Cells in at one end, tested packs off the other — one takt across both segments +86 15327155363 [email protected]
Battery module assembly line with welded and banded modules on their fixtures leaving station 17 on the module conveyor

Module segment · 17 stations

Battery Module Assembly Line, Seventeen Stations

All 17 stations of the battery module assembly line, each labelled AUTO, SEMI-AUTO or MANUAL for BLP-P8S at 4 to 8 PPM and BLP-P15 at 12 to 15 PPM. Graded cells go in at station 01; welded, banded and tested modules leave station 17 on their fixtures, each carrying its press curve, weld recipe and end-of-line results. Send the cell datasheet and module drawing; the station list with a level against your tier comes back within 24 hours.

Send cell and module drawings Read the 17 stations
  • 4 / 3operators On BLP-P8S and BLP-P15 inside the module segment. Cell handling ahead of it is staffed at 4 on both.
  • ≥1000N Pull force on every weld coupon at acceptance, on your busbars, before the segment ships.

One delivered scope

Battery Module Assembly Line Scope, One Delivered Segment

Graded prismatic cells arrive on pallets at one end. Welded, banded and tested modules leave on their fixtures at the other, 17 stations later. The segment is quoted, built, powered up in the pre-assembly bay and accepted as one scope, on one of two tiers.

BLP-P8S module segment rendered at 4 to 8 PPM with the semi-automatic taping and banding posts staffed
BLP-P8S4–8PPM4 operators in the segment. Stations 04, 06 and 17 semi-automatic, 12 manual.
BLP-P15 line rendered at 12 to 15 PPM with cell flipping, taping and line-off automated
BLP-P1512–15PPM3 operators in the segment. Stations 04, 06 and 17 automatic, 12 semi-automatic.

PPM counts cells entering the line at station 01, not modules or packs leaving it.

Who specifies this segment

  • Commercial and industrial storage pack plants.
  • Grid-scale storage integrators moving from bought-in modules to their own.
  • Residential storage manufacturers adding a prismatic module line.
  • EV module suppliers, on a different envelope and fixture set.
Feeds a pack segment at taktA good share of enquiries already run a pack segment sized correctly and need the module segment in front of it to keep up.

Station 01 to station 17

From Sorted Cells to Tested Modules

What arrives is a pallet of cells in foam trays. What leaves is a module that has been graded cell by cell and carries a file. Everything between is one of the 17 stations.

Row of 280 Ah prismatic cells in foam trays arriving at station 01 of the battery module assembly line
Arrives at station 01

A pallet of prismatic cells in foam trays

  • Blueprint cell: 280 or 314 Ah prismatic at 71.3 × 174 × 207 mm, picked five at a time.
  • Built into a 1P13S module of 978.4 × 178.9 × 205 mm, weighing 100 kg or less.
  • Graded at station 02 on OCV and resistance; NG cells ejected, the gap refilled.
Finished 1P13S prismatic module, banded, welded and tested, located on its fixture at station 17
Leaves station 17

A module located on the fixture the pack segment expects

  • Stacked, pressed to a known length and banded; addressed, welded, cleaned and inspected.
  • Polarity and insulation tested, communication checked, end-of-line tested with a verdict filed.
  • Located on the fixture the insertion station is built around, records already in your MES.

EV modules run the same 17 stations

EV module suppliers run the same sequence in the same order as storage customers. What changes is the envelope and therefore the fixtures: stacking pitch, pressing length, busbar geometry and CCS footprint come off your module drawing.

The segment ends at station 17 on purposeEnclosure gluing, module insertion, BMS and connector work, air-tightness and pack testing are the 15 stations of the pack assembly line, quoted as their own scope with their own headcount.
Set of graded prismatic cells grouped for stacking after sorting, before end plates and insulation sheets are placed
Graded cells grouped for one module between stations 03 and 08.
CAD view of the 1P13S blueprint module showing the stacking pitch, end plates and busbar geometry the fixtures are set to
Larger-format prismatic cells inside the 100 to 220 mm width and 20 to 80 mm thickness window the segment accepts

Compatibility envelope

The Cell and Module Envelope the Segment Takes

Six ranges decide whether your module runs on these 17 stations without re-planning them. The red marker on each bar is the blueprint the line is quoted against; anything inside the dark band is a fixture change, not a new line.

