Questions You Should Know about Battery PACK Automation Line

Battery manufacturing is quickly becoming a cornerstone of the green energy market. According to a report by the International Energy Agency (IEA), battery manufacturing has more than tripled in the last three years, and batteries will need to lead a sixfold increase in global energy storage to meet targets identified by the COP28 United Nations Climate Change Conference. Grid battery energy storage systems (BESS) are also playing an integral role in improving grid resilience.

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As battery manufacturers strive to meet this growing demand, it’s crucial to choose the right automation partner. Those with access to an experienced partner will be better suited to optimize product designs for manufacturing, enhance production efficiency, and reduce time to market. Here, we outline key questions to ask a potential automation partner to ensure they can help you navigate battery production now and in the future.

Does the Automation Partner Understand Core Technologies in Grid Battery Manufacturing?

The automation partner should demonstrate a deep understanding of the key technologies involved in grid battery production, such as high-speed assembly. Manufacturers should also consider the partner’s know-how in specific areas like laser welding, safety standards, integrating advanced robotics and high level of flexibility and can adapt to unique manufacturing process. Manufacturers can bring their safety director or plant safety manager to tour the partner’s facility and assess their commitment to safety and regulatory compliance.

Red Flags to Watch For:

• Basic Responses: Answers that lack detailed explanations of how the partner handles specific technologies should raise concerns.
• Inadequate Safety Measures: If the partner’s facility lacks visible protocols, like personal protective equipment (PPE), or they cannot articulate their approach, it may signal an insufficient commitment to safety standards.

Good Answers to Look For:

• Detailed Case Studies: A good partner will share specific samples of previous projects that implemented high-speed assembly, laser welding, or other relevant tech for grid battery manufacturing.
• Technical Expertise: The partner needs to demonstrate they can integrate automation technologies into the manufacturer’s processes to optimize production and ensure product quality. This can be done through tools like digital twins, SolidWorks, or 3D views of demonstrated processes.
• Safety Considerations: Battery manufacturing involves unique safety requirements to protect employees and ensure compliance. The partner should have experience with battery safety protocols, including clear mitigation strategies to prevent electrical shock and manage thermal runaways.

Can the Automation Partner’s Services Reduce the Manufacturer’s Need to Invest In-House?

Manufacturers need to consider how the partner can support the organization, from collaborating with the project team to providing technical expertise the manufacturer may lack. A good partner will offer problem-solving workshops and Kaizen events to develop solutions alongside the manufacturer. This collaborative approach ensures the partner not only supports those internal needs, but also equips the manufacturer with the information and skills needed to sustain the improvements.

Red Flags to Watch For:

• No Specific Examples: If the partner cannot point to past projects where they directly collaborated with customers, they may lack experience in the industry.
• Lack of Comprehensive Offerings: If the potential partner often relies on other suppliers for specific technologies in automation projects, they likely don’t offer turnkey solutions.
• Inadequate Collaboration: If the partner does not emphasize teamwork, they may not approach automation projects with a partnership mindset.

Good Answers to Look For:

• Collaborative Approach: The partner should share how they work with customers, including using Kaizen events to identify and solve challenges early. This shows their commitment to empowering the manufacturer even after the project ends.
• Technical Expertise: The partner needs to demonstrate how they provide solutions for specific challenges, such as laser welding. A good partner will also mention any proof of principle (POP) processes or benchtop models used to validate the solutions.
• Proactive Methods: Engaging a partner with commitment to collaboration can help manufacturers save time and expenses in the long run—from identifying potential manufacturing issues early to comprehensive training.

Can the Partner Deliver Turnkey Automation Solutions?

Manufacturers must consider whether the partner is accustomed to delivering automation offerings — from design to implementation. Manufacturers should inquire about the partner’s experience in integrating various automation technologies, including line and control integration capabilities. By engaging a partner with a comprehensive approach to automation, the manufacturer can optimize production, drive product quality, and better uphold safety standards.

Red Flags to Watch For:

• Limited Services: If the partner only offers a narrow range of services, they likely cannot support the manufacturer’s growing needs effectively.
• Basic Answers: Partners that give vague responses and don’t share how they handle line and control integration is a major red flag.
• Insufficient Resources: If the partner hesitates to let the manufacturer interview their project management team, controls engineers, or technicians, it’s possible they don’t have the necessary resources to deliver turnkey automation.

Good Answers to Look For:

• Proven Integration Capabilities: The partner needs to show how they integrate automation technologies into one system. This demonstrates their ability to manage complex projects.
• Resource Availability: The partner should be able to mention the number of technicians and controls, design, and electrical engineers on staff, underscoring their capacity to handle large-scale projects. As well as the ability, to expand and contract resources quickly.

Can the Partner Scale with the Company as Demand Grows?

