Bay dimensions and utilities
Battery pack line factory layout & utilities are stated at the interface to your building: the clear height, floor loading, 380 V supply, compressed air and nitrogen each of the three line tiers draws, and a layout drawn to your column grid rather than issued as a standard drawing. Send bay length, width and clear height to the lowest obstruction; the tier answer and a layout drawn into your building come back within 24 hours.
Plan · three footprints on one column grid · example grid 12 × 21 m BLP-P15 54 × 20 mBLP-P8S 56 × 10 mBLP-P8 55 × 9 m
Three footprints to one scale: length differs by 2 m, width by more than a factor of two. Width is what decides which tier a standing hall takes, and width is the dimension a standing building is least able to give.
One drawing, one schedule
A layout from BatteryLine Pro is drawn against the building you have rather than against a standard hall, and it arrives as one drawing and one schedule. The line begins where finished cells arrive and ends at a tested pack going out; the drawing covers that stretch of floor.
The drawing places the module segment and the pack segment in your bay, with all 17 module stations and 15 pack stations in the order they run, the handover between the two segments marked, and the aisles, maintenance faces and loading points where they actually land in your building. What happens at each position on it is on the battery pack assembly line page.
The schedule states what the line draws at the interface to your services for the tier you are quoted: clear height, floor loading, supply, compressed air and nitrogen. Seven rows, one per building figure, and every value is stated at the interface rather than somewhere inside the machines.
Clear height
The three tiers need 4 m, 3.5 m and 4 m of clear height, and clear height is measured to the lowest obstruction over the line route rather than to the underside of the roof.
Lighting, sprinkler mains, cable tray, ducting and crane rail sit below the structure and commonly occupy 300 to 500 mm, so a bay quoted at 4 m to the beam can leave 3.6 m of usable height along the run where the line stands.
It is the build that fits under a low beam line. Above the machines is working space rather than spare space: guarding, enclosure lids and the service access that keeps maintenance a task rather than a shutdown all live in the height above the machine envelope.
Floor loading
It applies to the strip rather than the hall average: machine frames, carriers, the modules and fixtures riding on them, and the tooling around each position. Load along the run is spread rather than concentrated: the module conveyor carries modules on their fixtures at 200 kg or more per position, and the weight over the pack segment is what your own handling places there.
Each of the four can sit inside a hall that meets the figure everywhere else, and each is cheaper on the drawing than under a machine.
Electrical supply
Supply is common to all three tiers: three-phase five-wire, 380 V plus or minus 5 per cent, at 50 Hz. Three properties, and each one is a separate question for whoever owns your distribution board.
Those installed figures are used together with takt, output and headcount to choose between tiers on the battery pack line capacity planning page. What belongs to the building is the form of the supply, which is the same for all three, and whether the board can present it where the line will stand.
Compressed air
Pressure is 0.5 to 0.7 MPa on all three tiers. Flow is not common to them, and the economy line takes more air than the standard line. The mechanism behind that is worth having before a compressor is sized.
+500 L/minEconomy above standard. Size the compressor, dryer and receiver against the tier on your order rather than an average of the three.
On the economy build more of the flow is worked by hand, and every hand-worked position is full of pneumatics. Each device consumes on every cycle:
The standard build converts part of that motion to servo drives, which draw electrical power continuously and air only where clamping remains. Flow tracks the count of pneumatic devices along the line rather than the automation level of the line.
Installed power rises through 200 kW, 250 kW or less, and 300 kW. Air runs the other way between the first two tiers: the standard build trades air for kilowatts, and the economy build trades kilowatts for air.
BLP-P15 has more positions and more transfer between them, and machine-paced transfer, guard interlocks, vacuum and clamping add flow of their own on top of what the remaining hand positions still use.
Shielding gas
Nitrogen is supplied at 0.5 MPa on all three tiers. It is shielding gas rather than utility air, and it is consumed where welding happens, so consumption follows how much welding a tier does and how continuously it does it.
The busbar welding station is where the gas shields the pool as the gantry and scanner run the joints; the parameters and weld criteria for that station are on the busbar welding station page.