Six ranges, one fixture change

DimensionRangeBlueprint
  • Cell · scale 0–240 mm
  • Cell width100–220174 mm
  • Cell height100–220207 mm
  • Cell thickness20–8071.3 mm
  • Module · scale 0–1300 mm
  • Module length400–1200978.4 mm
  • Module width100–300178.9 mm
  • Module height100–250205 mm
Cells per module
8 to 24 on the BLP-SP frame
Blueprint module
1P13S, 100 kg or less
Blueprint pack
1P52S from four modules, 400 kg or less

Delivered with the segment

Four Things That Come With the Segment

Each of the four is written into a document you sign or a file you receive, not claimed for the line afterwards.

Acceptance bench where the 17-station list with a level against each station is signed before the segment ships

Every station labelled before you sign

  • AUTO, SEMI-AUTO or MANUAL against your tier, station by station.
  • In the layout package and again in the acceptance document.
Module end-of-line test station whose four results are filed against the module number with the press curve and weld recipe

A file per module, not a pass stamp

  • Press force curve, post-press length, weld recipe number and end-of-line results.
  • Filed against the module number and sent to your MES over PROFINET.
Busbar weld coupons after pull testing to 1000 N or more during acceptance on the customer's own busbars

Coupons pull tested on your busbars

  • 1000 N or more on every coupon during acceptance.
  • Welded to the recipe stored under your busbar part number, not to a demonstration setup.
Pre-assembly bay where a module segment is built up, powered and run in its ordered configuration before shipping

Yield signed at 99 percent or better

  • Equipment-caused yield, with human factors excluded in writing.
  • Measured over 8 hours continuous at target takt on your floor.
  • 26engineers8 of them field installation and commissioning.
  • 6,000m²Assembly hall where the segment is built up and powered before it ships.
  • 3baysLine pre-assembly bays; factory acceptance runs in one of them on your parts.
ISO 9001CERoHS

The full sequence

Seventeen Stations of the Battery Module Assembly Line

The label each station carries on each tier is what goes into your layout package and your acceptance document. The headcount in the next section is built from these labels and nothing else.

AUTORuns without an operator at the station SEMIOperator-assisted at a machine-paced position MANUALA person does the work  One level higher on BLP-P15
All 17 stations of the module segment with the automation level on BLP-P8S and BLP-P15 and the key figures of the stations that carry a datasheet
#What the station doesBLP-P8SBLP-P15Key figures
01Cell tray unloading and feedingAUTOAUTOBLP-UL 220 kg payload · reach ≥2650 mm · ±0.06 mm · 5 cells per pick
02Scanning, OCV testing and sortingAUTOAUTOBLP-CS scan success ≥99.9% · voltage ±(0.01%rdg + 3dgt) · resistance ±(0.5%rdg + 10dgt)
03NG rejection and OK refillAUTOAUTOBLP-CS automatic ejection · gap refilled from the same stream
04Cell flipping and groupingSEMIAUTO— handling position built into the line
05Large-face plasma cleaningAUTOAUTO— cleaning position built into the line
06Cell tapingSEMIAUTO— taping position built into the line
07End plate and insulation sheet handlingSEMISEMI— handling position, staffed on both tiers
08Module stackingAUTOAUTOBLP-SP 8 to 24 cells per module
09Pressing, shaping and steel bandingSEMISEMIBLP-SP 0–8000 N · 10 N resolution · 1 kHz curve · dwell 0–60 s · length ±0.1 mm measured against ±0.5 mm · cycle ≤90 s
10Polarity and insulation testingAUTOAUTO— test position on the banded module, before anything is welded
11Terminal addressing and laser cleaningAUTOAUTOBLP-AD 200–300 mm/s · ≤±0.2 mm · one vision set for location and polarity
12Busbar plate and CCS assembly installationMANUALSEMI— fastening position; the only station that changes from MANUAL between tiers
13Busbar laser weldingAUTOAUTOBLP-W6 6 kW · 50–100 mm/s · penetration ≥1.0 mm · width ≥1.5 mm · pull ≥1000 N
14Post-weld cleaning and inspectionAUTOAUTO— runs at the welding station footprint
15Manual re-inspection and communication testingMANUALMANUAL— a person looks at every module on both tiers; no tier removes it
16Module end-of-line testingAUTOAUTOBLP-EOL insulation · hipot · total voltage with internal resistance · continuity
17Module line-offSEMIAUTO— onto the fixture and the BLP-CV conveyor at 900 ±50 mm

