Pack segment · 15 stations
Battery Pack Assembly Line, Fifteen Stations
All 15 stations of the battery pack 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. Tested modules arrive on their fixtures at station 01; closed, leak-tested, end-of-line-tested packs leave station 15 with a file written against the pack number. Send the enclosure and cooling plate drawings; the station list with a level against your tier comes back within 24 hours.
One delivered scope
Battery Pack Assembly Line Scope, One Delivered Segment
Tested modules arrive on their fixtures at one end. Closed, leak-tested, end-of-line-tested packs leave at the other, 15 stations later. The segment is quoted, built, powered up in the pre-assembly bay and accepted as one scope, on one of two tiers.
- PPM × 60Cells entering the line, per hour
- ÷ cells per pack52 on the blueprint 1P52S
- = packs/ hWhat your pack shop counts
- 4.6–9.2/ h52-cell pack on BLP-P8S at 4 to 8 PPM
PPM counts cells entering the line ahead of the module segment, not packs leaving this one.
Who specifies this segment
- Commercial and industrial storage manufacturers rebuilding a pack shop.
- Grid-scale storage integrators bringing pack assembly in-house.
- EV pack plants, on a different enclosure and a different fixture set.
- 26engineers8 of them field installation and commissioning.
- 6,000m²Assembly hall with three line pre-assembly bays.
- 3baysYour segment is built up, powered and run in its ordered configuration before it ships.
Delivered with the segment
Four Things That Ship With the Pack Segment
Each is a document you sign or a file you receive with the line, not a claim made afterwards. The company behind them is on the about page.
Every station labelled before you sign
- AUTO, SEMI-AUTO or MANUAL against your tier, all 15 stations.
- In the layout package and again in the acceptance document.
Both leak thresholds in writing
- 200 kPa on the cooling plate, 5 kPa on the closed pack, agreed before dispatch.
- Adjustable in writing to your enclosure and your project.
A file per pack, not a pass stamp
- Gluing volume, tightening torque, both leak values and end-of-line results.
- Filed against the pack number and sent to your MES over PROFINET.
Yield signed at 99 percent or better
- Equipment-caused yield, with human factors excluded in writing.
- Wear parts ship within 48 hours and remote diagnostics stay connected afterwards.
Station 01 to station 15
From Tested Modules to Closed Packs
What arrives is a module on its fixture, with an empty enclosure and its cooling plate coming in alongside. What leaves is a closed pack with both leak tests and end-of-line testing passed.
A tested module on its fixture, enclosure and plate alongside
- Banded to a length inside 0.5 mm, welded, polarity and insulation tested, carrying an end-of-line verdict.
- Located on its fixture at 900 ±50 mm on BLP-CV.
- Everything upstream is the 17 stations of the module assembly line, its own scope.
A closed pack with both leak tests and end-of-line testing passed
- Cooling plate leak tested and bonded down; modules seated and fixed.
- Copper bars, BMS, service disconnect, connectors and harness in place.
- Lid tightened to recipe, front panel on, the pack file already in your MES.
The pack envelope the segment takes
Inside this envelope the 15-station sequence does not change. The fixtures do.
| Dimension | Range | Where it lands |
|---|---|---|
| Pack length | 600–1200 mm | Insertion and fixing tooling |
| Pack width | 300–800 mm | Line-in fixture and lid fixtures |
| Pack height | 100–250 mm | Lid tightening recipe and sealing adaptor |
| Pack mass | ≤400 kg | Pack-segment handling at every position |
- Blueprint pack
- 1P52S from four blueprint modules
- Blueprint size
- 1152 × 810 × 243 mm, 400 kg or less
The full sequence
Fifteen Stations of the Battery Pack Assembly Line
The label each station carries is what goes into your layout package and your acceptance document, and the headcount in the next section is built from these labels alone. Both tiers carry the same 15 labels.
