Solution
587Ah / 628Ah Module & Pack Assembly Line
- Product description
-
- Commodity name: 587Ah / 628Ah Module & Pack Assembly Line
The 587Ah / 628Ah Module & Pack Assembly Line is a fully automated, AGV-driven production system engineered for next-generation large-capacity ESS battery manufacturing. It supports simultaneous mixed-format production of 587Ah, 628Ah, and 314Ah prismatic cells on a single floor footprint.
1. Equipment Overview
The 587Ah / 628Ah ESS Module & Pack Assembly Line represents Huiyao’s most advanced large-capacity production solution for the energy storage sector. As the market transitions toward 500Ah+ cell formats, traditional rigid conveyor systems face fundamental constraints in handling the increased cell weight, larger module dimensions, and shifting pack architectures. This line solves all three challenges simultaneously.
Built around a core AGV (Automated Guided Vehicle) logistics backbone, the line enables true mixed-flow manufacturing: the same installed floor footprint can process 3 to 5 different pack architectures in parallel, automatically routing packs to the correct station for each build variant. The robotic laser welding stations achieve ±0.02mm repeat positioning accuracy for busbar welding, ensuring consistent low-resistance joints across ultra-high-capacity cell terminals. All production data is logged per-cell from the moment of entry, generating an immutable traceability record compliant with the 2027 EU Battery Passport Regulation (EU 2023/1542).
2. Key Processes and Modules
2.1 Cell Incoming Inspection & OCV/IR Sorting Station
- Function: Performs automated optical inspection on incoming 587Ah/628Ah cells. Reads QR code or laser-engraved data matrix. Measures Open Circuit Voltage (OCV) and Internal Resistance (IR) to grade incoming cells and automatically route out-of-spec units before assembly begins.
- Specifications:
- OCV Measurement Accuracy: ±0.5 mV
- IR Measurement Accuracy: ±0.05 mΩ
- Barcode Scan Success Rate: ≥99.9%
- Throughput: Compatible with line takt time
2.2 Cell Stacking & Module Assembly Station
- Function: Robots pick, flip, and stack cells in the correct polarity orientation according to the module schematic. Automated foam pad and thermal interface material (TIM) insertion between cells.
- Specifications:
- Cell Stacking Accuracy: ±0.3 mm
- Compatible Cell Sizes: 587Ah, 628Ah, 314Ah prismatic formats
- TIM Dispensing Accuracy: ±0.5 mm
- Cycle Time: Adjustable per format
2.3 Busbar Laser Welding Station
- Function: Multi-axis robot laser welding system welds aluminum or copper busbars to the cell terminals of the stacked module. Real-time weld pool monitoring detects spatter, porosity, and under-penetration in-process.
- Specifications:
- Welding Method: Fiber laser (oscillating/wobble mode)
- Welding Power: 3,000–6,000 W (adjustable)
- Repeat Positioning Accuracy: ±0.02 mm
- Weld Speed: ≤5 seconds per busbar joint
- Quality Control: Real-time inline weld pool monitoring
2.4 Module Casing & End Plate Assembly Station
- Function: Automatically applies end plates and side plates to the completed cell stack. Fastens the module housing using automated torque-controlled tightening to the specified Newton-meter value.
- Specifications:
- Torque Setting Range: 5–50 N·m (fully programmable)
- Fastening Accuracy: ±2% of target torque
- End Plate Alignment Accuracy: ±0.5 mm
2.5 Module EOL Electrical Testing Station
- Function: After module assembly, each module undergoes a complete End-of-Line (EOL) electrical test: Hi-Pot (AC/DC insulation), Open/Short circuit check, OCV and IR re-measurement, and thermal scan using infrared thermography.
- Specifications:
- Hi-Pot Test Voltage: up to 5,000 V DC
- IR Thermography: 160×120 resolution minimum
- Test Parameters: Voltage, IR, Insulation Resistance, Leakage Current
- Testing Speed: ≤3 minutes per module
2.6 AGV Pack Logistics & Transport System
- Function: AGV carts automatically transport completed modules from the module assembly area to the pack assembly area. The AGV scheduling system dynamically routes packs by variant type, enabling true mixed-flow production of 3–5 different pack configurations on the same line simultaneously.
- Specifications:
- AGV Load Capacity: Up to 500 kg per unit
- Navigation Type: Laser SLAM or magnetic stripe (configurable)
- Positioning Accuracy: ±5 mm
- Concurrent AGV Units: 4–12 (scalable to line size)
2.7 Pack Assembly & Integration Station
- Function: Modules arriving by AGV are lifted into the pack housing by collaborative robots. Harness routing, HV connector insertion, and BMS (Battery Management System) mounting are completed at this station.