Seventeen stations is not seventeen machines

  • NG rejection runs at the sorting station; post-weld cleaning at the welding station; stacking and pressing on one BLP-SP frame.
  • They are listed separately because each is separately checkable at acceptance, not because each occupies its own floor space.

What the dash means

  • Handling, cleaning, taping, fastening and inspection positions built into the line rather than separately quoted machines.
  • The seven that carry their own datasheet are on the equipment page; the thresholds behind station 16 are on the EOL testing page.
Prismatic cells in a foam tray at station 01 of the battery module assembly line before the robot picks five at a time
Station 01. Foam trays, five cells per pick, empty trays stacked automatically.
BLP-CS scanning, OCV testing and sorting station at stations 02 and 03 with automatic NG ejection
Stations 02 and 03. Scan, OCV and resistance, grade, eject, refill from the same stream.
BLP-AD terminal addressing and laser cleaning station at station 11 locating each terminal to 0.2 mm
Station 11. Each terminal located to ±0.2 mm or better and its polarity read, then cleaned.

Headcount

Operator Posts on Each Tier

4 operators on BLP-P8S and 3 on BLP-P15 inside the segment; cell handling ahead of it is staffed at 4 on both. Use these numbers directly against your shift pattern and labour rate.

BLP-P8S · 4–8 PPM4operators
  • Station 07, end plate and insulation sheet handling.
  • Station 09, the banding pass on the pressing frame; also covers station 06 taping.
  • Station 12, busbar plate and CCS installation; also covers station 04 flipping and grouping.
  • Station 15, manual re-inspection with the communication test.
BLP-P15 · 12–15 PPM3operators
  • Station 07, end plate and insulation sheet handling, unchanged.
  • Station 09, the banding pass; station 12 becomes semi-automatic and folds into this post.
  • Station 15, manual re-inspection with the communication test, unchanged.
  • Stations 04 and 06 are automatic on this tier and need no cover.

Station 15 stays MANUAL on both tiers

A person looks at every module and runs its communication test before end-of-line testing, and no tier removes that. Every cell voltage is read back against the sorting record.

One operator and a takt bandThat is what the higher tier buys inside this segment. Red slots are staffed posts; grey slots are covered from a neighbouring post.
Operator training at the staffed stations of the module segment before site acceptance
The staffed posts are trained on the line before the 8-hour acceptance run.
Station 12 post where the busbar plate and CCS assembly are seated flat on the banded module before welding
Station 12. The busbar plate and CCS assembly seated flat, MANUAL on BLP-P8S and SEMI-AUTO on BLP-P15.

Between the two tiers

Four Stations and One Operator

The entire difference between BLP-P8S and BLP-P15 inside this segment: four stations move up one level and one operator leaves.

  • 04Cell flipping and groupingSEMIAUTO
  • 06Cell tapingSEMIAUTO
  • 12Busbar plate and CCS installationMANUALSEMI
  • 17Module line-offSEMIAUTO

Same on both tiers

  • The 17-station sequence and the order it runs in.
  • The fixtures, the recipes and the records written per module.
  • The acceptance criteria, signed station by station before shipping.
BLP-P15 battery module assembly line rendered with the four automated positions that replace one operator
BLP-P15 at 12 to 15 PPM. Flipping, taping and line-off run without a post; CCS installation becomes operator-assisted.
Station 04 cell flipping and grouping position turning graded cells into an alternating-polarity group
Station 04. Cells turned to alternate polarity and grouped for one module; SEMI-AUTO on BLP-P8S, AUTO on BLP-P15.

