{"id":103,"date":"2026-06-01T10:38:28","date_gmt":"2026-06-01T10:38:28","guid":{"rendered":"https:\/\/khkrh7q1ur.wpdns.site\/product\/lithium-battery-pack-module-automatic-production-line\/"},"modified":"2026-06-09T02:24:58","modified_gmt":"2026-06-09T02:24:58","slug":"lithium-battery-pack-module-automatic-production-line-product","status":"publish","type":"product","link":"https:\/\/benlongkj.com\/ar\/product\/lithium-battery-pack-module-automatic-production-line-product\/","title":{"rendered":"\u062e\u0637 \u0625\u0646\u062a\u0627\u062c \u0622\u0644\u064a \u0644\u0648\u062d\u062f\u0627\u062a \u0628\u0637\u0627\u0631\u064a\u0627\u062a \u0627\u0644\u0644\u064a\u062b\u064a\u0648\u0645"},"content":{"rendered":"
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EV & ESS \u00b7 Laser welding \u00b7 EOL test<\/div>\n

Fully Automatic Lithium Battery PACK Module Production Line<\/h1>\n

This new full\u2011automated lithium battery PACK module production line is specifically developed for volume assembly of Li\u2011ion battery packs for Electric Vehicles (EV) and Energy Storage Systems (ESS). This line consists of several integrated operations, such as automatically sorting cells by voltage and internal resistance, assembling modules, bonding modules rapidly using laser or ultrasonic welding, and conducting EOL testing in order to guarantee uniform performance, safety, and long-term dependability.<\/p>\n

Precision cell sorting takes place first, based on voltage (mV) and internal resistance (m\u03a9). Module assembly and installation of busbar, high-power laser welding or ultrasonic bonding of cells to busbars are performed by robots to achieve micron-level accuracy in the production of reliable electrical connections. Automated installation of the Battery Management System (BMS) and thermal management components (cooling plates, insulation pads) are just some of the key stations in the process. Final EOL functional testing is performed on finished packs, including insulation resistance checks, active\/passive balancing validation, and high-rate charge\/discharge performance testing. Throughout the entire process, every cell and module has a barcode for traceability, ensuring that every pack produced meets OEM specified international safety and performance standards for EV and ESS applications.<\/p>\n

The time required for standard delivery is between ninety and one hundred twenty days. All features are adjustable, including cylindrical and prismatic cells, pouch cells, and a turnkey system.<\/p>\n<\/p><\/div>\n

\n \"Lithium<\/p>\n
Battery module assembly line (actual product)<\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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What is a Lithium Battery PACK Module Automatic Production Line?<\/h2>\n

An automatic production line for a Lithium Battery Pack Module is a system that fully integrates the process of producing battery modules from individual Li-ion cells (Cylindrical, Prismatic, or Pouch). The line automates all major production processes: cell sorting (matching the cell voltage and internal resistance), cell stacking or putting cells into a tray, bus bar welding (laser or ultrasonic), installing BMS (Battery Management System) into the module, assembling thermal management components and End of Line (EOL) testing. The line is specifically designed for high volume production of battery modules used in electric vehicles (EV), electric bicycles (e-bikes), electric power tools, and stationary energy storage. The production line will maintain full traceability at the cell level through the pack level by either bar code or QR code. The production line also is a custom solution that can be configured with specific cell format, pack size, welding process and production volume for your product requirements.<\/p>\n

