Prismatic Battery Pack Assembly Line
The Prismatic Battery Module & PACK Production Line is designed for manufacturing energy storage battery modules and PACKs with prismatic cells, at 8 PPM and ≥99% yield.
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Details Introduction
This prismatic battery module & PACK assembly line is engineered for efficient production of prismatic aluminium‑cased cells into energy storage modules and PACKs. The system integrates cell processing, laser welding, mechanical assembly, and comprehensive testing into a high‑yield, cost‑effective solution. It supports cylindrical, prismatic, and energy‑storage cell formats with flexible configuration for medium‑scale manufacturing.
With a production capacity of up to 8 PPM and a yield rate of ≥99%, the line is ideally suited for BESS and commercial & industrial energy storage projects requiring 500 MWh–1 GWh annual output (single shift).
Key Features
✅️ Medium‑Scale Production Capacity
Delivers stable throughput for 500 MWh–1 GWh per year, matching the pace of C&I and grid‑side projects without over‑investing in full‑automation.
✅️ Multi‑Cell Format Compatibility
Supports cylindrical, prismatic, and energy‑storage cells, accommodating 50Ah–280Ah mainstream prismatic cells and diverse module topologies.
✅️ Semi‑Automated, Cost‑Effective Operation
Balances manual loading/unloading with automated cleaning, welding, and testing, achieving equipment uptime ≥95% and quick changeover ≤2 hours.
✅️ Complete Module & PACK Process Integration
Covers cell pretreatment, robotic stacking, busbar laser welding, liquid‑cooled PACK assembly, BMS installation, and EOL testing in one streamlined line.
✅️ Intelligent Quality Assurance
Features barcode traceability, CCD alignment, OCV/IR testing, insulation withstand voltage, gas tightness testing, and full EOL inspection to ensure ≥99% pass rate.
✅️ Compact Footprint & Fast Deployment
Requires only ~560㎡ floor space, standard utilities, and ≤15 days commissioning, with modular design allowing future capacity upgrades.
Production Process
Cell Loading → Cell Testing & Sorting → Module Assembly → Module Welding → Module EOL Testing → PACK Assembly → Electrical Testing → Final Inspection
Parameter
| Item | Details |
|---|---|
| Equipment Name | Prismatic Energy Storage Module & PACK Assembly Line |
| Design Cycle Time | 8 PPM (calculated based on cells, using 1P13S module as reference; reference cell 314Ah, with future compatibility for 587Ah large cells) |
| Overall Product Yield | ≥99% (attributed solely to equipment, excluding human factors) |
| Manpower Allocation | Cell processing section: 2 persons Module stacking & welding section: 5 persons PACK assembly section: approx. 12 persons |
| Equipment Footprint (L×W×H) | 55m × 9m × 3.5m (excluding warehouse and logistics aisles) |
| Estimated Utility Requirements | Power supply: 3‑phase 5‑wire 380V±5%, 50 Hz, rated power 250 kW Compressed air: 0.5‑0.7 MPa, flow ≥3000 L/min Shielding gas: Nitrogen 0.5 MPa, flow 40 L/min |
| Factory Floor Load Capacity | ≥800 kg/㎡ |
Keyword:
Prismatic Battery Pack Assembly Line
Related Products
How Are the Production Capacity and Yield Rate of A Lithium Battery PACK Production Line Measured?
There are two core indicators: production cycle time (PPM), which means the number of modules produced per minute – industry high‑efficiency lines can reach 12‑15 PPM; and yield rate, with the industry standard requiring ≥99%. The yield rate is affected by cell consistency, welding quality, and test coverage.
What Are the Main Processes in a Lithium Battery PACK Production Line?
From cell to battery pack, the process includes: cell sorting → module stacking → pole welding (spot welding/laser welding) → BMS installation and wiring connection → insulation voltage withstand test → EOL comprehensive test. Welding and testing are the critical steps that determine the yield rate.
Why Spot Welders Are Commonly Used for Cell Connection in PACK Lines?
A battery spot welder is a type of resistance welding that uses low voltage and high current to melt the metal at the contact point within milliseconds. The heat is concentrated and does not damage the cells, and the weld spot tensile strength reaches ≥12 kg, making it the most reliable and efficient connection method for cylindrical cell assembly.
What Welding Processes are Mainly Used in a Lithium Battery PACK Production Line?
In a lithium battery PACK production line, laser welding is the most widely used core process, suitable for cell tab welding, module busbar welding, housing sealing, and more. Its advantages include high precision, a small heat-affected zone, effective protection of cells from heat damage, and reliable joining of dissimilar metals such as copper and aluminum.
Contact us
Address: 5 Xingfu Road, Miaoshan Development Zone, Jiangxia District, Wuhan City, Hubei Province, China
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