Handling the "Fragile": Automation Secrets for Pouch Cell Module Assembly
Release time:
2025-11-24
Pouch cells are the “energy density champions” of the EV world, but for automation engineers, they are a nightmare. Soft, vulnerable and unforgiving, pouch cells differ from their rigid Prismatic or Cylindrical cousins in crucial ways.
Pouch cells are the “energy density champions” of the EV world, but for automation engineers, they are a nightmare. Soft, vulnerable and unforgiving, pouch cells differ from their rigid Prismatic or Cylindrical cousins in crucial ways.
A standard industrial robot gripper that works flawlessly for a prismatic can is likely to scratch it dent or even puncture it if it encounters a pouch cell. “Automation pouch battery solutions” are not just about moving things, but moving them with care.
This is how we design our lines for speed while handling the “fragile.”
1.The "Soft Touch" Challenge: Why Standard Automation Doesn't Cut It
The greatest single risk in the assembly of pouch modules is mechanical loads. Any slight pressure on the active area of the separator within the cell can cause dendrites to grow, leading to a short. Standard vacuum grippers leave suction marks. Standard mechanical grippers crush the edges. You need a fundamental redesign of the gripping element to accomplish the task.
2.Our Solution: Non-destructive gripping for touchy cells.
Floating Vacuum and Soft-Robotic end-effector design for our EV Pouch Battery Module Lines.
Distributed Suction: No high-pressure points or pincers here. We deliver a wide-area, low-pressure vacuum sponge lifting force across the entire cell face.
Edge-Only Handling: In stations without vacuum accessibility, we use mechanical grippers that engage only the inactive sealing edges (the “terraces”), leaving the sensitive active material untouched.
3.Flexible Pressure Control: Avoiding Compaction While Stacking
One of the steps in stacking pouch cells is to compress the foam pads to promote thermal contact.
How do you know that you have stacked a cell without crushing it?
With Force-Feedback Sensors in the stacking servo axis, the system monitors the resistance force in operation: if one cell is slightly thicker (tolerance variation) on average, then the machine automatically increases the stacking height to maintain constant pressure not position.
4. Tab Welding Delicacy
Joining delicate pouch tabs to a busbar requires precision welding techniques. Our lines employ Vision-Guided Laser Welding Systems that accurately locate flexible tabs prior to firing the laser beam; additionally, lower power, higher frequency pulsed lasers help prevent burn through on these delicate connections.
Do Not Break Under Pressure
Automation of pouch cells is an art. If your current solution is compromising your yield, perhaps a smarter approach might be more appropriate.
Explore our innovative solution:the EV Pouch Battery Module PACK Line.
AUTHOR:
The Huiyao Laser Engineering Team : A collective of solution architects and process engineers at Huiyao Laser, 100% dedicated to solving the core bottlenecks in EV and ESS battery manufacturing.
© 2025 Huiyao Laser Technology Co., Ltd. All Rights Reserved. No part of this content (including text, data tables, or original diagrams) may be reproduced without written permission.
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