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\n Pre\u2011cell sorting<\/strong>
\n Automated voltage & internal resistance measurement for consistent cell matching.\n <\/div>\n
\n High\u2011speed welding<\/strong>
\n Laser or ultrasonic welding for busbars and tabs with micron\u2011level accuracy.\n <\/div>\n
\n BMS & thermal integration<\/strong>
\n Automated placement of BMS PCBA and thermal management components.\n <\/div>\n
\n EOL functional testing<\/strong>
\n Insulation resistance, charge\/discharge, balancing validation, and data logging.\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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\u0645\u064a\u0632\u0627\u062a \u0648\u0639\u0645\u0644\u064a\u0629 \u062e\u0637 \u0627\u0644\u0625\u0646\u062a\u0627\u062c<\/h2>\n
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\n \"Intelligence<\/p>\n
\u0627\u0644\u0630\u0643\u0627\u0621 \u0648\u0627\u0644\u0631\u0624\u064a\u0629<\/div>\n<\/p><\/div>\n
\n \"Efficiency<\/p>\n
\u0627\u0644\u0643\u0641\u0627\u0621\u0629 \u0648\u0627\u0644\u0627\u0633\u062a\u062f\u0627\u0645\u0629<\/div>\n<\/p><\/div>\n
\n \"Design<\/p>\n
\u0627\u0644\u062a\u0635\u0645\u064a\u0645 \u0648\u0627\u0644\u062a\u0643\u0627\u0645\u0644<\/div>\n<\/p><\/div>\n
\n \"Safety<\/p>\n
\u0627\u0644\u0633\u0644\u0627\u0645\u0629 \u0648\u0627\u0644\u0645\u0648\u062b\u0648\u0642\u064a\u0629<\/div>\n<\/p><\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0627\u0644\u0645\u0648\u0627\u0635\u0641\u0627\u062a \u0627\u0644\u0641\u0646\u064a\u0629<\/h2>\n
Fully automated Li\u2011ion battery PACK assembly line. Cell sorting, laser\/ultrasonic welding, BMS integration, EOL testing. Customizable for EV\/ESS.<\/div>\n
\n\n\n\n\n <\/tr>\n\n\n\n <\/tr>\n\n\n\n\n\n\n
Cell types supported<\/th>\nCylindrical (18650, 21700, 26650, 4680), prismatic, pouch (custom fixtures)<\/td>\n<\/tr>\n
Cell sorting accuracy<\/th>\nVoltage: \u00b11mV | Internal resistance: \u00b10.5% of reading<\/td>\n<\/tr>\n
\u062a\u0643\u0646\u0648\u0644\u0648\u062c\u064a\u0627 \u0627\u0644\u0644\u062d\u0627\u0645<\/th>\nFiber laser welding (500\u20112000W) or ultrasonic metal welding (configurable)<\/td>\n<\/tr>\n
Welding accuracy<\/th>\nPosition repeatability \u00b10.05mm; optional weld penetration monitoring<\/td>\n<\/tr>\n
\u0632\u0645\u0646 \u062f\u0648\u0631\u0629 \u0627\u0644\u062a\u062c\u0645\u064a\u0639<\/th>\n3\u20118 seconds per cell (depending on pack size and welding spots)<\/td>\n<\/tr>\n
EOL test coverage<\/th>\nInsulation resistance, dielectric strength, charge\/discharge (up to 2C rate), active\/passive balancing, CAN communication validation<\/td>\n<\/tr>\n
BMS integration<\/th>\nAutomated BMS PCB placement, screw fastening, and optional firmware flashing<\/td>\n<\/tr>\n
\u0625\u0645\u0643\u0627\u0646\u064a\u0629 \u0627\u0644\u062a\u062a\u0628\u0639<\/th>\nBarcode\/cell ID linked to sorting data, welding parameters, and EOL results; MES export via OPC UA<\/td>\n<\/tr>\n
\u0645\u0635\u062f\u0631 \u0627\u0644\u0637\u0627\u0642\u0629 \u0648\u0627\u0644\u0647\u0648\u0627\u0621<\/th>\n380V \u00b110% 50Hz | Compressed air 0.6\u20110.8MPa | Chilled water for laser (optional)<\/td>\n<\/tr>\n<\/tbody>\n<\/table><\/div>\n

\u0627\u0644\u0645\u0632\u0627\u064a\u0627 \u0627\u0644\u062a\u0642\u0646\u064a\u0629 \u0627\u0644\u0623\u0633\u0627\u0633\u064a\u0629<\/h2>\n
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Precision cell sorting for matched modules<\/h4>\n

The line measures voltage and internal resistance of each incoming cell. It then groups cells with similar parameters into the same module \u2013 critical for pack longevity and balanced charging.\n <\/p><\/div>\n

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Micron\u2011level laser\/ultrasonic welding<\/h4>\n

High\u2011power fiber laser or ultrasonic welding ensures low\u2011resistance, high\u2011strength joints between busbars and cell tabs. Optional coaxial monitoring checks weld penetration in real time.\n <\/p><\/div>\n

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Integrated EOL test station<\/h4>\n

A comprehensive test bench validates insulation resistance, dielectric strength, charge\/discharge performance, and BMS balancing. Results are logged per pack serial number for full quality documentation.\n <\/p><\/div>\n

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Full traceability for safety compliance<\/h4>\n

Each cell ID is scanned and linked to its sorting data. Welding parameters and EOL test results are stored with the pack serial number, providing complete traceability for regulatory audits and customer requirements.\n <\/p><\/div>\n<\/p><\/div>\n

