What equipment are required for assembling the prismatic lithium battery packs?

The automated/semi-automatic prismatic battery pack assembly line used to integrate and assemble individual prismatic battery into battery modules or battery packs. The main equipment of prismatic battery pack assembly line includes battery capacity grading machine, battery OCV&ACIR sorting machine, battery stacking and pressing machine, laser cleaning machine, laser welding machine, BMS tester, battery comprehensive tester, battery pack aging machine.

Option 1 —— Semi-automatic prismatic lithium battery pack assembly line

Flow chart of Manual/Semi-auto prismatic battery pack assembly line:

Option 2 —— Full-automatic prismatic lithium battery pack assembly line

Flow chart of Auto prismatic battery pack assembly line:

The assembly process of prismatic lithium battery pack

Step 1 —— Prismatic Cell Capacity Grading

1) Product Description

Prismatic battery cell grading machine is an automatic detection and capacity division system for rechargeable batteries; It has the characteristics of high precision and energy saving. Suitable for the formation, capacity separation testing, and capacity sorting of lithium batteries.

2) Main Features

• Each battery channel has a completely independent constant current and constant voltage source, forming its own circuit without affecting each other.
• The software has the functions of editing and modifying the process library files, creating monitoring, opening and closing documents, printing and setting up.

3) Product Selection

Prismatic Battery Capacity Grading Machine
Equipment Type	Energy Regenerative
Clamps	Standard flat head fixture( optional alligator clip)
Machine Model	5V 30A	5V 60A	5V 100A	5V 200A	5V 300A	5V 400A	More Customization
Channels	8/16/32/64/128CH etc
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Step 2 —— Prismatic Cell OCV&ACIR Sorting

1) Product Description

Battery sorting machine is used to test the open-circuit voltage and AC internal resistance of general prismatic lithium battery.

2) Main Features

• Adapted to various types of batteries, easy to replace and operate.
• Built in high-precision Japanese BT3562A/HIOKI internal resistance tester, with high testing accuracy and fast speed.

3) Product Selection

Prismatic Battery Sorting Machine
Barcode Scanner	Standard
Tester	HK3561/HIOKI BT3562 Optional
Sorting Channels	7+1=8CHS	9+1=10CHS	Customizable
Product Picture			More Products

Step 3 —— Prismatic Cell Stacking And Pressing

1) Product Description

Prismatic battery stacking and pressing machine is suitable for stacking and forming prismatic lithium batteries, as well as trapping them.

2) Main Features

• 7-inch touch screen with PLC for control, easy to operate.
• Adapt to various size of batteries, can be edited and set different parameters, simple and easy to change the type.

3) Product Selection

Prismatic Cell Stacking And Pressing Machine
Control	PLC+Touch Screen Control
Strips	Plastic Steel Strips	Steel Strips	Customizable
Stacking Pressure	100KG	500KG
Product Picture

Step 4 —— Prismatic Battery Terminal Laser Cleaning

1) Product Description

Laser cleaning machine is used in the assembly of prismatic lithium-ion battery packs to clean terminals, busbars, connectors, battery modules, housing surfaces, and BMS contact points, remove oxides, dust, and debris, to ensure strong and reliable electrical connections and appropriate thermal management.

2) Main Features

• Cleanliness level ≤ 100000
• No corrosive gas, liquid or explosive gas on site

Step 5 —— Prismatic Battery Pack Laser Welding

1) Product Description

Laser welding machine is the most valuable and technology intensive core equipment in the PACK production line, mainly responsible for electrical connections between cells and busbars.

2) Main Features

• Continuous pure fiber laser, which can penetrate 0.5-5.8mm materials for direct welding.
• Precise servo system control to ensure welding accuracy.

3) Product Selection

Prismatic Battery Laser Welding Machine
Welding Material	Aluminium,Nickel, Copper, Composite Material etc.
Welding Method	Manual	Automatic
Product Type	Handheld	Gantry	Gantry
Power	1500W/2000W/3000W	1500W-6000W	1500W-6000W
Welding Thickness	0.3-3.5mm	0.5-5.8mm	0.5-5.8mm
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Step 6 —— Battery Management System Testing

1) Product Description

BMS Tester is a specialized device designed to verify the functionality and performance of battery protection boards (BMS).

2) Main Features

• Overcharge/Overdischarge Protection Test
• Overcurrent/Short Circuit Protection Test
• Temperature protection test
• Internal resistance and conduction resistance testing
• Self consumption detection
• Communication function verification (for intelligent BMS): Test communication interfaces such as CAN, RS485, I2C, etc. to read SOC, voltage, temperature and other data accurately.

3) Product Selection

Battery Management System Testing Machine
Pack Series	1-52S Battery Pack/Module
Current	120/150/200/300/400/500/600/800A etc		Customizable
Computer	Without computer	With computer
Product Picture

Step 7 —— Prismatic Battery Pack Comprehensive Testing

1) Product Description

Battery comprehensive tester is suitable for all lithium-ion battery packs with CH+P+CH - P - ports to test various comprehensive performance parameters of the battery pack.

2) Main Features

The battery comprehensive tester is to apply a load to the battery or apply a small AC current to measure the open circuit voltage, AC internal resistance, discharge test, discharge overcurrent test, short circuit protection test, charge test and charge protection test and other parameters to quickly screen and judge the performance of the battery and good or bad, by setting the upper and lower limits of the measurement parameters, it is easy to quickly detect the bad battery from a batch of finished batteries.

3) Product Selection

Battery Pack Comprehensive Tester
Voltage Range	50/60/100/120V/200V etc			Customizable
Current Range	120/200/300/500/600A etc
Machine Picture

Step 8 —— Prismatic Battery Pack Aging Testing

1) Product Description

Battery pack aging machine is applied to the integrated charge discharge cycle test system of low string lithium battery pack cycle charge and discharge, battery pack function test and charge discharge data monitoring, such as electric tools, solar energy storage, fascia gun and so on.

2) Main Features

The device has four test steps: charging, discharging, shelving, and cycling. By editing the corresponding steps, the battery can be tested in accordance with the set process.

3) Product Selection

Battery Pack Aging Testing Machine
Voltage	20V-1650V						Customizable
Current	10A-1200A
Channels	1/2/3/4/6/7/8/12/16/32 etc
Type	Standard type/with energy regenerative function (optional)
Voltage&Current	30V 10A charge 20A discharge	70V 5A charge 10A discharge	70V 10A charge 20A discharge	85V 10A charge 20A discharge	100V 10A charge 20A discharge	100V 20A charge 40A discharge
Product Picture

Product application areas

Prismatic battery PACK has become the mainstream choice in the three major fields of new energy vehicles, energy storage systems, and industrial equipment due to its high structural strength, good heat dissipation, high space utilization, and good safety. Its application covers a wide range of scenarios from giant power grids to micro robots.