Semi-automatic
BLP-P8SOutput bought with operators and a narrower building, on a 56 by 10 m run.
- Takt
- 4 – 8 PPM
- Installed power
- 200 kW
- Annual output
- 500 MWh – 1 GWh
Turnkey module & pack lines
Battery Assembly Line Systems for Module and Pack Plants
BatteryLine Pro builds turnkey battery assembly line systems for plants that receive finished cells and ship tested packs. Three line tiers run at 4 to 8, 8, and 12 to 15 PPM, built around 17 module stations and 15 pack stations, laser busbar welding and full EOL testing.
Energy storage pack makers, EV module and pack suppliers, and system integrators moving upstream buy the whole line, one workstation, or a retrofit of one segment.
Cell handlingModule segmentPack segmentLine-off
- 4 to 15 PPMThree battery assembly line tiers
- 500 MWh to 2 GWhA year, on the 314 Ah blueprint
- 17 + 15Module stations and pack stations
- 99% or betterEquipment-caused yield
- 1000 N or moreBusbar pull force
The Module & Pack Line
End-to-end production architecture
Everything after the cell arrives
Battery Assembly Line for Storage Packs
A battery assembly line from us covers everything after the cell arrives: cell testing and sorting, module stacking and welding, pack assembly and testing, line-off.
- Commercial and industrial energy storage pack plants
- Grid-scale storage integrators
- Residential storage manufacturers
- EV module and pack suppliers
- Plants already running a line that need a station added
Certification
ISO 9001, CE and RoHS.
Answer time
A tier recommendation, layout and station list come back within 24 hours.
What a turnkey order covers
Turnkey Delivery Package
More on how we are set up is on the company page.
Installation and commissioning
Done on your floor by our engineers.
Acceptance
Runs against a written station-by-station criteria set agreed before shipment.
Operator training
Covers operation and maintenance for the people who will run each segment, on the line they will run.
- Layout design
- Included
- Equipment
- Included
- Acceptance
- Included
A complete line
Quoted as one project.
A single workstation
Integrated into a line you already have.
One segment rebuilt
The usual route when a module segment is holding back a pack segment already sized correctly.
Scope boundary
Four Segments After Cell Arrival
Cell handling
Takes cells off the tray, scans and tests each one, sorts it, and refills the gap a rejected cell leaves.
- Stations
- BLP-UL, BLP-CS
Module segment
Groups, cleans, tapes, stacks, presses, addresses, welds and tests until a finished module comes off.
- Stations
- 17
Pack segment
Loads the enclosure and cooling plate, glues, inserts and fixes modules, wires the pack, closes it and tests it.
- Stations
- 15
Line-off
Releases the pack with its test record attached.
- Gate
- Pack EOL, station 14
Both segments are documented in full on the battery module assembly line and battery pack assembly line pages.
Our own designs
Nine Workstations Built In House
Nine workstations are our own designs, built in house rather than bought in and relabelled.
The full range sits on the equipment overview.
BLP-UL
Cell de-tray loading
Takes cells off the tray with a six-axis robot and vision.
BLP-CS
Cell testing and sorting
Scans, tests and sorts them.
BLP-SP
Stacking and pressing
Stacks and presses modules under servo-controlled force.
BLP-AD
Terminal addressing
Addresses terminals and checks polarity.
BLP-W6
Busbar laser welding
Welds busbars in line with a 6 kW laser.
BLP-WG
Off-line gantry welder
For work that does not belong in the takt.
BLP-EOL
Module EOL testing
Runs module end-of-line testing.
BLP-GL
Cooling plate gluing
Dispenses cooling plate and enclosure adhesive.
BLP-CV
Module conveying
Conveys modules between stations.
ISO 9001CERoHSNine stations, our own drawings
Held certifications
Issued against the stations, not the trading company.
Before committing
Ask for the layout drawn to your building and the labelled station list for both segments.
Also on request
The EOL test item list, and the acceptance criteria the line is signed off against.
Takt, footprint, installed power
Three Battery Assembly Line Tiers
The tiers separate on automation level, floor area and installed power. BLP-P8S buys output with people and a narrower building, BLP-P15 with automation and twice the width, and BLP-P8 holds 8 PPM in the smallest footprint.
