Jisheng Automation's Battery Pack Fully Automatic Assembly Line, Officially Launched! With an hourly production capacity of 550 packs

In the current era of rapid iteration in the new energy electric tool industry, lightweight, high-rate, and long-range lithium battery packs have become the core competitive field for electric tools. With the explosive demand from the downstream market, customers have set unprecedentedly high requirements for the production capacity efficiency, product consistency, production cost, and quality control accuracy of battery packs. 

With a long-term focus on the lithium battery industry of power tools, Jisheng Automation has concentrated on the core field of lithium battery assembly automation. It has continuously deepened research and development, iterated processes, and optimized the overall line solutions. Leveraging its profound non-standard automation design experience, mature lithium battery manufacturing technology, and full-process customized service capabilities, it has launched a fully automated production line solution for 18650 cylindrical lithium batteries with 1P5S configuration for power tools. The entire production line achieves a production capacity of 550 battery packs per hour, and is compatible with 18650 cells in 1P5S, 2P5S configurations, as well as 21700 cells in 1P5S, 2P5S configurations. It can accommodate various battery pack sizes, fully meeting the intelligent upgrade needs of small and medium-sized lithium battery manufacturers and power tool manufacturers. 

I. Cutting-edge Technological Breakthrough! 1P5S Battery Pack Unmanned Continuous Line Process Analysis

This newly implemented 1P5S electric tool battery pack automated continuous line by Machine Saint Automation is a standardized + modular integrated design. The layout of the entire line is compact and reasonable, with seamless and smooth process connections. The entire process does not require manual intervention. From the raw material battery cells to the semi-finished battery pack formation, all production processes are completed automatically.

1. Automatic Battery Cell Loading, Intelligent Supply without Human Intervention

The front end of the production line is equipped with a fully automatic battery cell loading mechanism, combined with the sorting, directional correction, and automatic material distribution modules, to achieve automatic and orderly loading of bulk / trayed battery cells. The equipment is equipped with intelligent error prevention and anti-scuffing design, with flexible transportation throughout the process, avoiding damage to the battery cell shell, scratches, and bumps. This ensures the intact appearance of the battery cells from the source. At the same time, it is equipped with material shortage warning and automatic shutdown alarm functions, achieving 24-hour stable and uninterrupted supply, completely replacing manual sorting and loading, and reducing material loss and safety hazards caused by human contact.

2. Automatic Testing + Barcode Binding, Full Data Information Traceability

After the battery cells are loaded, they automatically flow to the integrated testing and scanning workstation. The equipment integrates the automatic detection module for battery cell voltage, internal resistance, and open-circuit voltage, accurately and real-time collecting the core performance parameters of the battery cells, quickly screening out defective battery cells.

Simultaneously, it completes automatic scanning, information entry, and data binding. Each battery cell QR code / barcode is automatically recognized, and the batch information, test data, production time, equipment number, etc. are uploaded to the system in real time, achieving one item, one code, full traceability. This effectively realizes the classification and retention of good and defective product data, providing complete data support for later quality control, after-sales traceability, and quality analysis, meeting the standardized production management requirements of the lithium battery industry.

3. Intelligent Automatic Sorting, Precise Elimination of Defective Products

Based on the performance data of the battery cells collected at the testing workstation, the production line is equipped with an intelligent automatic sorting system. According to the preset parameter thresholds, it automatically distinguishes good products, substandard products, and scrap products. Through the high-speed sorting manipulator +分流 conveying structure， it quickly eliminates and classifies defective battery cells， preventing defective battery cells with high pressure difference， abnormal internal resistance， and appearance defects from flowing to the next process. The high-precision sorting logic significantly reduces the safety hazards of the final battery pack products， stabilizes the product yield， and reduces rework costs.

4. Automatic Inserting into Bracket + Cover Assembly， Precise Assembly with Zero Deviation

The qualified battery cells after screening are automatically transported to the assembly workstation， and complete automated operations of battery cell automatic insertion into bracket and bracket automatic cover assembly are completed successively. Machine Saint Automation adopts customized positioning fixtures + visual auxiliary positioning technology to precisely match the size of the 1P5S battery pack dedicated bracket， ensuring the close and uniform placement of the battery cells； the fully automatic pressing mechanism smoothly completes the bracket assembly， with controllable assembly pressure and a tight and reliable cover， without loosening， misalignment， or deformation. The entire assembly process does not require manual placement or manual pressing， achieving uniform assembly accuracy and a significant improvement in consistency， perfectly solving the problems of inconsistent assembly tightness and frequent defects in manual assembly.

