Scope 01Complete line
A whole line against your building
One project at one of three takt tiers between 4 and 15 PPM, laid out against your bay dimensions, floor loading and utility drops.
- Usual reader
- First line
- Acceptance
- Both segments
Equipment catalogue
Battery Manufacturing Equipment, Station By Station
Nine workstations we design and build for prismatic module and pack lines, and nine more for the cylindrical branch. Each is shown at the position it occupies in the 17-station module or 15-station pack sequence, with the figures that decide the fit.
Module segment17 stations
- 01BLP-UL
- 02BLP-CS
- 03
- 04
- 05
- 06
- 07
- 08BLP-SP
- 09
- 10
- 11BLP-AD
- 12
- 13BLP-W6
- 14
- 15
- 16BLP-EOL
- 17
Pack segment15 stations
- 01
- 02
- 03BLP-GL
- 04
- 05
- 06
- 07
- 08
- 09
- 10
- 11
- 12
- 13
- 14BLP-EOL
- 15
BLP-CV Between stations, and into the pack segment
BLP-WG Off the takt, beside the line
Two of the nine sit outside the sequence.
- BLP-UL Module 01
- BLP-CS Module 02–03
- BLP-SP Module 08–09
- BLP-AD Module 11
- BLP-W6 Module 13
- BLP-EOL Module 16 & Pack 14
- BLP-GL Pack 03
- BLP-CV Between stations
- BLP-WG Off the takt
Red positions are our own designs. The rest are handling, cleaning, taping, fastening and inspection stations supplied with the line.
Supply boundary
Battery Manufacturing Equipment Supply Boundary
The line begins where a finished cell arrives on a pallet and ends where a tested pack leaves the floor. Everything between is ours.
Cell in, tested pack outStated before the enquiry, not after the quotation.
Inside the scope
- Unloading cells from trays, stacking the empty trays
- Grading every cell to a window you sign
- Stacking, servo pressing and steel banding, 300 to 1100 mm
- Terminal addressing, polarity reading, laser cleaning
- Inline busbar welding and off-line gantry welding
- Cooling plate gluing, module insertion, pack assembly
- End-of-line testing on the module and again on the pack
Outside it
- Cell manufacturing: coating, winding, electrolyte filling
- Formation and grading upstream of the pallet
- Container-level assembly after the pack
- Cell supply: the cells that run through acceptance are yours
Three scopes
Three Buying Scopes: Line, Segment, Station
Most enquiries arrive as one of three shapes. Which one yours is decides how much layout work and acceptance sits around the machines, not which machines you get.
Scope 02One segment
A segment holding the rest back
A station sequence with its own acceptance criteria — usually a module segment that cannot feed a pack segment already sized right.
- Usual reader
- Plant already running
- Acceptance
- At the existing takt
Scope 03One station
One machine into your line
Its own interface sheet: transfer height, supply, air and network figures, so it drops into a line somebody else built.
- Usual reader
- Adding one station
- Acceptance
- On your conveyor
The machine specifications are identical in all three cases. A press is the same press whether it arrives as station 08 of a new line or as a pallet on your dock. What changes is the layout work in front and the acceptance behind.
Layout against your building
Signed acceptance criteria
Installation and commissioning
Interface sheet per station
The nine
Nine In-House Battery Manufacturing Equipment Stations
Nine workstations on the module and pack lines are our own designs, not bought-in units carrying our label. Each card gives the position, the two figures customers buy against, and the datasheet.
- In-house workstations
- 9
- Branch machines
- 9 more
- Module stations
- 17
- Pack stations
- 15
BLP-ULModule 01
Cell unloading
A six-axis robot lifts five cells per pick off the tray, checks post orientation and stacks the empty trays.
- 220 kgRobot payload
- ±0.06 mmPositioning
BLP-CSModule 02–03
Cell testing and sorting
Every cell scanned and sorted into up to ten settable grades. Rejects are ejected and the gap refilled from a buffer.