Standard
BLP-P8Holds 8 PPM in the smallest footprint of the three, at 55 by 9 m.
- Takt
- 8 PPM
- Installed power
- up to 250 kW
- Bay height
- 3.5 m
High automation
BLP-P15Output bought with automation and twice the width, on a 54 by 20 m run.
- Takt
- 12 – 15 PPM
- Installed power
- 300 kW
- Annual output
- 1 – 2 GWh
| Tier | Takt | Footprint L x W x H | Installed power |
|---|---|---|---|
| BLP-P8S semi-automatic | 4 to 8 PPM | 56 x 10 x 4 m | 200 kW |
| BLP-P8 standard | 8 PPM | 55 x 9 x 3.5 m | up to 250 kW |
| BLP-P15 high automation | 12 to 15 PPM | 54 x 20 x 4 m | 300 kW |
Annual output is counted on the 314 Ah blueprint, 300 working days, 8 hours a day. Any tier can be quoted as a battery pack production line alone where a module segment already exists.
Line utilisation, as we define it
A PPM figure alone does not tell you what a line ships in a year. Two numbers sit under it, both written into the contract before the line is built.
- Line utilisation is time utilisation multiplied by performance utilisation multiplied by first-pass yield.
- First-pass yield is input quantity minus NG units divided by input quantity.
- Tier selection against a target output is worked through on the capacity planning page.
99%
or better, counted on equipment causes alone, with human factors excluded from the count.
Every station, named
Battery Module Assembly Line Sequence
Detail is on the module line and pack line pages.
17 Module segment stations
- Cell tray unloading
- Scanning, OCV testing and sorting
- NG rejection and OK refill
- Cell flipping and grouping
- Large-face plasma cleaning
- Cell taping
- End plate and insulation sheet handling
- Module stacking
- Pressing, shaping and steel band strapping
- Polarity and insulation testing
- Terminal addressing with laser cleaning
- Busbar and CCS assembly installation
- Busbar laser welding
- Post-weld cleaning and inspection
- Manual re-inspection and communication testing
- Module EOL testing
- Module line-off
15 Pack segment stations
- Enclosure and cooling plate loading and cleaning
- Cooling plate air-tightness testing
- Enclosure floor gluing
- Module insertion
- Module fixing
- Series copper busbar installation
- BMS installation
- MSD and high and low voltage connector installation
- Harness dressing
- Upper cover installation
- Upper cover tightening
- Front panel installation
- Whole-pack air-tightness testing
- Pack EOL testing
- Pack line-off
Seventeen and fifteen are the numbers we quote against, and every station in both lists is labelled AUTO, SEMI-AUTO or MANUAL in the layout package before you sign.
Where the packs go
Storage and EV Pack Applications
Storage-specific line configuration is covered on the energy storage pack line page.
Commercial and industrial storage
Our first market. Pack count per project is high enough that takt and headcount decide the case.
- Capacity
- 100 kWh – 10 MWh
- Voltage
- 400 – 800 V
- Architecture
- Modular, independent PCS
Grid-scale storage
Second. Containerised with central PCS, liquid-cooled, built from the same prismatic modules.
- Capacity
- 10 MWh – 1 GWh+
- Voltage
- 10 kV and up
- Cooling
- Liquid
Residential storage
Third. Usually air-cooled and built on the semi-automatic tier.
- Capacity
- 5 – 30 kWh
- Voltage
- 48, 120 or 240 V
- Architecture
- Inverter and battery unit
EV module and pack suppliers
Fourth. Arriving with a pack drawing fixed by their customer and a takt fixed by the vehicle line.
- Drawing
- Customer-fixed
- Takt
- Vehicle-line fixed
- Scope
- Module and pack
What the roster will cost you
Line Headcount by Segment
Every quotation for a battery assembly line carries a headcount, and it sets your shift roster and labour cost long after the equipment is paid for. Ours, per segment:
| Tier | Cell handling | Module welding | Pack assembly |
|---|---|---|---|
| BLP-P8S | 4 | 4 | 12 – 14 |
| BLP-P15 | 4 | 3 | 12 – 14 |
The high-automation tier takes one person out of the module segment and none out of the pack segment.