Station 09

Station 09, Pressing and Banding

Everything from station 10 onward assumes the stack has stopped moving and is the length the pack enclosure was drawn for. Station 09 is where that becomes true.

  • 0–8000NServo press force
  • 10NForce resolution
  • 1kHzCurve sampling
  • 0–60sDwell, per recipe
  • ±0.1mmLength measurement
  • ±0.5mmDelivered length tolerance
  • ≤90sCycle, banding included

What the press does to the stack

The stack arrives from station 08 with end plates and insulation sheets placed, 8 to 24 cells depending on your module. A servo press closes it to the recipe force in 10 N steps. Force, platen position and time are sampled at 1 kHz through approach, ramp and dwell and written as one curve.

The module is measured under load and again after release with the steel bands on, and the released length is the one that counts. A complete cycle, banding included, runs in 90 seconds or less on the blueprint 1P13S.

Who does what at this station

  • The recipe holds target force, dwell, target length and banding passes, stored by module type.
  • Operators select it. Only the process engineer who wrote it edits it, and quality countersigns the change.
  • A module whose curve or released length falls outside its recipe is held under its module number for the process engineer. The welder never inherits it.

What leaves this station with the module

A force curve and a released length per module, and at acceptance the length distribution across a batch of your own modules pressed in front of you. Full datasheet on the module stacking and pressing station page.

BLP-SP stacking and pressing station with the servo press head over a banded prismatic module
BLP-SP. Stacking at station 08 and pressing at station 09 on one frame.
Steel banding pass applied to the pressed module while the stack is held at recipe force
The banding pass, operator-assisted at a machine-paced position on both tiers.
Post-press length measurement of the released module against the 0.5 mm tolerance
Released length measured to ±0.1 mm and judged against ±0.5 mm.
Press platen and locating fixture set that changes with the module drawing
Platens and locating fixtures come off your module drawing; they set pitch and pressed length.
SEMI-AUTO on both tiers, on purposeThe banding pass is operator-assisted, so the station carries the label it earns. A fully automatic label costs you a person you will actually be rostering.

Station 13

Station 13, Busbar Welding Recipes

Station 13 is where the module stops being reversible. Up to it, a stack can be re-pressed and an insulation sheet replaced. After it, correcting anything underneath the joint means cutting.

  • 6kWLaser source
  • 50–100mm/sWeld speed
  • ≥1.0mmPenetration
  • ≥1.5mmWeld width
  • ≥1000NPull force

The BLP-W6 welds where it is pointed: station 11 has located each terminal to ±0.2 mm or better and read its polarity, station 12 has seated the busbar plate flat, and station 09 has fixed the length all three work from. Single-row and double-row modules run without a mechanical change.

What you receive from this station

  • A recipe list covering every welded part number on your line.
  • A change record per recipe: what changed, which account changed it and when.
  • Both handed over at acceptance and kept being written afterwards, so a joint welded in month 18 traces to its parameter set and approver.

Station figures are on the busbar welding station page and the offline welder on the gantry laser welding machine page.

The recipe rule, the same at every station that puts energy into a part

  1. Recipes are stored by part number, which for welding means the busbar geometry. Operators select but never edit.
  2. A recipe for a new geometry is not tuned at the line. It is created offline on the BLP-WG gantry welder and run onto sample parts.
  3. The samples are pull tested. Once they meet 1000 N, the recipe moves to the inline BLP-W6 unchanged, under the same part number and the same two signatures.
  4. Rework goes back to the gantry and is rewelded to the recipe stored against its own part number, never to a fresh setup.
BLP-WG offline gantry laser welder where new busbar recipes are created and run onto sample parts
BLP-WG, off the takt. New recipes and rework are welded here.
First-article weld coupons from the gantry welder pull tested before the recipe moves to the inline station
First-article coupons. The recipe moves inline only after these pass 1000 N.