| # | What the station does | BLP-P8S | BLP-P15 | Key figures |
|---|---|---|---|---|
| 01 | Enclosure and cooling plate cleaning at line-in | MANUAL | MANUAL | — line-in position; cleaning aids and fixture change with the enclosure |
| 02 | Cooling plate leak testing | AUTO | AUTO | 200 kPa dry air · 60 s hold · drop 1 kPa or less |
| 03 | Enclosure floor gluing | AUTO | AUTO | BLP-GL vision ±0.2 mm · bead path ±2 mm · volume held to 5% · dual-servo metering · live pressure curve |
| 04 | Module insertion | SEMI | SEMI | Blueprint 1P52S 1152 × 810 × 243 mm · 400 kg or less · fixture cut from three drawings |
| 05 | Module fixing | MANUAL | MANUAL | — fixing tooling changes with the station 04 insertion set |
| 06 | Series copper bar installation | MANUAL | MANUAL | — bench position with torque tools |
| 07 | BMS installation | MANUAL | MANUAL | — bench position; the layout follows your BMS drawing |
| 08 | Service disconnect and connector installation | MANUAL | MANUAL | — bench position with torque tools |
| 09 | Harness routing | MANUAL | MANUAL | — routed to your BMS layout; one of the three positions where a second pair of hands adds packs |
| 10 | Lid fitting | MANUAL | MANUAL | — lid fixtures change with the enclosure |
| 11 | Lid tightening | SEMI | SEMI | Twin-spindle servo tightening · 8–25 N·m by enclosure recipe · torque and angle filed by pack number |
| 12 | Front panel installation | MANUAL | MANUAL | — bench position |
| 13 | Whole-pack leak testing | AUTO | AUTO | 5 kPa · 60 s hold · drop 0.3 kPa or less · against an IP67 target |
| 14 | Pack end-of-line testing | AUTO | AUTO | BLP-EOL insulation · hipot · total voltage and resistance · continuity |
| 15 | Pack line-off | SEMI | SEMI | — onto pack-segment handling built for 400 kg or less |
- 4Run themselvesAUTO
- 3Machine-paced, operator on themSEMI
- 8People with fixtures, torque tools and bench aidsMANUAL
What the dash means
- Assembly and handling positions built into the line rather than separately quoted machines. Each one is still separately checkable at acceptance.
- Thresholds behind station 14 are on the pack EOL testing page; the full station 03 specification, with its two workpieces and its vision set, is on the cooling plate gluing station page.
Headcount
Headcount and Operator Posts in the Pack Segment
The pack segment runs with 12 to 14 people on both tiers. That is not a number waiting to be automated away.
- 01
- 02
- 03
- 04
- 05
- 06
- 07
- 08
- 09
- 10
- 11
- 12
- 13
- 14
- 15
- Eleven posts are staffed by the labels: the eight manual stations, plus an operator each at module insertion, lid tightening and line-off.
- The people above eleven go where volume puts them: module insertion, harness routing and lid fitting.
Why a person with a fixture, not a machine
A 400 kg pack, an enclosure that changes between projects, harness routing that follows your BMS layout. A person with a fixture is quicker to set up, quicker to change over and easier to move than a machine cut to one enclosure.
Where automation earns its place
At the four stations where the measurement matters more than the handling. Gluing, both leak tests and end-of-line testing are automatic on both tiers, and nothing else is.
Module insertion
A second pair of hands here converts directly into packs.
Harness routing
The longest bench time in the segment; the route follows your BMS layout.
Lid fitting
The third position where an extra person adds shift output.
Between the two tiers
Same Fifteen Labels on Both Tiers
The difference between BLP-P8S and BLP-P15 sits upstream. Choosing between them is a module-segment decision, not a pack-segment one.
- The 15-station sequence and every label on it.SAME
- 12 to 14 people per shift.SAME
- Both leak criteria and the pack file.SAME
- The module segment in front of it: four stations up one level, one operator fewer on BLP-P15. See the module assembly line.43
Station 03
Station 03, Enclosure Floor Gluing
The first station in the segment that decides something irreversible. Once the plate is bonded to the floor, correcting the bead means removing it.