01
Cell handling and the module segment carry the automatic stations: tray unloading, scanning and sorting, stacking and pressing, terminal addressing, busbar welding, module EOL.
02
The pack segment is predominantly manual on every tier, and on BLP-P8 its one automatic station is enclosure floor gluing.
03
That work is:
- Module insertion and fixing
- Series copper busbar installation
- BMS installation
- MSD and connector installation
- Harness dressing
- Cover installation and tightening
- Front panel installation
04
Each changes shape with the pack variant: a different harness route, bracket or connector position. Automating them means dedicated tooling per variant, written off the day that variant is superseded. Twelve to fourteen people absorb a variant change on the day the drawing lands.
Multiply the pack segment headcount by your shift pattern and local labour rate, add it to the equipment figure, and compare that against a quotation calling the same pack segment fully automatic. The gap is usually wider than the gap between the two equipment prices, and it recurs every month.
Station 13 of the module segment
Busbar Laser Welding Station BLP-W6
A 6 kW laser lays each busbar-to-terminal joint at 50 to 100 mm/s, and one station handles single-row and double-row modules without a mechanical change.
≥1.0 mmPenetration
≥1.5 mmBead width
≥1000 NPull force
Three figures define an accepted joint.
Sample
Pull testing destroys the joint, so it can never run on a production module. Parameters are set on sample joints made from your own busbar and terminal material.
Lock
Samples are pulled until the 1000 N floor is met with margin, and the power, speed, focus and beam pattern that produced them are locked as the recipe for that busbar geometry.
Call
The operator does not hold the recipe. It is stored per busbar geometry and called by the part that arrives, and the station will not run a geometry with no locked recipe.
Read
Every production joint is checked on the two measurements that survive the part, penetration and bead width, read at station 14, post-weld cleaning and inspection.
A joint outside penetration or width
- Marked at station 14; the module leaves the flow before manual re-inspection at station 15 and module EOL at station 16.
- Rework is a decision on your side of the line, because a re-welded joint no longer matches the sample the recipe was proved against.
- The station records what it found, so the module is judged on a measurement.
You receive
- The locked recipe for each busbar geometry
- The sample pull-test results it was proved against
- The penetration and width record for every production joint
A burn-through writes off thirteen cells bought with your money, and a cold joint leaves the plant and shows up as rising resistance months later.
Detail is on the busbar welding station page.
Two gates, one record
Cell Sorting and End-of-Line Testing
Two gates carry everything between them: cells are graded before a module is stacked, modules and packs are tested before they leave, and both write to the same record.
Detail is on the cell testing and sorting station and pack EOL testing pages.
BLP-UL · BLP-CS
Incoming gate — scan, test and sort
BLP-UL takes cells off the incoming tray with a six-axis robot carrying vision, and palletises the empty foam trays without an operator. BLP-CS scans, tests and sorts every cell against the criteria you set.
- Robot payload / reach
- 220 kg / 2650 mm+
- Positioning
- 0.06 mm, 5 cells a pick
- Scan success
- 99.9% or better
- Voltage accuracy
- ±0.01% rdg + 3 dgt
- Resistance accuracy
- ±0.5% rdg + 10 dgt
Rejecting a cell is the simple half. The gap it leaves is the half that stops a line, because a module cannot be stacked one cell short and downstream stations are indexed on a full group.
BLP-CS rejects the NG cell and refills the position from the sorted buffer in the same cycle, so the group leaving station 3 is complete and matched.
BLP-EOL
Outgoing gate — module and pack EOL testing
Module end-of-line testing runs at station 16 of the module segment. Four items, each with a pass criterion set before the line runs and recorded per module.
| BLP-EOL test item | Condition | Criterion |
|---|---|---|
| Insulation | DC 1000 V | 500 MegaOhm floor |
| Hipot | DC 2800 V | Leakage 10 mA or less |
| Total voltage and resistance | Per module | Recorded |
| Continuity | Per module | Recorded |
Station 2Cooling plate air-tightness, on its own
Station 13Whole-pack air-tightness
Station 14Pack EOL testing
The cooling plate is tested before a module goes into the enclosure, because a leak found after insertion costs the modules as well as the plate.
Every unit carries a test record from module EOL through to pack line-off, and that record is what your own customer will ask for.