- 99.9%Scan success
- ±(0.5%rdg+10dgt)Resistance
BLP-SPModule 08–09
Stacking and pressing
A servo press closes a stack of 8 to 24 cells, holds it by recipe, measures the length and bands it with steel.
- 0–8000 NPress force
- ±0.5 mmModule length
BLP-ADModule 11
Terminal addressing
One vision set finds each terminal centre and reads polarity in one shot; a pulsed laser cleans a 2 mm ring on the post.
- ±0.2 mmAddressing
- 200–300 mm/sMotion
BLP-W6Module 13
Inline busbar welding
A 6 kW laser welds single-row and double-row modules at 50 to 100 mm/s, on the recipe stored against that busbar geometry.
- ≥1000 NJoint pull force
- ≥1.0 mmPenetration
BLP-EOLModule 16 & Pack 14
End-of-line testing
Insulation, hipot, voltage with resistance and continuity, run once on the module and again on the pack.
- ≥500 MΩInsulation, DC 1000 V
- DC 2800 VHipot, ≤10 mA
BLP-GLPack 03
Cooling plate gluing
Twin servo pumps meter adhesive onto the cooling plate and enclosure floor, with a live pressure trace per pack.
- ±0.2 mmPhoto location
- 5%Dispensed volume
BLP-CVBetween stations
Module conveying
Double-speed chain moves modules on 1200 × 400 mm fixtures, each carrying an RFID tag.
- ≥200 kgLoad
- ≤20 m/minSpeed
BLP-WGOff the takt
Off-line gantry welding
A four-axis gantry beside the line, where a new weld recipe is created and pull tested on samples.
- ±0.01 mmRepeat positioning
- 4–6 PPMReference part
The rest are handling, cleaning, taping, fastening and inspection positions supplied with the line. Both sequences are walked station by station, with the automation label on each, on the module line and pack line pages.
17 module stations
15 pack stations
9 designed here
Station counts, module and pack.
- 17Module stations
- 15Pack stations
- 9Designed in house
- 9Branch machines
- 3Takt tiers
Module 01–03
Cell Unloading, Testing And Sorting
The first three stations decide what the rest of the line works with. A group that reaches stacking complete but mixed passes every station after it and is still a bad module.
BLP-ULModule 01
Unloading, and the tray stack nobody wants to staff
A six-axis robot with 220 kg payload and 2650 mm reach picks five cells at a time to ±0.06 mm. Vision checks post orientation; a cell facing the wrong way never reaches sorting. Empty trays stack automatically and alarm out at twenty layers.
BLP-CSModule 02–03
Measured, graded, refilled from the buffer
Voltage is measured to ±(0.01%rdg + 3dgt) and resistance to ±(0.5%rdg + 10dgt), and each cell falls into one of up to ten settable grades. Cells outside the window are ejected and the gap refilled from a 60-cell buffer, same grade.
Barcode, voltage, resistance, grade and refill go to your MES by cell number. The grading window comes off your datasheet and grouping rules, signed by both sides before shipment.
| Measured | Accuracy |
|---|---|
| Barcode | 99.9% or better |
| Open-circuit voltage | ±(0.01%rdg + 3dgt) |
| Internal resistance | ±(0.5%rdg + 10dgt) |
| Post orientation | Vision, pre-sorting |
Module 08–09
Stacking, Pressing And Banding
BLP-SP takes a stack of 8 to 24 cells with end plates and sheets already placed, closes it, holds it, measures it and bands it — then writes one curve per module.
1 kHz, whole pressForce, platen position and time sampled through approach, dwell and release.
| Parameter | Figure |
|---|---|
| Press force | 0–8000 N servo, 10 N resolution |
| Dwell | 0–60 s by recipe |
| Post-press measurement | ±0.1 mm |
| Module length tolerance | ±0.5 mm |
| Pressing span | 300–1100 mm |
| Cycle, blueprint 1P13S | ≤90 s, banding included |
The blueprint 1P13S module is 978.4 mm long, well inside the span. Recipes carry target force, dwell, target length and banding passes.