- Specifications:
- Module Positioning Accuracy into Pack: ±1 mm
- HV Connector Assembly: Automated with torque validation
- Assembly Cycle: Configurable per pack variant
2.8 Pack Final Sealing & EOL Testing Station
- Function: Final laser seam welding or mechanical crimping of the pack enclosure. EOL electrical test including full pack Hi-Pot, discharge test, and optional formation cycling connection.
- Specifications:
- Sealing Method: Laser seam weld or mechanical crimp (project-specific)
- Final Pack Hi-Pot: Up to 5,000 V DC
- Final Yield Rate: ≥ 99.8%
- Hardware Failure Rate: ≤ 2.0%
3. Production Line Specifications
Parameter
Specification
Compatible Cell Formats
587Ah (1P26S), 628Ah, 314Ah prismatic
Mixed-flow Variants
3–5 different pack specs on one line
Final Assembly Yield
≥ 99.8%
Hardware Failure Rate
≤ 2.0%
Automation Level
Fully automated with AGV logistics
Data Traceability
100% per-cell scan, EUBP compliant
MES Integration
Standard (WMS/ERP API available)
4. Vision and Quality Inspection Systems
- Incoming Cell Inspection: 8 MP industrial cameras for OCV grading, surface defect, and label quality check.
- Stacking Alignment Vision: High-speed CCD cameras verify cell polarity and stack geometry before welding.
- Weld Quality Inspection: Real-time weld pool monitoring camera integrated at the welding head; defect classification (spatter, crack, under-weld) reported to MES within 200ms.
- Data Management: All inspection results linked to cell UID and stored in the centralized MES database for lifetime traceability.
5. Control and Interface
- Control System: Distributed PLC system (Siemens S7 or equivalent) with centralized SCADA supervision.
- Human-Machine Interface (HMI): 15-inch touchscreen with real-time production status, alarm management, and multi-language support (including Chinese and English).
- IoT Integration: Remote monitoring, predictive maintenance alerts, and cloud data synchronization available.
- AGV Scheduling Software: Proprietary dispatch software with live floor map, route conflict avoidance, and automatic battery management for AGV units.
6. Safety Features
- Enclosure: Fully enclosed with interlocked safety doors; line cannot operate with any safety door open.
- Emergency Stop: Distributed E-Stop system; any station can halt the full line.
- Laser Safety: Class 1 laser enclosures with dual interlock switches and key management.
- HV Safety: All HV connector operations require mandatory low-voltage pre-connection validation before HV energization.
- Fire Suppression: Optional integrated aerosol-type suppression system compatible with thermal runaway detection.
7. Electrical Specifications
Parameter
Specification
Power Supply
AC 380V ±10%, 50/60 Hz, 3-phase
Maximum Power Consumption
250 kW (varies with configuration)
Control Voltage
24V DC for auxiliary systems
Laser Power
3,000–6,000 W per laser station
8. Cooling System
- Type: Centralized closed-loop water cooling for laser sources and high-power servo amplifiers.
- Cooling Capacity: 20 kW (configurable)
- Flow Rate: 35–80 L/min
- Water Quality Requirement: Deionized water, conductivity ≤ 50 μS/cm
9. Frequently Asked Questions (FAQ)
Q: Can this assembly line handle both 314Ah and 587Ah cells simultaneously?
A: Yes. The line utilizes AGV (Automated Guided Vehicle) mixed-flow routing and dynamic robotic end-effectors, allowing multiple cell formats to be processed on the same floor footprint without requiring physical line changeovers.
Q: What is the maximum pack size the AGV system can transport?
A: The standard heavy-duty AGV units support payloads up to 500 kg, which easily accommodates C&I pack configurations. For utility-scale string architectures, higher capacity dual-AGV synchronized transport can be configured.
Q: How does the welding station adapt to different busbar thicknesses?
A: Our 3D profilometry vision system scans every joint prior to welding. The MES dynamically adjusts the laser power and focal depth based on the exact material thickness detected in real-time, preventing under-penetration or blowholes.
Key words:
Series of Products
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Huiyao Laser is a leading battery laser welding machine manufacturer offering professional battery pack and battery module welding solutions for many fields, such as energy storage systems of research and development machines, as well as complete assembly lines for module and battery pack production.
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