Lithium battery PACK automatic production line: A complete automated solution for the entire process

The lithium battery PACK process involves combining individual cells through series and parallel connections, structurally fixing them, and integrating protection measures. This is the core step in manufacturing the final usable battery pack, directly determining the safety, consistency, and lifespan of the battery pack. The lithium battery PACK fully automated production line developed by Jisheng Automation focuses on the core of full-process automation and closed-loop control of all processes. It enables unmanned and standardized production from cell input to product output, perfectly meeting the mass production requirements of battery packs in various fields such as consumer electronics and power storage. 

I. Core Advantages of the Production Line 

The entire production line is based on the core design concept of "optimizing processes, reducing manpower, improving efficiency, and ensuring quality". Through the substitution of automated equipment for manual operations, it completely avoids human errors, significantly enhances production efficiency and product yield, and simultaneously enables traceability of all process data, meeting the strict quality control requirements of the new energy industry.

◎Cost reduction and efficiency improvement: The full-process automation replaces manual operations, reducing over 80% of frontline operation personnel, increasing production efficiency by 3-5 times, and significantly reducing the manufacturing cost per unit product.

◎Quality control: Full-process visual inspection + automated operations eliminate human errors, improving product consistency by 99%, and reducing the defect rate to below 0.1%.

◎Flexibility and adaptability: Modular design allows for quick model changes to adapt to different specifications of cells, battery packs, and various application scenarios such as consumer, power, and tool use.

◎Traceability loop: All process data is networked, with laser marking + system traceability, enabling the tracking and traceability of battery pack data throughout the entire life cycle, meeting industry compliance requirements.

◎Safety and reliability: Fully enclosed protective design, multiple safety interlocks, avoiding safety risks in processes such as welding and high-voltage testing, and meeting safety production standards. 

II. Detailed Explanation of All Process Workstations 

1.Cell sorting balance test + Insert into bracket 

As the first core process of the production line, this station is responsible for the source control of the consistency of the battery pack. Through high-precision testing equipment, it conducts comprehensive detection and sorting of key parameters such as the voltage, internal resistance, and capacity of the cells, selecting cells with consistent performance; at the same time, it automatically completes the assembly of cells into brackets, achieving precise positioning and fixation of the cells, laying the foundation for subsequent series and parallel assembly, and avoiding battery pack lifespan reduction and safety hazards caused by differences in cell performance from the source.

2. Automatic soldering + mold entry

After the cell positioning is completed, this station automatically completes the loading, assembly, and mold entry of soldering sheets (connection sheets), precisely achieving the physical connection positioning between cells, ensuring the accuracy of the connection between the soldering sheets and the cell terminals, providing a reliable guarantee for the subsequent welding process, and at the same time, ensuring the structural consistency of the cell group through mold positioning.

3. Battery pack automatic spot welding + mold removal + mold return

This is the core welding process of cell series and parallel connection. Through automated spot welding equipment, it performs high-precision and high-stability welding at the connection positions of cells and soldering sheets, forming a reliable electrical connection; after welding, it automatically completes the mold removal and mold return operations, achieving the recycling of the mold, while ensuring the consistency of welding quality, avoiding false welding and missed welding problems, and guaranteeing the electrical performance and structural strength of the battery pack.

4. Automatic NTC glue application + BMS PCB assembly

This station is responsible for the integration of the core protection system of the battery pack: automatically completing the point application and assembly of NTC temperature sensors to ensure the accuracy of temperature collection; at the same time, it automatically assembles the BMS (Battery Management System) PCB board to achieve voltage, temperature, and current monitoring and protection functions for the battery pack, which is a key link in ensuring the safe operation of the battery pack.

5. Automatic soldering

For the connection between BMS PCB boards and cells, batteries, and wiring harnesses, it completes high-precision welding through automated soldering equipment, replacing manual soldering, ensuring the consistency and reliability of solder joints, avoiding false soldering and missed soldering caused by electrical faults, and improving the electrical connection stability of the battery pack.

6. Soldering inspection position

As the quality control link of the welding process, through visual inspection equipment, it conducts a comprehensive inspection of all soldering points, identifying defects such as missed soldering, false soldering, excessive or insufficient soldering, etc., promptly eliminating defective products, ensuring that all soldering points meet the process standards, and eliminating electrical safety hazards from the source.

7. Automatic spring assembly + mold entry + lock screw installation

After the electrical connection is completed, this station enters the battery pack structure assembly process: automatically completing spring assembly (for cell buffering and structural fixation), battery group mold entry (shell assembly), and automatic lock screw installation processes, achieving the structure encapsulation and fixation of the battery pack, ensuring the mechanical strength and structural stability of the battery pack, and adapting to the requirements of different specifications of battery pack shells.

8. Automatic lubrication

For the lubrication and sealing requirements of battery pack structural components, it automatically completes the precise addition of lubricating grease / sealing glue, improving the service life and sealing performance of the structural components, and ensuring the reliability of the battery pack in complex working conditions.

9. Finished product automatic testing + laser marking

After the battery pack assembly is completed, it enters the comprehensive testing of finished products: through professional testing equipment, it conducts a comprehensive test of the battery pack's voltage, internal resistance, charging and discharging performance, protection functions, etc., verifying the performance of the finished product; at the same time, through laser marking equipment, it assigns a unique identity mark (QR code / barcode) to each battery pack, achieving full lifecycle production data traceability, meeting industry traceability management requirements.

10. Automatic labeling

According to product requirements, it automatically completes the precise application of the appearance label of the battery pack, including product model, parameters, production date, trace code, etc., replacing manual labeling, improving labeling accuracy and efficiency, and ensuring the standardization of product labels.

11. Appearance inspection 

As the final quality control point of the production line, the visual inspection equipment conducts a comprehensive inspection of the appearance of the battery pack, identifying appearance defects such as scratches on the shell, deformation, tilted labels, and loose screws, to ensure that the appearance quality of the factory-finished products meets the standards, and providing customers with high-quality finished battery packs. 

III. Adaptation Scenarios and Industry Applications

Core Adaptation Scenarios

◎Consumer lithium battery packs: Portable power banks, laptops, power tools, smart home devices, wearable devices, etc. for small-sized battery packs

◎Power lithium battery packs: Electric two-wheel/ three-wheel vehicles, low-speed electric vehicles, AGV robots, forklifts, etc. for power battery packs 

Industry Value

◎Help new energy battery enterprises achieve large-scale production and solve the bottleneck of manual production capacity

◎Meet the quality requirements of new energy vehicle manufacturers and energy storage companies for high consistency and high safety of battery packs

◎Adapt to the PACK process requirements in the field of battery recycling and secondary utilization

◎Comply with the upgrading direction of intelligent manufacturing and Industry 4.0 in the new energy industry, and can be connected to the MES system to achieve digital factory management 

IV. Summary of Production Line Value

The automatic production line for lithium battery PACK of Jisheng Lithium Battery achieves full-process unmanned production of lithium battery packs from cell sorting to finished product delivery through the sequential operation of 11 core stations. This not only significantly reduces labor costs and improves production efficiency, but also ensures the consistency and safety of the products through full-process automated control. It is an ideal solution for large-scale and standardized production in the new energy battery industry.

Whether it is consumer lithium battery packs, power lithium battery packs, or energy storage lithium battery packs, this production line can be adapted to different product specifications through flexible design, helping enterprises achieve capacity upgrade and quality improvement.