Two stations, two automation labels
Station 08 · Auto
Stacking of 8 to 24 cells, end plates and sheets in place.Station 09 · Semi-auto
Press, dwell, measurement and steel banding, operator on the banding pass.Station 09 is written as semi-automatic rather than letting “automatic” cover a position where somebody is standing.
Auto
Semi-auto
Manual
Labelled per station
Full sequence on the module line page; the station on the stacking and pressing page.
Module 11 → 13
Addressing And Inline Welding, One Pair
These two are quoted together more often than separately, and the reason is worth spelling out.
BLP-ADModule 11
Where every terminal actually is
One vision set finds the terminal centre and reads polarity in the same shot; a 100 W pulsed laser then cleans a 2 mm ring on the post. Three seconds or less per terminal, and the coordinates leave as a joint map.
- ±0.2 mmAddressing accuracy
- ≤4 hOpen time after cleaning
Joint map
Weld recipe
BLP-W6Module 13
What the recipe is allowed to assume
A 6 kW laser welds the busbars at 50 to 100 mm/s, to a penetration of 1.0 mm or more, a width of 1.5 mm or more and a pull force of 1000 N or more — single-row and double-row on one station.
- ≥1000 NJoint pull force
- ≥1.5 mmWeld width
Why the pair holds
A recipe fixes beam power, speed and focal position against one joint geometry. If the terminal is half a millimetre from where the recipe assumes, it is running against a different joint — and the pull number stops describing what came out.
What acceptance measures
- Addressing repeatability at station 11, against a standard module
- Destructive pull tests on joints from station 13, against the signed criterion
What gets recorded
- Recipe number, power, speed, defocus and nitrogen flow
- Sequence and timestamp of every weld, by module number
- Station 14 measures weld width on 100% of joints
Datasheets: terminal addressing and busbar welding.
Off the takt
The Off-Line Gantry Welder
A four-axis gantry laser welder standing next to the line rather than in it. Plants running our lines usually take it too; the reason is in the first card below.
±0.01 mmRepeat positioning; CCD location to the same figure available.
| Parameter | Figure |
|---|---|
| Wavelength | 1070 ±10 nm |
| Rated power | 1000 / 2000 / 4000 / 6000 W |
| Fibre core | 14 / 20 / 50 / 100 µm |
| Power adjustment | 10–100%, stability ≤3% |
| Travel | X 800 / 1000, Y 400 / 600, Z 200 / 400 mm |
| Takt, reference part | 4–6 PPM |
What the takt figure is measured on
One clamping, weld length of 600 mm or less, a module-level part with a single busbar row. For anything else we convert to a shift output against your own fixture drawing rather than publish a second headline number.
4 × 2 m footprint
External chiller
5–45 °C ambient
Recipes leave from here
First articles
A new busbar recipe is created here, welded onto samples and pull tested before it goes near the takt.
Rework under a part number
Parts pulled off the line are rewelded here to the recipe stored against their own part number, not to whatever is convenient on shift.
Low-volume welding
Module or bracket welding for a plant that does not yet need an inline welder, on either of two frame sizes. Detail on the gantry page.
Module 16 & Pack 14
End-Of-Line Testing, Module And Pack
BLP-EOL appears twice on a line, and reading that as duplication is the commonest misreading of the station list.
| Module station 16 | Pack station 14 | |
|---|---|---|
| Object under test | One module — 13 cells in series on the blueprint 1P13S, its own busbars and barriers | A complete 1P52S pack: enclosure, cooling plate, BMS, MSD, connectors, harness |
| Insulation path | Cell group to module structure | Runs to a metal enclosure absent at module 16 New path |
| Failures it catches | Cell and module level: a bad joint, a displaced barrier, a cell out of grade | Assembly: a pinched harness, a fastener through a barrier, a connector not seated |
| What a failure costs | One module, held before it is glued in and wired to twelve others | A pack opened again after gluing, fixing and harness dressing |
| Items run | Insulation at DC 1000 V against 500 MΩ or better · hipot at DC 2800 V, leakage 10 mA or less · total voltage with resistance · continuity | |
Why the module run earns its place
- It separates a problem the cells or module segment created from one the pack line created.
