Cells in at one end, tested packs off the other — one takt across both segments +86 15327155363 [email protected]

End-of-line testing / seven stations, two segments

Battery Pack End of Line Testing Equipment, and the
Thresholds It Is Judged On

Seven test stations across the module and pack segments. Two of them have thresholds we publish here; the other five have criteria set with your parts and written into the acceptance document.

Ask for the test specification See the seven stations

Seven gates — four in the module segment, three in the pack segment.

What is published, and what is agreed

  • Two thresholds published on this page
  • Five criteria set with your parts
  • All seven in the same acceptance document

The acceptance document is written before the line ships, from the test list

Which makes the test list the most commercially important page in the whole quotation, and the one most often left vague.

You are signing for behaviour, not hardware

Steel arrives whatever happens. What you are buying is a set of statements about what the line will produce, and every one of them traces back to a test.

The test list decides what you can refuse

If a property is not tested, it is not refusable. That is not a legal position, it is an operational one — nobody rejects a pack for a property nobody measured.

Vague is not neutral

“Full EOL testing included” transfers the definition to the supplier, after the order. Every unstated criterion becomes theirs to choose at the moment it matters.

This page exists to be specific

Seven stations, named. Two with published thresholds. Five with criteria set against your parts. And a clear statement of which is which.

The station lists themselves live elsewhere — the module segment and the pack segment each publish their own. This page is only about the positions where something is measured.

Instrument cabinet with control panels along the front of a test station
What a test station looks like on the floor

Three ways a test specification fails you, and none of them is a broken instrument

All three happen on paper, months before anything is measured.

Test station with its control screen at the head of a line

Measured, but never defined

A station tests. Nobody wrote down what counts as a pass. At ramp-up the operator asks, and whoever answers first sets the standard for the next ten years.
Bench station with control screen and clamping mechanism

Written in the presentation, not in the acceptance document

A threshold on a slide is a marketing figure. The same threshold in the acceptance document is a commitment. The two look identical until the day you need the second one.
Assembled pack enclosure with modules and cooling plate installed

The module was tested and the whole pack was not

Every module passes and the pack still leaks, because the property that failed only exists once the pack is closed. That failure arrives at your customer, not at your line.
Section 08

The first two are avoidable with a list. The third is avoidable only by testing the assembled pack as its own object — which is why the last gate on the line is the one this page opens up.

A property nobody measured is a property nobody can refuse. The test list is the shortest version of your acceptance document.

Module segment

Four gates — stations 02, 10, 15 and 16.

Pack segment

Three gates — stations 02, 13 and 14.

Seven in total

The only places the line forms an opinion.

Seven places on the line where something is measured

Four in the module segment, three in the pack segment. Their positions matter as much as their thresholds — a test late in the line is a test that has already let work accumulate behind it.

Module segment · 4 gates
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Pack segment · 3 gates
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Module segment 02 · 10 · 15 · 16 / Pack segment 02 · 13 · 14

Published In your acceptance document
WhereStationCriterion source
MOD 02Cell scanning, OCV test and sortingPublished
MOD 10Polarity and insulation testIn your acceptance document
MOD 15Manual re-inspection and communication testIn your acceptance document
MOD 16Module end-of-line testPublished
PAC 02Liquid-cooling plate leak testIn your acceptance document
PAC 13Whole-pack air-tightness testIn your acceptance document
PAC 14Pack end-of-line testIn your acceptance document

Two of the seven are published

Stations 02 and 16 of the module segment carry figures we can print in advance. They are printed in section 06, unrounded.

Five are set against your parts

A leak criterion depends on the enclosure it is applied to; a communication test depends on the BMS you chose. Those go into the acceptance document rather than a brochure.

The order is the argument

Four gates before a module is closed into a pack, three after. Everything the first four miss becomes something the last three have to catch.
Test station in the module segment with its measurement fixture
Module segment — four gates
Test station in the pack segment with the enclosure open
Pack segment — three gates
Line seen along its length, gates distributed through it
Where they sit in the run

The thresholds that are published, exactly as they are quoted

Two stations, and every figure below is the figure that goes into the acceptance document — not a rounded version of it.