Send Your Cell Specification
A tier recommendation, a layout and a station list come back within 24 hours.
Cell datasheet
Module configuration
Pack drawing
Target takt
Floor plan
Blueprint parts and their limits
Cell and Module Compatibility Envelope
A cell that stays inside the envelope is a tooling change rather than a line change, and that distinction decides what happens when your cell supplier moves you to the next format.
The full picture is on the cell compatibility and changeover page.
Blueprint cell314 Ah prismatic, 72 x 173 x 207 mmThickness by width by height, held to plus or minus 0.5 mm on each axis. The semi-automatic and high-automation tiers are also blueprinted on the 280 Ah cell of the same family, quoted there as 71.3 x 174 x 207 mm.
Blueprint module1P13S, 978.4 x 178.9 x 205 mm100 kg or less.
Blueprint pack1P52S, 1152 x 810 x 243 mm400 kg or less.
Each tier carries an envelope
| Envelope | BLP-P8S and BLP-P15 | BLP-P8 |
|---|---|---|
| Cell | 100 – 220 wide, 100 – 220 high, 20 – 80 thick | — |
| Module | 400 – 1200 x 100 – 300 x 100 – 250 mm | 300 – 1000 x 150 – 370 x 100 – 240 mm |
| Pack | — | 600 – 1200 x 300 – 800 x 100 – 250 mm |
Compatibility with 587 Ah large-format cells is on our roadmap, not a capability of these tiers today.
Changeover tooling inside the envelope
Four things change with the part
- BLP-ULThe gripper and tray pattern, because the pick geometry follows the cell face.
- BLP-SPThe stacking and pressing fixture, since press length is set for the module.
- BLP-ADThe addressing programme and fixture, because terminal positions move.
- BLP-CVThe stop and lift positions, which locate the module for the station that follows.
Four things do not change
- ConveyorThe conveyor run.
- BLP-W6The laser source and gantry.
- InstrumentsThe test instruments in BLP-CS and BLP-EOL.
- BLP-GLThe metering system.
A format change inside the envelope is therefore a set of fixtures and programmes, quoted as such — not a new line, and not a rebuild of the conveyor run.
Stations 8, 9 and 11 of the module segment
Stacking, Gluing and Addressing Stations
Three stations decide whether a module holds its dimension, seals, and presents its terminals where the laser expects them. Each writes a curve the next station reads.
Full data sheets on the stacking and pressing, cooling plate gluing and terminal addressing pages.
BLP-SP
Stacking and pressing
Stacks the grouped cells with their end plates and insulation sheets, presses the stack, and applies the steel bands that hold it.
- Press force
- 0 – 8000 N servo
- Module length
- 300 – 1100 mm
- Sensor reading
- Full stroke
- The 0 to 8000 N range is what the machine can apply; the setpoint inside it belongs to your cell and end plate, fixed at commissioning.
- The sensor reads through the stroke, so every module leaves with a force curve, not a single end-of-stroke number.
BLP-GL
Cooling plate gluing
Dispenses adhesive onto the cooling plate and enclosure floor under dual-servo metering, with camera positioning on every bead.
- Camera positioning
- 0.2 mm
- Bead path
- 2 mm
- Dispensed volume
- Metered to 5%
- Volume is controlled; pressure proves it. A blocked nozzle or an air pocket in the cartridge shows up in the pressure curve while the part is still on the station, long before an air-tightness test.
- Curves upload to your MES over PROFINET, so the record travels with the pack.
BLP-AD
Terminal addressing
Finds every terminal and confirms its polarity before the busbars go on, with one vision set doing both jobs.
- Speed
- 200 – 300 mm/s
- Addressing
- 0.2 mm or better
- Vision
- Locate and polarity
- An address off by more than the tolerance puts the weld off the terminal.
- A polarity read wrong puts a short into a module about to be welded shut — cheap here, expensive one station later.
PROFINET to MESDual-servo meteringServo press, full-stroke curveSingle vision set
All three are quoted as single stations as readily as they are quoted inside a line, because each one is the station a plant discovers it needs after the line is already running — a press that will not hold the module dimension, a bead that fails air-tightness, an address that walks off the terminal.
BLP-CV
Module conveying between them
Moves modules and fixtures between stations, with modular stop and lift units that locate the part for the station that follows.