- Without it, every failure at pack 14 is an argument about whose station caused it.
- On the branch, packs at 60 V or under get DC 500 V insulation instead of a DC 2800 V hipot.
Insulation
Hipot
Voltage and resistance
Continuity
Thresholds and fixtures on the end-of-line testing page.
Send four things
An Equipment List, Named Station By Station
Your cell datasheet, module and pack configuration, target takt, and what is on your floor now. Back within 24 hours: every machine named, its position in the two sequences, and whether this reads as one station, a segment or a whole line.
Cell datasheet
Module and pack configuration
Target takt or annual output
Your existing line, if any
Pack 03
Gluing And The Pack Segment
BLP-GL applies adhesive to the enclosure floor and cooling plate before modules go in. It is also one of only four automatic stations out of fifteen on the pack segment.
Volume, not speedA fast thin bead covers the same path as a correct one.
What the station controls
- Camera location ±0.2 mm, bead path ±2 mm, volume to 5% on twin servo pumps
- Two-component adhesive, ratio settable 1:1 to 2:1, static mixer changed in line
- Path, volume and pressure to your MES over PROFINET, by pack number
The pressure trace exposes a partially blocked nozzle: the path completes, pressure climbs, delivered volume drops below the window, and the part is held rather than passed on looking finished.
Open time is counted, not assumed
A part past the stored open time is held: uncured, cleaned and recoated in the station; cured, sent to rework under its enclosure number.
Cooling plate
Enclosure floor
One pressure trace per pack
Pack segment, all fifteen stations labelled
Auto Semi-auto Manual- 01
- 02
- 03
- 04
- 05
- 06
- 07
- 08
- 09
- 10
- 11
- 12
- 13
- 14
- 15
- 4 of 15Auto: leak test, gluing, pack leak, EOL
- 3 of 15Semi-auto: insertion, tightening, offload
- 12–14People on a P8S or P15 pack segment
Module fixing, copper bar mounting, BMS and MSD installation, harness dressing and lid fitting are hands. Station by station on the pack line page.
Between stations
Module Conveying
Modules on fixtures, not finished packs
- Load
- 200 kg or more
- Speed
- 20 m/min or less
- Stop repeat
- ±0.5 mm
- Lift pin
- ±0.1 mm, 30 mm stroke
It does not carry packsThe blueprint module is 100 kg or less, so the rating carries roughly a factor of two. The 1P52S pack is 400 kg or less and moves on pack-segment handling.
Sections and transfer heights on the conveyor system page.
Cylindrical branch
Nine More Machines For Cylindrical Packs
Power tools, light electric vehicles and portable storage are built from 18650, 21700 and 26650 cells. Seven single stations, two complete lines.
Cell sorter
4,000–6,000 cells/h · 10 grades
Insulation washer
≤0.3 mm offset · 40–60/min
PVC sleeve and shrink
Zoned heat · 40–60/min
Side tape
Per bracket · 40–60/min
Nickel tab weld and bend
0.1–0.3 mm · 60–90 welds/min
Bracket adhesive
±0.2 mm · ±5% metering
Shell heat sealing
15–25 pieces/min
Cylindrical pack line
300–600 packs/shift
Consumer pack line
500–1,000 packs/shiftBLP-CLSemi-automatic line
Sorting through to packing
Sorting, bracket loading, nickel welding, BMS assembly, testing and packing, on 5S2P to 13S4P builds. Sampled pull testing at 30 N or more.
