debugging, and full process closed-loop traceability
4、 Core advantages of automated PACK production line
Significant improvement in quality consistency
Manual operation error elimination, digital closed-loop of welding, pressure, and testing parameters, module pressure difference ≤ 5mV, overall line yield ≥ 99.5%, significantly reducing after-sales safety hazards.
Reduce labor costs by half
The semi-automatic line has 12-18 people per shift; The fully automated line only has 3-6 people on duty, and the long-term production amortizes equipment costs.
Full lifecycle quality traceability
Each battery cell, module, and battery pack are bound with SN, and welding parameters, test data, and equipment parameters are stored in the cloud, with one click fault tracing.
Standardization of Safety Control
High voltage process isolation, automatic short circuit protection, welding smoke purification, explosion-proof electrical, anti mistake scanning to prevent reverse connection and wrong installation.
Flexible quick changeover
Modular installation, one click program switching, compatible with multiple capacity square shell battery cells, suitable for product iteration.
Digitization of production data
Real time production capacity, yield, equipment utilization rate, and defect statistics, integrated with factory ERP to achieve intelligent production scheduling
5、 Core factors affecting price
Automation level: Semi automatic/Standard fully automatic/High speed flexible line with significant price difference
Production cycle PPM: The more output per minute, the more robots, welding, and testing stations will increase exponentially
Compatibility range of battery cells: single cell vs multi capacity compatibility, non-standard tooling costs 20% -40% more
Core equipment brands: Imported lasers, servos, robots are about 30% higher than domestic ones
Integrity: Only module line/module+PACK integrated whole line/supporting storage AGV, drying room
Intelligent configuration: equipped with MES, AI visual inspection, digital twin, remote operation and maintenance
Process customization: liquid cooling system, high-pressure explosion-proof, friction stir welding, CTP process with additional charges
Delivery support: turnkey installation, on-site debugging, training, warranty period, on-site after-sales service
6、 Complete pre-sales, in sales, and after-sales supporting services
Pre sales technical services
Factory layout planning, 3D simulation of production lines, and capacity estimation
Customize process flow based on cell size, series parallel scheme, and cooling method
Free sample welding, stacking, testing process validation
Provide production line investment return analysis, workshop power distribution/gas supply/dust removal solutions
Interface scheme for MES/ERP system with clients
Delivery service during sale
Visualization of modular equipment production progress, factory full load joint debugging
Overall packaging, professional logistics, equipment positioning and lifting guidance
Turnkey project: equipment installation, pipeline wiring, program debugging, cycle optimization to meet production standards
Special training for operators and equipment maintenance engineers (operation, changeover, troubleshooting, welding parameter debugging)
After sales maintenance service
1-3 year warranty for the entire machine, original factory warranty for laser and robot core components
24/7 remote technical support, engineers will come to repair within 48 hours nationwide
Regular preventive inspections: clean the optical path, calibrate vision, replace vulnerable seals, and perform servo maintenance
Long term spot supply of original vulnerable parts (welding heads, lenses, rubber valves, sealing rings, etc.)
Production line upgrade and renovation: adding compatible battery cells, speeding up renovation, installing AI detection, MES upgrade
Lifetime process technical support, free optimization and debugging of new product battery cell processes
7、 Mainstream application scenarios
PACK line for power batteries of new energy passenger vehicles and commercial vehicles
Industrial and commercial energy storage cabinets, household energy storage battery module production line
Forklift, construction machinery, AGV lithium battery PACK production line
Large capacity battery automation line for two/three wheeled electric vehicles
Communication backup power supply, special military energy storage module production line