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Module segment · station 16

TestConditionCriterionAs it appears in the acceptance document
InsulationDC 1000 V≥500 MΩInsulation resistance
Withstand voltageDC 2800 V≤10 mALeakage current
Total voltage and internal resistanceNot a condition of oursTest itemCriterion in your acceptance document
ContinuityNot a condition of oursTest itemCriterion in your acceptance document
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Module segment · station 02

MeasurementInstrument accuracyQuoted from the cell sorting station
Scan success rate≥99.9%Excluding incoming defects
Voltage accuracy±(0.01%rdg + 3dgt)
Internal resistance accuracy±(0.5%rdg + 10dgt)
Handling of a rejectNG removed automatically, the gap refilled automatically
⚠️ The three figures in the second table are instrument accuracy, not pass thresholds. What counts as a pass — how wide a group may be — is set with your cell. The difference is the subject of section 10.
Those three figures belong to the sorting station, not to this page. They are quoted here only to place station 02 on the test map; what they mean for the machine — how a cell enters the line, how a reject is removed and how the gap it leaves is refilled — is written up in full on the cell testing and sorting station page. This page owns thresholds and verdicts, not instrument specifications.
Four test items at station 16, two of them with numbers. Insulation and withstand voltage carry published criteria; total voltage, internal resistance and continuity are test items whose criteria come from your pack.
Nothing here is rounded. Every figure is quoted as it appears in the specification it came from.
End-of-line test cabinet with the instrument front panel in frame
Station 16 — where the two thresholds are applied
Measurement fixture at the cell scanning and sorting station
Station 02 — where accuracy is specified

Five stations whose criteria are set with your parts, and why we do not print a number here

Printing one would make this page look more complete and make your acceptance document less true.

  1. MOD 10Polarity and insulation testIn your acceptance document
  2. MOD 15Manual re-inspection and communication testIn your acceptance document
  3. PAC 02Liquid-cooling plate leak testIn your acceptance document
  4. PAC 13Whole-pack air-tightness testIn your acceptance document
  5. PAC 14Pack end-of-line testIn your acceptance document

A criterion without its object is a number without meaning

A leak rate is a statement about a specific enclosure and a specific sealing design. Quoted before either exists, it is a number chosen to look reassuring.

They are not optional, they are deferred

Each of the five is a station on the line, with an instrument, a cycle and a verdict. What is deferred is the threshold, not the test.

Where they get fixed

They are agreed during engineering and written into the acceptance document before the line ships — the same document the two published thresholds go into.

This is the part of a test specification worth reading closely when you compare suppliers. A specification that prints a figure for all seven has either engineered your pack already, or has printed something it will renegotiate later.

Test positions on the line whose pass criteria are set during engineering
Five stations that exist, with criteria that are not yet numbers

The last gate that can still stop a problem from leaving

By the time a pack reaches this station, everything that could have gone wrong has already gone wrong or not. This is where the line finds out which.

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Pack segment · station 13 — the last gate before the pack is a product

  1. Why this one

    The only test that examines the pack as a single closed object.

    Every earlier gate tests a part, or a property of a part. This one tests the thing you actually ship, in the state you actually ship it — and it is the last position where a decision costs you a rework rather than a site visit.
  2. What arrives here already wrong

    Twelve stations of pack assembly sit behind it.

    The enclosure floor bead, the module insertion, the fixings, the busbars, the harness, the cover and its tightening, the front panel. Any of those can leave a sealing path imperfect, and none of them reports it. The bead in particular was laid ten stations earlier and has been invisible since.
  3. What it costs to find out later

    Not a warranty event. An access event.

    A pack that leaves sealed-enough and fails in the field means somebody has to reach an installed pack, in a cabinet, on a site, with the system down. The same defect caught at this station is a cover off and a re-work on your own floor.
  4. What we do about it

    Test the assembled pack, and test it before the electrical gate.

    The station tests the assembled pack rather than sampling it, and it sits before the pack end-of-line test rather than after — so a sealing problem is separated from an electrical one instead of arriving as a single ambiguous failure at the last station.
  5. What proves it

    ⚠️ This station's pass criterion is not published on this page.

    It is set against your enclosure and your sealing design during engineering, and written into the acceptance document before the line ships — in the same document, and with the same standing, as the module EOL thresholds in section 06.

The other end of this argument — how a bead laid at pack station 03 stays invisible for ten stations — is on the pack assembly line page.

Closed unit with test leads attached at the test position
Closed, and about to be asked a question
Test position with the enclosure open and the fixture visible
The station itself
Cover and sealing face geometry above an assembled pack
The sealing path everything upstream can spoil

Module EOL and pack EOL are different tests with different jobs

They are often quoted as one line item, which is how a line ends up with only one of them.

Module end-of-line test position in the module segment
Module EOL — segment station 16

Module end-of-line test

Judges a module before it is closed inside a pack. Insulation at DC 1000 V with insulation resistance ≥500 MΩ; withstand voltage at DC 2800 V with leakage current ≤10 mA; plus total voltage, internal resistance and continuity as test items.
Pack end-of-line test position at the end of the pack segment
Pack EOL — pack station 14

Pack end-of-line test

Judges the assembled pack, after the whole-pack air-tightness test has separated sealing problems from electrical ones. Its criteria are set with your pack and written into the acceptance document.