5. Automatic Adhesive Film Installation + Precise Spot Welding， Comprehensive Upgrade of Welding Process

As the core key process of battery pack production， the welding quality directly determines the conductivity performance， structural strength， and service life of the battery pack. This production line is equipped with fully automatic adhesive film loading， positioning， and alignment mechanisms to achieve automatic cutting， precise placement， and automatic alignment of adhesive films， eliminating problems such as adhesive film deviation， omission， and misplacement； it is also equipped with a high-precision medium-frequency spot welding system， with constant temperature welding control， real-time pressure monitoring， and weld point visual detection functions， completing the automatic precise spot welding of the battery pack's electrode and adhesive film. The weld points are uniform and full， and the welding is firm， effectively avoiding common defects such as false welding， detachment， and burn-through of the battery cells， with welding stability and safety far exceeding manual welding.

6. 550 Battery Pack/h Continuous Line High Capacity Implementation 

The entire process is designed with modular interconnection, ensuring deep coordination of each workstation's production cycle. There is no waiting or stalling, and the production capacity of 550 1P5S battery packs per hour is successfully achieved steadily. Compared to traditional manual production lines, the production capacity has directly increased by more than double. The entire production line operates in an automated flow, from loading materials, testing, sorting, assembly, attaching solder tabs to spot welding and forming. Throughout the process, there is no need for manual supervision, manual transportation, or manual assistance. Only regular simple inspections and routine equipment maintenance are required, significantly reducing the workforce configuration on the production line and helping enterprises effectively lower labor costs and management costs. 

II. Multiple Core Advantages, Empowering Lithium Battery Enterprises to Reduce Costs and Enhance Efficiency

1. Ultimate Production Capacity, Efficient Delivery

Relying on mature process cycle optimization and automation linkage technology, stable 550 units/hour production capacity is achieved, significantly increasing daily and monthly production capacity, quickly handling large orders, shortening delivery cycles, and enhancing the market competitiveness of the enterprise in accepting orders.

2. Unmanned Production, Significant Cost Reduction

Full-process unmanned operation, eliminating the reliance on a large number of operators on the assembly line, reducing comprehensive costs such as personnel recruitment, management, social security, and work-related injuries. At the same time, it avoids human errors and efficiency fluctuations caused by manual operations, making production more stable and controllable.

3. High Precision Process, Upgrade in Yield

From cell detection and sorting, precise assembly to automated spot welding, all processes are standardized and intelligent. Unified production process standards effectively reduce assembly defects, welding defects, and cell mix-up issues, significantly improving the overall yield of the products, reducing material waste and rework losses.

4. Full-Process Traceability, Compliance Control

Scanning binding + real-time data collection system, achieving full lifecycle data traceability of battery packs. The production process is transparent and visualized, meeting the quality audits of downstream customers and the compliance production requirements of the industry, helping enterprises achieve standardized and standardized management.

5. Modular Design, Flexible Expansion

The production line adopts a modular integrated structure, with a compact layout and smaller占地面积. It is suitable for the implementation in small and medium-sized workshops； at the same time， it reserves interfaces for process upgrades and model expansions， enabling rapid adaptation to the transformation and upgrading of the same specification multi-string battery packs based on the subsequent product iteration requirements of the customer. The equipment has a high reuse rate and a stronger investment cost-effectiveness.

6. Stable and Durable， Easy Maintenance

The core components of the equipment are equipped with first-line brand configurations. The structural design is solid and durable， suitable for long-term continuous production conditions. Combined with intelligent fault self-checking， alarm prompts， and simplified operation interfaces， the equipment operation is simple， reducing the equipment maintenance threshold and cost for the enterprise. 

III. Deeply Engaging in the Automation Field, Jisheng Automation Continuously Supports Industry Upgrades

Over the years, Jisheng Automation has focused on the research, design, production, and delivery of automated equipment for entire lines of electric tool batteries, household appliance battery packs, energy storage power supplies, consumer lithium batteries, and electric two-wheeled and three-wheeled vehicles. It has deeply specialized in the lithium battery assembly sub-sector and has profoundly understood the industry development trends and the actual production pain points of customers. 

We do not limit ourselves to the development of a single device. Instead, we focus on creating integrated solutions for the entire production line. From the customization of the initial plan, the development and production of the equipment, the on-site installation and commissioning, to the later after-sales maintenance, process upgrading, and technical support, we provide customers with a one-stop, full-process service. 

In the future, Jisheng Automation will continue to increase its investment in technological research and development, refine more efficient, smarter, more energy-saving and more cost-effective automation solutions. Through technological innovation, it will drive industrial upgrading and work hand in hand with a wide range of industry customers to achieve mutual success and jointly explore the new blue ocean of lithium battery manufacturing for electric tools!