Module Production Line

Specifications

The modular battery module production line is designed for high-precision manufacturing processes.
Product flow between all stations is ensured by a fully automated conveyor system.
Independent process monitoring can be done at each station, and production data can be digitally tracked through MES integration.
Each station is equipped with emergency stop and process complete control buttons.
Product handling capacity up to 500kg
Operates with a PLC and computer-based hybrid automation architecture.
The system can be monitored and controlled from any device that can run Chrome.

Module Production Line Introduction

System Features

Industry 4.0 Compliant Battery Module Production Line
Real-time production data tracking (MES)
Reflow: Product transport plates are automatically returned to the start under the production line.
Battery passport with QR code integration for traceability
Remote access and management
Energy-efficient motor control

Battery Module Production Line with Lithium-Ion Prismatic Cells

Production Line Stations

Sorting Machine

Battery cells are sorted according to capacity, voltage, and internal resistance values. This step ensures that the cells perform optimally within the module. Measurement results are automatically recorded in the MES system.

Compression Machine

Sorted cells are grouped with endplates and compressed in a pressure- or position-controlled manner. The compression machine can apply up to 1000 kg of pressure.

Buffer Station

Stations that provide flexibility in production ensure modules are ready for the next process. Overall line balance and synchronization are managed here.

Laser Welding Section (4 Stations)

  • Cell Pole Detection: Cell pole coordinates are detected with an autonomous camera, and cell QR codes are read to create a group code. The system triggers an alarm if cells are misaligned.

  • Laser Cleaning: Prismatic cell surfaces are prepared before laser welding. Oxide, oil, and particle residues are removed using a galvo-head fiber laser.

  • CCS Busbar Assembly: The module code is automatically generated by the system and printed from a barcode printer at this station. The barcode is attached to the module, and the CCS assembly is completed.

  • Laser Welding: Cell poles are welded to the busbars on the CCS. The 6kW galvo-assisted fiber laser can weld aluminum bars up to 3mm thick.

Visual Inspection Station

Manual visual inspections and quality control checklists are completed at this station, and all modules are carefully transferred to the test station.

EOL Electrical Test Station

Electrical tests are performed in the final stage. Operations such as voltage, current, insulation resistance measurements, and bonding tests are conducted and added to the quality report.

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