\n \u0645\u0648\u062b\u0648\u0642 \u0628\u0647 \u0645\u0646 \u0642\u0628\u0644 \u0631\u0648\u0627\u062f \u0627\u0644\u0635\u0646\u0627\u0639\u0629<\/span><\/p>\n
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\n \"ABB\"\n <\/div>\n
\n \"DELIXI\"\n <\/div>\n
\n \"EKF\"\n <\/div>\n
\n \"KRIPAL\"\n <\/div>\n
\n \"HPL\"\n <\/div>\n
\n \"CHAC\"\n <\/div>\n
\n \"Schneider\"\n <\/div>\n
\n \"IEK\n <\/div>\n
\n \"SUNIR\"\n <\/div>\n
\n \"Bevone\"\n <\/div>\n
\n \"Weg\"\n <\/div>\n
\n \"HUYU\"\n <\/div>\n
\n \"RAAD\"\n <\/div>\n
\n \"WALTONE\"\n <\/div>\n
\n \"HAVELLS\"\n <\/div>\n
\n \"C&S\n <\/div>\n<\/p><\/div>\n<\/p><\/div>\n
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Customer Success Story \u2013 EV Battery Pack Manufacturer<\/h3>\n

A European electric vehicle battery pack manufacturer was to increase capacity to build (800 volt) modules using cylindrical cell size 21700. Their current semi-manual lines suffered from both cell sorting errors and welding penetration inconsistencies; however, to remedy this, Benlong designed and built a complete fully automated lithium battery PACK module production line including:<\/p>\n

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98%<\/strong> Cell sorting yield (voltage\/IR matching)<\/div>\n
0.2%<\/strong> Weld defect rate (down from 2.5%)<\/div>\n
+150%<\/strong> Throughput (from 60 to 150 modules\/shift)<\/div>\n<\/p><\/div>\n

In 14 months, the customer recouped their investment in lines along with receiving an industry-approved standard of quality.<\/p>\n<\/p><\/div>\n

\u0627\u0644\u062a\u0637\u0628\u064a\u0642\u0627\u062a \u0648\u0627\u0644\u062a\u0643\u0627\u0645\u0644<\/h2>\n
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Electric vehicle (EV) battery packs<\/strong> \u2013 400V\/800V modules, cylindrical or prismatic cells<\/div>\n
Energy storage systems (ESS)<\/strong> \u2013 Residential and utility\u2011scale battery racks<\/div>\n
E\u2011bike \/ e\u2011scooter batteries<\/strong> \u2013 High\u2011volume small pack assembly<\/div>\n
Power tool batteries<\/strong> \u2013 Cylindrical cell PACKs for cordless tools<\/div>\n<\/p><\/div>\n<\/p><\/div>\n

\u0627\u0644\u0647\u0646\u062f\u0633\u0629 \u0648\u0627\u0644\u062a\u0633\u0644\u064a\u0645 \u062d\u0633\u0628 \u0627\u0644\u0637\u0644\u0628<\/h2>\n
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1. Process design<\/strong> 30-45 days \u00b7 cell & pack specifications, target capacity<\/div>\n
2. Line layout & simulation<\/strong> 20-30 days \u00b7 3D layout, cycle time analysis<\/div>\n
3. \u0627\u0644\u062a\u0635\u0646\u064a\u0639<\/strong> 90-120 \u064a\u0648\u0645\u064b\u0627<\/div>\n
4. Pre\u2011FAT<\/strong> \u0641\u064a \u0645\u0635\u0646\u0639 \u0628\u0646\u0644\u0648\u0646\u062c<\/div>\n
5. Installation & commissioning<\/strong> On-site 15\u201120 days<\/div>\n
6. \u0627\u062e\u062a\u0628\u0627\u0631 SAT \u0627\u0644\u0646\u0647\u0627\u0626\u064a \u0648\u0627\u0644\u062a\u062f\u0631\u064a\u0628<\/strong> 7\u201110 days \u00b7 acceptance report<\/div>\n<\/p><\/div>\n
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Request a Custom Lithium Battery PACK Line Quote<\/h2>\n

Please share your battery cell spec(s), packaging design, and desired finish production. Based on these details, our engineering team will develop a custom line incorporating all elements of the process (sorting, welding\/machining, BMS integration, end-of-line testing) along with a complete ROI evaluation.<\/p>\n

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\u0648\u0627\u062a\u0633\u0627\u0628: +86 150 5837 0007 | \u0627\u0644\u0628\u0631\u064a\u062f \u0627\u0644\u0625\u0644\u0643\u062a\u0631\u0648\u0646\u064a: xsb@benlongkj.cn | \u062f\u0639\u0645 \u0628\u0627\u0644\u0644\u063a\u062a\u064a\u0646 \u0627\u0644\u0625\u0646\u062c\u0644\u064a\u0632\u064a\u0629 \u0648\u0627\u0644\u0635\u064a\u0646\u064a\u0629<\/p>\n<\/p><\/div>\n

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Why Choose Benlong for Battery PACK Automation?<\/h3>\n