The file that travels

Battery Module Assembly Line Records, Written per Module

A module leaving this segment carries a file rather than a pass stamp. Four record sets are written against its module number as it moves, and one sign-off is added by hand.

Module traveller · M-000217Written at five stations
09 Pressing and banding 1 kHz force curve · released length · recipe no. · banding passes 10 Polarity and insulation test On the banded module, before anything is welded to it 13 Busbar laser welding Part number and recipe number under which each joint was welded 15 Re-inspection and communication test Sign-off by the operator at the manual post, both tiers 16 Module end-of-line testing Insulation · hipot · total voltage with internal resistance · continuity
Each stamp is written to your MES over PROFINET at the moment the module leaves that station, indexed by module number.

From station 09 BLP-SP

  • The 1 kHz force curve through approach, ramp and dwell.
  • The released length and the recipe number it was pressed to.
  • The number of banding passes applied.

From station 10

  • Polarity result on the banded module.
  • Insulation result before anything is welded to it.

From station 13 BLP-W6

  • The part number and recipe number each joint was welded under.
  • The account that approved it and when it last changed.

From station 16 BLP-EOL

  • Insulation, hipot, total voltage with internal resistance, continuity.
  • Station 15 adds the re-inspection and communication test sign-off.

Records, not screens

A live display tells your operator what is happening now. A stored curve tells your process engineer what happened to the module that came back from a site two years later, against the modules built either side of it on the same shift.

The same four items run again on the packThresholds are on the EOL testing page. On the finished pack, with enclosure, cooling plate, BMS and harness in place, they are a different measurement of a different object.
Station control panel with the three account levels: operator selects, process engineer edits, quality countersigns
Three account levels on every station that writes a record.
Remote diagnostics desk connected to the line where module records are read back by module number
Remote diagnostics connect to the same records your MES holds.

Your station list

The 17 Stations, Marked for Your Tier, Within 24 Hours

A cell datasheet and a module drawing resolve into a station list with a level against each station, the tooling that comes off your drawing and a layout drawn into your building.

Send the cell datasheet and module drawing
AUTO / SEMI-AUTO / MANUAL per station Headcount for your shift pattern Tooling off your module drawing Handover height to your pack segment

Station 17 onward

The Handover to the Pack Segment

A module reaching station 17 is banded inside ±0.5 mm, welded, cleaned and inspected, polarity and insulation tested, communication checked, carrying an end-of-line verdict, and located on its fixture.

It moves on BLP-CV

The conveyor carries modules on their fixtures with stop-and-lift positioning and panels on both sides for dust and guarding. The blueprint module is 100 kg or less, so with its fixture the rating carries roughly a factor of two in hand.

  • ≥200kgLoad on the fixture
  • ≤20m/minConveying speed
  • 900±50 mmTransfer height, adjustable
BLP-CV does not carry finished packsThe blueprint 1P52S pack is 400 kg or less and moves on pack-segment handling. The conveyor is listed on the pack side because it delivers located modules into the insertion station, and that is the extent of it.

Send the height and pitch of your pack-side conveyor

With the module fixture drawing, the interface comes back marked up: what matches, what we adjust, what you adjust. PROFINET carries the module records across at the same point, so the pack segment’s MES entry starts with the file already written.

Module on its fixture on the BLP-CV conveyor at the 900 mm transfer height entering the pack segment insertion station
The physical interface: 900 ±50 mm, set against the conveyor you already have if this segment joins an existing line.
1P52S energy-storage pack that the pack segment builds from four modules delivered at the handover
What the pack side builds from four handed-over modules: the 1P52S blueprint pack.

Conveyor figures, segment lengths, corner units and the RFID that carries the module number on the fixture are on the assembly conveyor system page.

Changeover

Tooling That Changes With Your Module

A different module inside the envelope does not re-plan this segment. The 17 stations stay in the same order; five of them carry the change.