The gantry welding machine draws nitrogen when first-article recipes are welded and when a part is reworked to its stored recipe. The high-automation build welds more and welds more continuously, which is why it sits at the top of the three.
Four services, three configurations
Every building figure for the semi-automatic economy build, the standard build and the high-automation build in one table. Read across each row: three of the seven rows are identical across the tiers, and the two flow rows are the ones that move.
| Interface |  |
 |
 |
|---|---|---|---|
| Footprint L × W | 56 × 10 m | 55 × 9 m | 54 × 20 m |
| Clear height required | 4 m | 3.5 m | 4 m |
| Installed power | 200 kW | 250 kW or less | 300 kW |
| Electrical supply | Three-phase five-wire, 380 V ±5 %, 50 Hz | Three-phase five-wire, 380 V ±5 %, 50 Hz | Three-phase five-wire, 380 V ±5 %, 50 Hz |
| Compressed air | 3500L/min0.5–0.7 MPa · economy above standard | 3000L/min0.5–0.7 MPa | 5500L/min0.5–0.7 MPa |
| Nitrogen | 20–40L/min0.5 MPa | 40L/min0.5 MPa | 40–80L/min0.5 MPa |
| Floor loading | 800 kg/m² or more | 800 kg/m² or more | 800 kg/m² or more |
Every value above is stated at the interface to your building. Footprint and installed power appear here as demands the building has to accept; the same two figures are set against takt, annual output and headcount on the battery pack line capacity planning page, where they are used to choose a tier.
Every value is stated at the interface to your building.
The transformer, board, compressor, dryer, receiver, nitrogen source and slab stay yours.
The deciding dimension
Across the three tiers the line is 54 to 56 m long and 9 to 20 m wide, so width is usually what decides whether a hall takes a given tier, and width is the dimension a standing building is least able to give.
Straight or folded
A bay shorter than the run does not rule the line out; it folds. A folded line runs at the same takt as a straight one, because takt is set at the loading point and by the stations rather than by the shape of the route.
Modules leave the module segment on their fixtures and enter the pack segment at a fixed height and orientation, so the corner is placed away from that handover and the legs are set so the handover itself stays straight. The pack segment tolerates a corner better than the pressing and welding stations do, because its stations are mostly hand positions.
Your column grid
The layout is drawn to the grid, the height and the openings of your building rather than issued as a standard drawing for the building to match. Four rules govern where things land.
A machine base cannot straddle a column, and an aisle behind a hand position cannot end at one.
Tall stations, welding enclosures and anything with a lid that lifts stand under the bays that carry the height; the low bays take conveyor and hand positions.
Door widths, aisle turns and the route from the unloading point to the run are settled on the same drawing as where the line stands.
A press, a rack line or a crane column is a fixed object in the layout rather than something assumed away.
With those four the first layout comes back drawn into the building rather than beside it.
Your bay
Bay length, width, clear height to the lowest obstruction and the column grid resolve into a tier answer, a layout drawn into your building and a seven-row utility schedule.
Send bay length, width and heightSingle stations
The tier figures are line totals. Individual stations carry their own interfaces as well, and those are the numbers that matter when a station joins a line that already exists.
Before commissioning
Four things are live at the line before commissioning begins rather than during it.
The line runs for 8 continuous hours at the target takt with the rate counted at the loading point, and equipment-caused yield is judged over that run against criteria signed before shipping. It is the first time every station cycles together for a full shift, which makes it the first real test of your air system as well as of the equipment. The acceptance sequence, what each side brings and how a shortfall is retested are on the pack line FAT and SAT acceptance page.
Send and return
Six things on the way out, four on the way back, within 24 hours.
If none of the three fits, that arrives in the first reply rather than after a drawing. A bay short on width and a bay short on height are different conversations, and only one of the two is usually solved by folding the line.
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Start the layout enquiry
More than 40 line segments have been built for plants in 12 countries, as whole lines, single stations and segment retrofits, and the same layout drawing and utility schedule come with all three. The company holds ISO 9001, CE and RoHS. Wear parts ship within 48 hours and remote diagnostics connect to the line. Send your bay dimensions and the clear height to the lowest obstruction, and the tier answer with a layout drawn into your building comes back within 24 hours. You can also start on the contact page.