300–600 packs per shift
BLP-CMSemi-automatic line
Protection board through to test
Protection board welding, taping, bending, packing and testing — voltage, resistance, charge and discharge function, insulation.
500–1,000 packs per shift
The branch shares three rules with the main line: the sorting window is agreed in writing, welding parameters live in recipes, and operators do not hold them. Both lines on the cylindrical and consumer page.
One rule, four machines
Recipes And Signatures Across Stations
Every station that puts energy into a part runs from a stored recipe, and three rules cover all of them.
Operators select, never editThe process engineer writes recipes; quality countersigns each change.
The three rules
- Stored by part number. A busbar geometry, a bracket and strip specification, a module type — each has its own set, and the machine will not run one against another.
- Selected, not edited. The shop-floor account calls a recipe and releases a held part; it cannot change a number.
- Two signatures per change. Process engineer writes, quality countersigns, both names recorded.
Off-line to inline, unchanged
A recipe for a new busbar geometry is created on BLP-WG, welded onto samples and pull tested. Once the samples meet the criterion, it moves to BLP-W6 unchanged — same format, same part number, same two signatures.
BLP-W6Inline busbar welding — power, speed, focal position, nitrogen.
BLP-WGOff-line gantry — where recipes are created and proved.
BLP-CWBranch nickel welder — bracket and strip instead of busbar.
BLP-SPPress — target force, dwell, target length, banding passes.
You receive a recipe list covering every welded and pressed part number, plus a change record: what changed, by whom, when.
Scope 03, in detail
One Station Into An Existing Line
A machine specification is half of what decides whether a station fits a line somebody else built. The other half is the interface sheet, different for every machine.
One sheet per stationYou get the sheet for the station you are buying, marked up against your line.
BLP-SP as the worked example
Transfer height is 900 ±50 mm, adjustable against your existing conveyor. Modules travel on their fixture, handed over by BLP-CV. Communication is PROFINET, force curve and pressed length by module number.
Those figures belong to BLP-SP and nothing else. BLP-WG is 4 × 2 m, 10 to 25 kW, external chiller. One house standard for both would be wrong for at least one.
Send four things, get the sheet back
The layout it is joining, conveyor height and pitch either side, and the fixture drawing.
- Reply
- Within 24 hours
- Minimum order
- One machine
- Acceptance
- On your conveyor
| BLP-SP interface | Figure |
|---|---|
| Transfer height | 900 ±50 mm, adjustable |
| Handover | Module on fixture, from BLP-CV |
| Communication | PROFINET, by module number |
| Rated power | 8 kW, 380 V, 50 Hz |
| Compressed air | 0.5–0.7 MPa, ≤200 L/min |
| Changeover | Platen, fixture, stops — about 2 h |
Envelope ranges on the cell compatibility page; bay dimensions on the layout and utilities page.
Before it ships
Battery Manufacturing Equipment, Run Before Shipment
A line is set up in your ordered configuration, powered and run in a pre-assembly bay — not shipped as crates to be discovered on your floor.
The bay, and who stands in it
The assembly hall is 6,000 square metres with three pre-assembly bays. Factory acceptance happens there, on your cells, busbars, end plates, enclosures and cooling plates, against criteria signed before shipment.
- 8Mechanical
- 6Electrical and controls
- 4Laser and vision process
- 8Field installation
26 engineers
3 pre-assembly bays
40+ line segments into 12 countries
- Send your cell drawing, configuration and takt two weeks ahead and a bay is set up for your visit.
- Wear parts ship within 48 hours; remote diagnostics connect for fault work.
- Acceptance step by step on the FAT and SAT page; the team on about.
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
Battery Manufacturing Equipment List In 24 Hours
Four lines to our engineering team and an equipment list naming each machine, its position in the two sequences, and whether this is one station, a segment or a complete line comes back within 24 hours.
Email
Phone / WhatsApp
Address
Wuhan, Hubei, China
Response
Within 24 hours