- Load
- 200 kg or more
- Speed
- up to 20 m/min
- Guarding
- Both sides panelled
- BLP-CV also appears at the handover into the pack segment, carrying modules and fixtures to that point; it does not convey finished packs.
- Detail is on the conveyor system page.
Measured under the lowest obstruction
Building, Floor Load and Utilities
Your building is an input to the layout, and the one most often measured wrong.
- Clear height is measured under the lowest obstruction over the line run rather than to the roof.
- A ceiling service layer of cable tray, sprinkler, ducting and crane rail commonly takes 300 to 500 mm, so a 4 m beam soffit can leave 3.6 m usable.
- Floor loading is 800 kg per square metre or more.
Power
Three-phase five-wire 380 V plus or minus 5% at 50 Hz.
Compressed air and shielding gas
Air at 0.5 to 0.7 MPa; nitrogen shielding gas at 0.5 MPa.
| BLP-P8S | BLP-P8 | BLP-P15 | |
|---|---|---|---|
| Bay | 56 x 10 m | 55 x 9 m | 54 x 20 m |
| Clear height | 4 m | 3.5 m | 4 m |
| Installed power | 200 kW | up to 250 kW | 300 kW |
| Compressed air | 3500 L/min | 3000 L/min | 5500 L/min |
| Nitrogen | 20 – 40 L/min | 40 L/min | 40 – 80 L/min |
On your floor, on your parts
Installation, Acceptance and Operator Training
Detail is on the FAT and SAT acceptance page.
Installation
Installation and commissioning are carried out on your floor by our engineers, working from the layout drawn to your building.
Criteria agreed first
Acceptance runs against criteria agreed before shipment, station by station, with takt measured on the utilisation definition above.
Your parts, our programme
You supply cells, busbars, end plates, enclosures and cooling plates from your own supply chain. We supply the test programme, the recording and the engineers.
Training on the line
Operation and maintenance for each segment, delivered on your line to the people who hold the shift.
The yield criterion is 99% or better on equipment causes with human factors excluded, and both sides agree in writing what counts as an equipment cause before the run.
What lets us answer with a layout
Five Documents to Send
Cell datasheetWith dimensions and tolerances.
Module configurationSeries and parallel count, and finished dimensions.
Pack or enclosure drawingThe pack you have to build.
Target taktIn PPM, or annual output in GWh.
Floor planMarked with clear height under the lowest obstruction, floor loading, and where power, compressed air and nitrogen enter the building.
What comes back within 24 hours
- A tier recommendation with the reason for it
- A layout drawn against your floor plan
- The labelled station list for both segments
- The equipment list behind it
Not every project is a whole line
Single Stations and Line Upgrades
Any of the nine workstations can be quoted on its own and dropped into a line you already run, and one segment can be rebuilt while the rest stays.
BLP-W6
Busbar laser welding
Bought where a line welds busbars by hand or with a fixed-optic head.
BLP-EOL
Module EOL testing
Bought where a plant adds a test gate it did not originally build.
BLP-GL
Cooling plate gluing
Bought where gluing sets the takt.
BLP-WG, the off-line four-axis gantry welder, takes work that should not sit inside the line takt; its data sheet is on the gantry laser welding machine page.
Cylindrical and consumer formats
Branch Equipment for Cylindrical Packs
The same workshop builds a cylindrical and consumer branch: 18650 sorting, taping, wrapping, sealing and nickel strip welding, as single machines or a complete branch line.
Quoted from the same station list.
Also built on this branch
- Dispensing machine for cylindrical cell holders
- Cell back double-sided tape applicator
- Complete cylindrical and consumer lithium pack lines
Those are described on the cylindrical and consumer pack line page.
Your enquiry, ready to send
If your email client opened, it is already in the message. If nothing opened, use one of the two routes below.
Start a project
Start a Battery Assembly Line Project
Send the five documents and we will answer with a layout, a tier recommendation and a station list within 24 hours. For a single station, send the drawing of the part it handles and the takt it holds, and we will quote that instead of a line.
Email
Phone / WhatsApp
Address
Wuhan, Hubei, China
Response
Reply within 24 hours
Reach the engineering team through the contact page.