Manufacturers must consider whether the potential partner can handle automation for high-volume production and—eventually—deliver sufficient gigafactory equipment, and support parallel development of multiple locations. As demand grows, it’s critical for manufacturers to evaluate the partner’s ability to support global programs, manage extensive resources, and adapt to increasing production needs.

Red Flags to Watch For:

• Limited Space or Resources: If the partner has only one facility, a small team, and cannot currently expand operations, they may not be able to support major automation programs.
• Hesitant to Provide Information: If the partner doesn’t facilitate interviews with their project management team, engineers, or technicians, they might not be able to adequately deliver gigafactory equipment.
• Poor Partnerships: Smaller partners that lack established relationships with suppliers may not be able to scale effectively.

Good Answers to Look For:

• Demonstrated Scalability: An experienced partner can explain how they successfully scaled operations and personal in previous projects and show they can tackle increasing production needs.
• Capacity for Expansion: The potential partner would highlight their ability to expand operations, including their network of facilities and partnerships.
• Proven Track Record: A good partner will talk about how they’ve created, built, and delivered large-scale automation programs. This gives the manufacturer confidence the partner can support the company as it grows.

Can the Partner Overcome Challenges in Battery Manufacturing?

Manufacturers must consider whether the partner has solved common challenges associated with optimizing battery manufacturing and meeting critical timelines. This involves assessing the partner’s ability to handle complex manufacturing tasks and their understanding of the time it takes to optimize production.

Red Flags to Watch For:

• No Proactive Approach: If the partner does not leverage design for manufacturability (DFM) and can’t say how they’ve delivered automation systems on time, they may lack industry experience.
• Limited Understanding of Schedules: If the partner does not understand the time it takes to optimize critical processes, they won’t be well-equipped to support the manufacturer’s operations.

Good Answers to Look For:

• Demonstrated Expertise: A good partner will show they have successfully overcome specific battery manufacturing challenges. Examples include validating processes through rigorous testing methods and developing unique material handling situations.
• Ability to Meet Timelines: The partner should understand the time required to implement the solution. An automation company that prioritizes POP processes and DFM principles will help the manufacturer solve potential issues early —minimizing recalls, downtime, and costs.

Battery manufacturers looking to scale their operations as global demand grows need the right automation partner at their side. An ideal partner will not only bring a wealth of industry know-how — they’ll also work collaboratively, helping ensure your product designs are optimized for manufacturability. By leveraging the partner’s experience and global resources, manufacturers can enhance production efficiency, save critical time and expenses, and achieve market success.

The shift from module-based to cell-to-pack assembly in battery technology is revolutionizing the electric vehicle (EV) industry. The transition eliminates the need for intermediate modules, which means manufacturers can directly integrate individual cells into the battery pack. This approach can increase volume utilization by up to 50% and reduce the number of parts by 40%. It also saves manufacturers significant time and resources.

Despite this promising approach, there are several factors manufacturers must consider while navigating cell-to-pack assembly. Without the guardrail that modules provide, manufacturers need to carefully plan for a strong thermal management strategy, rigorous testing, and an increased focus on quality control.

Considerations for Cell-to-Pack Assembly

Because cell-to-pack assembly doesn’t require modules, this method significantly enhances energy density. By avoiding the modular structure, the design allows more cells to be packed into the same volume, increasing the overall capacity. With fewer structural components needed to hold the cells together, this approach also reduces the weight of the battery pack.

With fewer parts to assemble, the production line becomes more streamlined, reducing the time and cost associated with cell-to-module-to-pack assembly. This efficiency may be crucial for manufacturers to meet a growing demand in the battery production industry.

However, it can be challenging to maintain optimal temperature without modular barriers. The absence of modules means fewer guardrails for heat dissipation, which can lead to uneven temperature distribution within the pack. Product teams must implement effective thermal management strategies to ensure all cells operate within safe temperature ranges.

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Another critical consideration is ensuring the pack’s structural integrity without modules. The design must include robust structural elements that can withstand mechanical stresses to maintain the battery pack’s durability and avoid thermal runaway events.

Fewer interconnects in the cell-to-pack design can also reduce potential failure points. While this enhances the reliability and safety of the battery pack, there needs to be a robust design to ensure the electrical connections between cells are secure and able to handle operational stresses.

Challenges Associated with Module-Free Structures

Designing battery packs without modules introduces significant complexities to the process. The absence of modular structures requires innovative approaches to maintain performance and safety.

A cell-to-pack design can increase the risk of thermal runaways due to a closer proximity of cells. Without the separation modules provide, cells are more susceptible to overheating. A strong thermal management strategy can mitigate these risks and confirm the final battery pack is safe for consumers.

Quality control also becomes more challenging without the presence of modules. Ensuring consistent quality and performance across cells without modular separation requires rigorous testing and stringent inspection processes to ensure the pack’s overall reliability.