- ±0.2mmVision location before the nozzle moves
- ±2mmBead path tolerance
- 5%Dispensed volume held to
- 2axesServo metering
- 1curveLive pressure curve per enclosure
Volume is the controlled variable, not time
The station photographs the enclosure and locates it to 0.2 mm before the nozzle moves, so the path is registered to the part in front of it, not to where the part is supposed to be.
Two servo axes meter the adhesive. The dispensed volume is held to 5%, with a live pressure curve recorded through the pass.
A timed shot delivers whatever the adhesive viscosity allowed that morning. A servo-metered shot delivers the volume in the recipe and shows you the pressure it took to deliver it.
Who does what at this station
- The bead path, the volume per zone and the pressure window are stored as a recipe against your enclosure part number.
- Operators select it and cannot edit it. Only the process engineer who wrote it changes it, and quality countersigns before the change goes live.
- An enclosure whose curve leaves its window, or whose volume leaves the 5% band, is held under its enclosure number for the process engineer rather than sent forward to have a module dropped onto it.
Station 04
Station 04, Module Insertion Fixtures
Semi-automatic on both tiers, and the station where three drawings have to agree. Insertion clearance, seating datum and insertion order are set by those three together, and none of them is ours.
- Enclosure drawingCavity and fixing points
- Cooling plate drawingInterfaces and seating face
- Module drawingConfiguration and insertion order
First article is a written step, not a feel
- On a new enclosure the first packs run with the seating checked against the drawing at each module position; the result is signed before release. After that the fixture reproduces it.
- The label stays SEMI-AUTO on both tiers rather than being rounded up, and the station changes over faster than a fully automated equivalent would.
- The tooling list is written per part number: fixtures you own and fixtures a new project needs are two separate lines.
Stations 02 and 13
Two Leak Tests, Two Pressures
Twice, at two pressures, on two different objects, for two different reasons. Both criteria are written into the acceptance table both sides sign before the line ships.
- 60sHold
- ≤1kPaDrop to pass
- 1plateWhat a failure costs here
A plate that fails at station 02 is a plate off the line. The same plate found leaking after gluing is an enclosure, a bead and four modules as well.
- 60sHold
- ≤0.3kPaDrop to pass
- IP67Sealing target
This one measures the sealing of the enclosure the pack will live inside for a decade. That is why the pressure is low and the allowed drop is tighter.
A pack that fails either test
- Held under its pack number with the measured value recorded beside the criterion, and released only after retest.
- The tightening result at station 11 is a release condition for station 13: a pack reaches the whole-pack test with its lid torque already confirmed, never as a possible explanation for a failure.
- Both criteria can be adjusted in writing before dispatch to suit your enclosure and project. Whatever is agreed is what the acceptance run is measured against and what the station judges afterwards.
- Enclosure floor gluingrecipe no.dispensed volumepressure curve
- Lid tighteningtorque, spindle 1torque, spindle 2angle ×28–25 N·m recipe
- Both leak tests200 kPa drop5 kPa dropcriterion beside each
- Pack end-of-line testinginsulationhipottotal V and Rcontinuity
- Travelling in with the modulesmodule no. ×4press force curvereleased lengthweld recipe no.
What travels with each pack
A File Per Pack, Written Station by Station
A pack leaving this segment carries a file rather than a pass stamp. Five sets of data are written against its pack number as it moves.
The module records come in with the modules
Each module number inside the pack, with its press force curve, released length and weld recipe number, crosses the handover with the module. The pack file starts with those four already in it.
Your station list
The 15 Stations, Marked for Your Tier, Within 24 Hours
An enclosure drawing and a cooling plate drawing resolve into a station list with a level against each station, the tooling that comes off your three drawings, and a layout drawn into your building.