Passing the first does not predict the second

A module can be correct and a pack built from correct modules can still fail — the failure modes added by pack assembly did not exist when the module was judged.

One line item, two instruments

If a quotation shows a single “EOL test”, ask which of the two it is. The answer is usually the module one, because it is the cheaper station.

Both belong in the acceptance document

Module EOL with the published figures above; pack EOL with the criteria agreed for your pack.

Accuracy is not a threshold, and a threshold is not a verdict

Three different things, routinely quoted as if they were one. Telling them apart is the fastest way to read a test specification.

Accuracy — what the instrument can resolve

Voltage accuracy of ±(0.01%rdg + 3dgt) and internal resistance accuracy of ±(0.5%rdg + 10dgt) — both the sorting station's figures, borrowed here as an example — describe the measuring device. They say nothing about whether a cell passes. An accurate instrument measuring against no threshold produces precise numbers and no decisions.

Threshold — the line between pass and fail

Insulation resistance ≥500 MΩ at DC 1000 V is a threshold: it converts a measurement into a verdict. Some of ours are published; some are set with your parts. Either way a threshold exists, in writing, before the line ships.

Verdict — what the line does about it

A verdict only matters if the line acts on it: an NG cell removed automatically and the gap refilled, a module held back, a pack routed to rework. A test that reports without acting is a log file, not a gate.

When you compare three test specifications, sort every figure into one of these three. A specification heavy on accuracy and light on thresholds is describing its instruments rather than its results — and instruments are the part nobody argues about at acceptance.

Test leads contacting module terminals during a measurement
Where a measurement becomes a verdict

One line-level figure sits above the seven station-level ones

The seven gates judge parts. This one judges the line, and it is the figure the acceptance meeting turns on.

≥99% Line acceptance yield
counting equipment-caused defects only, excluding human factors

Station-level and line-level are different claims

A station threshold says what one measurement must show. The line figure says how much of what goes in comes out accepted. Neither substitutes for the other.

The qualifier is the whole meaning

Equipment-caused only. Incoming cell defects and bench work are outside it, in both directions — which is what makes it a figure both sides can measure the same way.

How yield is defined is stated once

The utilisation and first-pass yield definitions live on the home page, so this page does not restate them.
Offload position at the end of the line where accepted units leave
Where the line figure is either met or it is not

Ask for the test specification before you ask for the price

Send your pack drawing and your BMS, and the seven stations come back with a criterion against each — published where published, and marked where it is set with your parts.

Ask for the test specification WhatsApp

Reply within 24 hours / Every criterion we send is one we are willing to put in the acceptance document

Four things about testing that end up in the document you sign

Everything on this page exists to make these four specific rather than reassuring.

  1. Item 01

    The station list

    Which of the seven gates your line has, and where each one sits.
  2. Item 02

    The criterion for each

    Published figures where they exist, agreed figures where they do not — with no gaps left to be settled during ramp-up.
  3. Item 03

    The line figure

    ≥99% acceptance yield, counting equipment-caused defects only.
  4. Item 04

    What happens to a reject

    Removal, refill, hold or rework — stated per station, because a verdict with no action attached is not a gate.

Certifications

ISO 9001, CE and RoHS. We name them and provide certificates on request; we do not print certificate numbers on a web page.

The document is one document

The published thresholds and the agreed ones sit in the same place, with the same standing. That is the point of deferring rather than inventing.
Test station used during commissioning and acceptance
Run against the document, not against a memory
Finished assembly leaving the line after acceptance
What the document describes

Four questions that separate a test specification from a test list

How many test stations, and where?
A count is not enough — position decides how much work has accumulated behind a gate before it fires.
Which criteria are published, and which are agreed?
Both answers are acceptable. “All of them published” before your pack exists is the answer worth probing.
Is the whole pack tested as an object, or only its modules?
Two different tests. One line item often means only the cheaper one.
What does the line do with a fail?
A number with no action behind it is a log, not a gate.

We publish two of seven thresholds and say so. A specification that publishes seven of seven, for a pack it has never seen, is not more transparent — it is less careful. That distinction is the whole reason this page is laid out the way it is.

Instrument cabinet seen along the line
Read the specification, not the cabinet

Where the stations, the machines and the line figures are written up

  1. Cell handling
  2. Module segment
  3. Pack segment
  4. Testing — you are here

Send the enclosure detail with the pack drawing

Sealing design is what most of the outstanding criteria are waiting on.

Without it they stay deferred, not estimated

Which criteria are waiting, and what each one needs before it can be written, is set out in section 07.
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Finished module leaving the line after its last gate
Seven gates behind it