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PRISMATIC LITHIUM BATTERY PACK ASSEMBLY LINELINE
What are the components of a prismatic lithium battery pack?
The main materials of the prismatic lithium battery pack include prismatic battery cells, battery management system, steel strip/plastic steel strip, busbar, positive, negative, etc.
What equipment are required for assembling the prismatic lithium battery packs?
The automated/semi-automatic prismatic battery pack assembly line used to integrate and assemble individual prismatic battery into battery modules or battery packs. The main equipment of prismatic battery pack assembly line includes battery capacity grading machine, battery OCV&ACIR sorting machine, battery stacking and pressing machine, laser cleaning machine, laser welding machine, BMS tester, battery comprehensive tester, battery pack aging machine.
Option 1 —— Semi-automatic prismatic lithium battery pack assembly line
Flow chart of Manual/Semi-auto prismatic battery pack assembly line:
[Cell capacity grading] → [Cell voltage & IR sorting] → [Module stacking & pressing] → [Terminal laser cleaning] → [Module laser welding] → [BMS testing] → [Battery pack comprehensive testing] → [Battery pack aging testing]
Option 2 —— Full-automatic prismatic lithium battery pack assembly line
Flow chart of Auto prismatic battery pack assembly line
[Robot Loading] → [OCV Sorting] → [Automatic Stacking] → [CCD Polarity Detection] → [Laser Cleaning] → [Laser Welding] → [Module EOL] → [AGV Loading] → [Automatic Glue Lock Attachment] → [Pack Air tightness Test] → [PACK EOL Test] → [PACK Off-line]
Capacity Grading Machine
Energy Feedback
Different Fixtures Optional
20A/30A/60A/100A/200A/300 Etc
8/16/32/48/64/128/160/256 Channels Optional
Customization Avaliable
Product Description
Prismatic battery cell grading machine is an automatic detection and capacity division system for rechargeable batteries; It has the characteristics of high precision and energy saving. Suitable for the formation, capacity separation testing, and capacity sorting of lithium batteries.
Main Features
Each battery channel has a completely independent constant current and constant voltage source, forming its own circuit without affecting each other.
The software has the functions of editing and modifying the process library files, creating monitoring, opening and closing documents, printing and setting up.
Product Selection
| Prismatic Battery Capacity Grading Machine |
| Equipment Type |
Energy Regenerative |
| Clamps |
Standard flat head fixture( optional alligator clip) |
| Machine Model |
5V 30A |
5V 60A |
5V 100A |
5V 200A |
5V 300A |
5V 400A |
More Customization |
| Channels |
8/16/32/64/128CH etc |
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Stacking & Pressing Machine
PLC + Touch Screen Control
50 Groups/Hour (10 Batteries Per Group)
Customized Stacking Pressure
Product Description
Battery sorting machine is used to test the open-circuit voltage and AC internal resistance of general prismatic lithium battery.
Main Features
Adapted to various types of batteries, easy to replace and operate.
Built in high-precision Japanese BT3562A/HIOKI internal resistance tester, with high testing accuracy and fast speed.
Product Selection
| Prismatic Battery Sorting Machine |
| Barcode Scanner |
Standard |
| Tester |
HK3561/HIOKI BT3562 Optional |
| Sorting Channels |
7+1=8CHS |
9+1=10CHS |
Customizable |
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Stacking & Pressing Machine
PLC + Touch Screen Control
50 Groups/Hour (10 Batteries Per Group)
Customized Stacking Pressure
Product Description
Prismatic battery stacking and pressing machine is suitable for stacking and forming prismatic lithium batteries, as well as trapping them.
Main Features
7-inch touch screen with PLC for control, easy to operate.
Adapt to various size of batteries, can be edited and set different parameters, simple and easy to change the type.
Product Selection
| Prismatic Cell Stacking And Pressing Machine |
| Control |
PLC+Touch Screen Control |
| Strips |
Plastic Steel Strips |
Steel Strips |
Customizable |
| Stacking Pressure |
100KG |
500KG |
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Laser Cleaning Machine
Laser Cleaning & Marking
Auto, Atic & High Efficiency
Customization Avaliable
Product Description
Laser cleaning machine is used in the assembly of prismatic lithium-ion battery packs to clean terminals, busbars, connectors, battery modules, housing surfaces, and BMS contact points, remove oxides, dust, and debris, to ensure strong and reliable electrical connections and appropriate thermal management.