Send the enclosure and plate drawingsFrom the module segment
The Handover From the Module Segment
Modules reach this segment on BLP-CV. The conveyor appears on the pack side of an equipment list for one reason: it delivers located modules into the insertion station.
Leaves module station 17 on BLP-CV
- ≥200kgLoad on the fixture
- ≤20m/minConveying speed
- ×2in handBlueprint module 100 kg or less, plus its fixture
- Modular stop-and-lift positioning; panels on both sides for dust and guarding.
900 ±50 mm, PROFINET alongside
- Transfer height adjustable, set against the conveyor you already have if this segment joins a running line.
- PROFINET carries the module records across at the same point.
- Send the module-side height and pitch and your module fixture drawing; the interface comes back marked up: what matches, what we adjust, what you adjust.
Into station 04, on pack-segment handling
- BLP-CV does not carry finished packs. The blueprint pack is 400 kg or less and is handled at pack-segment positions built for it.
- Its involvement with packs ends at the insertion station.
- Conveyor figures, segment lengths and the RFID on the fixture are on the assembly conveyor system page.
Changeover
Tooling That Changes With Your Enclosure
A different enclosure inside the envelope does not re-plan this segment. The 15 stations stay in the same order, and six of them carry the change.
Six stations carry the change
- Cleaning aids and the line-in fixtureThe first thing the new enclosure touches.
- A different stored bead path and volume setCalled under the new enclosure part number; nobody types a parameter at the station.
- Insertion and fixing toolingThe largest single item, because it carries the seating datum.
- Lid fixtures and the tightening recipeTorque and angle window stored against the new lid.
- The sealing adaptor and the criterion it is judged againstSigned in the same pass as the gluing path.
- ≤2hInsertion and fixing tooling, enclosure already qualified
- 1shiftWhole line back in production
- 3–5daysFirst-time configuration, whole line, first article included
The hour-by-hour figures per station and how tooling is quoted per part number are on the cell compatibility and changeover page.
What to send
Send the Enclosure and Cooling Plate Drawings
Five things are enough for the station list. Four of them are on documents you already hold.
- Enclosure drawingWith the cavity and the fixing points.
- Cooling plate drawingWith its interfaces.
- Module drawing and pack configurationHow many modules, in what order.
- Target takt or annual outputEither one; the other is derived and shown back to you.
- Bay dimensions with clear heightSo the layout is drawn into your building rather than onto a standard sheet.
Joining a line you already run? Add a sketch of what is on your floor now and the transfer height on the module side. The reply also says whether what you need is a station, a segment or a whole line.
Signed before shipping
Battery Pack Assembly Line Acceptance, Station by Station
Written station by station by the process engineer who set the parameters, countersigned by quality: the person judging the line is the person who set the number.
In the pre-assembly bay, on your own parts
- 5packsThrough the full item list
- 2–3daysWorking days in the bay
- 15stationsEach separately checkable
- Your enclosures, cooling plates and modules, not demonstration parts.
- Both leak tests to the signed criteria, end-of-line testing to its thresholds.
On your floor, after installation
- 8hContinuous at target takt
- 99%Equipment-caused yield, human factors excluded
- 3–5daysWorking days on site
- Both leak tests and end-of-line testing to the signed criteria on every pack in the run.
- Both tiers accepted to the same list.
Open items, line by line
Recorded with the station, the measured value and the criterion beside each other.
Only the open items are retested
The engineer who owns that criterion closes it. The whole run is not repeated.
Training on your line, 5 working days
Split into three roles.
The eight-step sequence, the material both sides bring and the documents that come out of it are on the FAT and SAT acceptance 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.
Talk to an engineer
Battery Pack Assembly Line Enquiry
Send the enclosure and cooling plate drawings, the module drawing with the pack configuration, your target takt or annual output, and your bay dimensions with clear height. The reply comes within 24 hours with the station list, the labels against your tier, and a read on whether what you need 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. You can also start on the contact page.