Five stations carry the change

  • 01
    Gripper and tray programThe BLP-UL robot picks a different cell footprint from a different tray layout.
  • 08–09
    Press platens, locating fixtures and banding stopsThe largest single item: it sets both the stacking pitch and the pressed length.
  • 11
    Re-taught, not re-tooledThe vision set learns the new terminal positions; no hardware changes.
  • 13
    A different stored recipeCalled under the new busbar part number, created offline and pull tested first.
  • 02
    No hardware at allThe grading window is a document both sides sign rather than a setting an operator types in.
Back in production within one shiftInside the envelope, changing to a module type that has already been qualified on your line is completed and back in production within one shift.
Robot gripper set for a second prismatic cell format, the station 01 changeover item
Station 01. Gripper and tray program change with the cell.
Fixture set logged in at the tooling entry before a module changeover on the segment
Each fixture set is quoted and stored per part number.

The hour-by-hour figures per station, what a first-time introduction of a new type adds, and how tooling is quoted per part number are on the cell compatibility and changeover page.

What to send

Send the Cell and Module Drawings

Six items are enough for the station list. Five of them are on documents you already hold.

  1. 01
    Cell datasheetFormat, dimensions, terminal layout and the grading you buy it at.
  2. 02
    Module drawingLength, width, height and the end plate form.
  3. 03
    Cells per module8 to 24 on the stacking frame; the blueprint is 13.
  4. 04
    Target takt or annual outputEither one; the other is derived and shown back to you.
  5. 05
    Bay dimensions with clear heightSo the layout is drawn into your building rather than onto a standard sheet.
  6. 06
    A sketch of what is on your floor nowOnly if this segment is joining a line you already run.

Returns within 24 hours

  • The 17-station list with a level marked against each station on your tier.
  • The tooling that comes off your module drawing, per part number.
  • A layout drawn into your building, with the handover placed.
  • A read on whether this is a station, a segment or a whole line.
Prismatic 280 Ah cell whose datasheet is the first of the six items sent for the station list
The cell datasheet decides the gripper, the sorting window and the stacking pitch before anything else.

Still working out the tier? The takt bands, headcount and annual output per tier are on the capacity planning page, and the building side is on the factory layout and utilities page.

Signed before shipping

Battery Module Assembly Line Acceptance, Station by Station

Criteria are written by the process engineer who set the parameters and countersigned by quality, so the person judging the line is the person who set the number.

Factory acceptance bench in the pre-assembly bay where 20 modules from the customer's own parts run the full item list
Factory acceptance

In the pre-assembly bay, on your own parts

  • 20modulesSampled through the full item list
  • 17stationsEach separately checkable
  • 1baySegment powered in its ordered configuration
  • Your cells, busbars, end plates and insulation sheets, not demonstration parts.
  • The length distribution across the pressed batch shown in front of you.
Site acceptance record desk where the 8-hour run at target takt and the 99 percent yield are signed
Site acceptance

On your floor, after installation

  • 8hContinuous at target takt, counted at station 01
  • 99%Equipment-caused yield, human factors excluded in writing
  • ≥1000NWeld coupons pull tested
  • End-of-line testing run to the signed criteria on every module in the run.
  • Both tiers accepted to the same list; only the levels beside each station differ.

Open items are closed by the engineer who owns the criterion

Open items are recorded line by line with the station, the measured value and the criterion beside each other. Only the open items are retested rather than the whole run.

Eight steps, five documentsThe eight-step sequence, the material both sides bring and the five documents that come out of it are on the FAT and SAT acceptance page.

How to reach you

[email protected]

Talk to an engineer

Battery Module Assembly Line Enquiry

Send four things: your cell datasheet, your module drawing and configuration, your target takt or annual output, and a sketch of your floor if this segment joins a line you already run. The reply comes within 24 hours with the station list, the levels against your tier, and a read on whether this is a station, a segment or a whole line. More than 40 line segments have gone to plants in 12 countries under ISO 9001, CE and RoHS; wear parts ship within 48 hours. You can also start on the contact page.

Phone / WhatsApp
+86 15327155363
Address
Wuhan, Hubei, China
Response
Within 24 hours