本龍 
鋰電池PACK模組自動化生產線
Fully automatic lithium battery PACK module production line for EV & ESS. Cell sorting (voltage/IR), laser/ultrasonic welding, BMS installation, EOL test (insulation, charge/discharge, balancing). Customizable for cylindrical, prismatic, or pouch cells. Full traceability. IEC/UL compliant.
Fully Automatic Lithium Battery PACK Module Production Line
This new full‑automated lithium battery PACK module production line is specifically developed for volume assembly of Li‑ion 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.
Precision cell sorting takes place first, based on voltage (mV) and internal resistance (mΩ). 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.
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.
What is a Lithium Battery PACK Module Automatic Production Line?
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.
Automated voltage & internal resistance measurement for consistent cell matching.
Laser or ultrasonic welding for busbars and tabs with micron‑level accuracy.
Automated placement of BMS PCBA and thermal management components.
Insulation resistance, charge/discharge, balancing validation, and data logging.
生產線特性及流程
技術規格
| Cell types supported | Cylindrical (18650, 21700, 26650, 4680), prismatic, pouch (custom fixtures) |
|---|---|
| Cell sorting accuracy | Voltage: ±1mV | Internal resistance: ±0.5% of reading |
| 焊接技術 | Fiber laser welding (500‑2000W) or ultrasonic metal welding (configurable) |
| Welding accuracy | Position repeatability ±0.05mm; optional weld penetration monitoring |
| 組裝週期時間 | 3‑8 seconds per cell (depending on pack size and welding spots) |
| EOL test coverage | Insulation resistance, dielectric strength, charge/discharge (up to 2C rate), active/passive balancing, CAN communication validation |
| BMS integration | Automated BMS PCB placement, screw fastening, and optional firmware flashing |
| 可追溯性 | Barcode/cell ID linked to sorting data, welding parameters, and EOL results; MES export via OPC UA |
| 電源和空氣供應 | 380V ±10% 50Hz | Compressed air 0.6‑0.8MPa | Chilled water for laser (optional) |
核心技術優勢
Precision cell sorting for matched modules
The line measures voltage and internal resistance of each incoming cell. It then groups cells with similar parameters into the same module – critical for pack longevity and balanced charging.
Micron‑level laser/ultrasonic welding
High‑power fiber laser or ultrasonic welding ensures low‑resistance, high‑strength joints between busbars and cell tabs. Optional coaxial monitoring checks weld penetration in real time.
Integrated EOL test station
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.
Full traceability for safety compliance
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.
Customer Success Story – EV Battery Pack Manufacturer
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:
In 14 months, the customer recouped their investment in lines along with receiving an industry-approved standard of quality.
應用與集成
客製化工程與交付
Request a Custom Lithium Battery PACK Line Quote
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.
WhatsApp：+86 150 5837 0007 | 信箱：xsb@benlongkj.cn | 提供中英文支持
Why Choose Benlong for Battery PACK Automation?
- 15年以上設計經驗 自動化裝配線 for energy storage and EV components
- Proven cell sorting (±1mV, ±0.5% IR) and laser welding (500‑2000W) expertise
- Integrated EOL test station (insulation, charge/discharge, balancing)
- Full traceability – cell ID to pack serial number
- Worldwide service and spare parts support
典型客製化產品線包括
Cell sorting system (voltage/intermediate resistance), robotic stacking and assembling, laser or ultrasonic welding station, module for BMS installation and attachment, thermal-management assembly, conveyor system, end-of-line testing bench, PLC with HMI (Siemens), traceability software (via bar code), safety guards, installation and training, and a one-year guarantee.
常見問題解答
The system is capable of processing cylindrical batteries (18650, 21700, 26650, 4680), prismatic batteries, and pouch style batteries. Stations for sorting and welding can easily accommodate different formats and are set up using dedicated fixtures.
When it comes to high-volume, high-speed applications , laser welding is typically chosen. Examples include cylindrical cells with large busbars but more commonly it is used in ultrasonic welding which utilizes a heat source for minimized heat input to thin tabs or heat sensitive cells (e.g. pouch). We are able to incorporate one, or both methods depending on your choice of cell type and tab materials used.
Scanned at the sorting point of the sorting station is the QR code or barcode from each cell. At the sorting station, the same identification number is connected to welding parameters and module assembly data. Finally, during the end-of-line testing process, the module serial number is connected to all historical cell-level data, providing a complete record for safety certification and customer audits.
Customer-defined safety and performance criteria for EV and ESS applications, such as compliance with transportation regulations, electrical safety testing, and verification of performance, can be achieved through EOL testing stations tailored specifically to these specifications; we will collaborate with you to determine what criteria will apply to each of your target markets when designing the testing protocols used at each stage of manufacturing.
For a cylindrical production line, such as standard-sized cylindrical batteries (18650/21700), with laser welded connections and EOL testing, the lead time from signing a contract to factory acceptance is typically 90 to 120 days. For prismatic (or pouch) cell production lines with custom fixturing, the lead time is generally between 120 and 150 days.