Main Features
Cleanliness level ≤ 100000
No corrosive gas, liquid or explosive gas on site
Laser Welding Machine
Customized Welding Stroke
Welding Material: Aluminium/Nickel/Copper Etc
Welding Power:
10000W/1500W/2000W/3000W/4000W/6000W Optional
Customization Avaliable
Product Description
Laser welding machine is the most valuable and technology intensive core equipment in the PACK production line, mainly responsible for electrical connections between cells and busbars.
Main Features
Continuous pure fiber laser, which can penetrate 0.5-5.8mm materials for direct welding.
Precise servo system control to ensure welding accuracy.
Product Selection
| Prismatic Battery Laser Welding Machine |
| Welding Material |
Aluminium, Nickel, Copper, Composite Material etc. |
| Welding Method |
Manual |
Automatic |
| Product Type |
Handheld |
Gantry |
Gantry |
| Power |
1500W/2000W/3000W |
1500W-6000W |
1500W-6000W |
| Welding Thickness |
0.3-3.5mm |
0.5-5.8mm |
0.5-5.8mm |
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Management System Tester
1-52 Series Battery Pack
Support Smart/Hardware BMS
120A-800A Overdischarge Current
With Computer
With Temperature Test Function
With Can
Customization Avaliable
Product Description
BMS Tester is a specialized device designed to verify the functionality and performance of battery protection boards (BMS).
Main Features
Overcharge/Overdischarge Protection Test
Overcurrent/Short Circuit Protection Test
Temperature protection test
Internal resistance and conduction resistance testing
Self consumption detection
Communication function verification (for intelligent BMS): Test communication interfaces such as CAN, RS485, I2C, etc. to read SOC, voltage, temperature and other data accurately.
Product Selection
| Battery Management System Testing Machine |
| Pack Series |
1-52S Battery Pack/Module |
| Current |
120/150/200/300/400/500/600/800A etc |
Customizable |
| Computer |
Without computer |
With computer |
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Comprehensive Tester
Voltage Range: 60V-200V
Charge Current Range: 30A-300A
Discharge Current Range: 120A-600A
With Computer
Customization Avaliable
Product Description
Battery comprehensive tester is suitable for all lithium-ion battery packs with CH+P+CH - P - ports to test various comprehensive performance parameters of the battery pack.
Main Features
The battery comprehensive tester is to apply a load to the battery or apply a small AC current to measure the open circuit voltage, AC internal resistance, discharge test, discharge overcurrent test, short circuit protection test, charge test and charge protection test and other parameters to quickly screen and judge the performance of the battery and good or bad, by setting the upper and lower limits of the measurement parameters, it is easy to quickly detect the bad battery from a batch of finished batteries.
Product Selection
| Battery Pack Comprehensive Tester |
| Voltage Range |
50/60/100/120V/200V etc |
Customizable |
| Current Range |
120/200/300/500/600A etc |
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Aging Tester
Energy-Feedback Optional
Voltage Range: 20V-1650V
Discharge Current Range: 10A-1200A
Aging Channel: 7-100 Channel Optional
Customization Avaliable
Product Description
Battery pack aging machine is applied to the integrated charge discharge cycle test system of low string lithium battery pack cycle charge and discharge, battery pack function test and charge discharge data monitoring, such as electric tools, solar energy storage, fascia gun and so on.
Main Features
The device has four test steps: charging, discharging, shelving, and cycling. By editing the corresponding steps, the battery can be tested in accordance with the set process.
Product Selection
| Battery Pack Aging Testing Machine |
| Voltage |
20V-1650V |
Customizable |
| Current |
10A-1200A |
| Channels |
1/2/3/4/6/7/8/12/16/32 etc |
| Type |
Standard type/with energy regenerative function (optional) |
| Voltage&Current |
30V 10A charge 20A discharge |
70V 5A charge 10A discharge |
70V 10A charge 20A discharge |
85V 10A charge 20A discharge |
100V 10A charge 20A discharge |
100V 20A charge 40A discharge |
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Key Indicators for Designing Prismatic Battery Pack Factory
1. Capacity target: Clearly define annual production capacity (such as 1GWh/Year) or daily production requirements
2. Battery cell type: Prismatic cell type (Eg: 100Ah/280Ah/314Ah) which determines the module structure, fixture design , and line layout.
3. Product applications: Energy storage batteries, electric vehicles, drones, electric tricycles, ets.
4. Automatic level requirements: Semi-auto or full auto.
5. The specific process flow for manufacturing prismatic battery pack.
6. Estimated budget range and factory layout.
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