Maintenance and repair can also be difficult in a cell-to-pack design. It’s a more complex process to replace individual cells than modular designs, where operators can more easily swap faulty modules. Still, it’s not impossible to repair a cell-to-pack design battery — it just necessitates a more meticulous approach.

Finally, cell-to-pack designs normally require cell handling with a larger motion platform, as manufacturers now need to distribute cells over a larger area in a pack compared to a module. Particular attention needs to be paid to pack level transportation and accuracy to precisely position and bond individual cells over a much larger area.

Prismatic Cell Use Case

With their rectangular shape and robust aluminum casing, prismatic cells are well-suited for cell-to-pack assembly. Their design allows for efficient stacking and better space utilization, enhancing overall energy density while simplifying manufacturing.

In a cell-to-pack line, prismatic cells present unique material handling considerations, including wrapping and compression. These cells often require wrapping for additional protection, which adds a layer of complexity to the assembly process. Compression also manages the swelling of cells during operation, keeping them securely in place and maintaining overall structural integrity.

Cooling techniques and thermal interface materials (TIMs) are critical to manage the heat that prismatic cells generate. These materials help remove air gaps and improve thermal conductivity, which helps maintain the battery pack’s optimal temperature.

Battery Assembly for Cell-to-Pack Lines

Cell Preparation and Testing

In the cell-to-pack assembly process, cell preparation and testing are critical steps to make sure every cell meets the required standards before being integrated into a pack. Initial inspection and quality control measures can identify any cell defects or inconsistencies. This involves a thorough visual inspection to check for physical damage and automated testing solutions to verify each cell’s dimensions and overall conditions.

It’s crucial that teams test for capacity, voltage, and internal resistance. When each cell undergoes rigorous testing to measure its capacity, manufacturers can confidently validate that the pack can store the expected amount of energy. Voltage testing confirms that the cells operate within the specified voltage range, while internal resistance testing helps identify potential issues affecting performance and longevity. These tests, among others, prove that the cells can function reliably in the final battery pack.

Another important step is sorting and matching cells for uniform performance. Cells are sorted based on their test results to ensure that only those with similar performance characteristics are grouped together. This matching process helps maintain uniformity within the battery pack. By only including cells with similar capacities, voltages, and internal resistances, the manufacturing team can prevent imbalances that could lead to reduced efficiencies or premature failures.

Pack Assembly Process for Cell-to-Pack-Lines

The pack assembly process for cell-to-pack lines involves several critical steps to ensure the battery pack is reliable. The first step is arranging the cells in the desired configuration to maximize space and optimize performance.

Once the cells are positioned, they must be held in place. Teams typically do this with brackets, adhesives, or other mechanisms that prevent the cells from shifting during operation.

The final step in assembly is connecting the cells according to the design. By creating electrical connections between the cells to form a complete circuit, the pack can deliver the required power output.

Effective thermal management and insulation are crucial during pack assembly so cells can operate within safe temperature ranges. Cooling systems, such as liquid cooling or thermal interface materials, help dissipate heat away from the cells. Proper insulation also protects the cells from external temperature fluctuations and maintains a stable operating environment, enhancing the battery pack’s overall safety and longevity.

Quality Control and Testing of Assembled Packs

The final inspection involves thorough quality control and testing of the pack to identify any physical defects or inconsistencies. This includes checking the integrity of the connections, cell alignment, and the pack’s overall structural soundness. Automated systems can assist in this process to ensure precision and consistency during operations.

Additional testing measures that aid in quality control include:

• Performance testing, which involves checking the battery pack for capacity, cycle life, and thermal performance
• Capacity testing to ensure the pack can store and deliver the expected amount of energy
• Cycle life testing to evaluate how well the pack maintains its performance over charge and discharge cycles
• Thermal performance testing, which assesses the pack’s ability to safely manage heat during operation

Stringent testing to verify the pack meets performance, safety, and environmental standards is essential to comply with industry guidelines and requirements set by regulatory bodies.

Optimizing Battery Packs: The Shift to Cell-to-Pack Design

Innovations in battery technology are driving significant advancements in battery assembly. Advancements in materials science are also driving the creation of more efficient and durable battery components. Meanwhile, innovations such as silicon anodes and advanced electrolytes are enhancing the performance and longevity of batteries, making them suitable for a wider range of applications.

Continuous improvement and quality assurance are paramount in the battery manufacturing industry, especially with cell-to-pack designs. Production teams must focus on refining processes and implementing rigorous quality control measures to ensure every battery pack meets the highest performance and safety standards. Regular testing, monitoring, and analysis of designs and processes can help teams identify any adjustments needed and maintain consistency in production. By prioritizing continuous improvement, manufacturers can stay ahead of industry trends.

Choosing an experienced automation partner for battery assembly and testing offers several advantages. Our automation and precision engineering expertise ensures battery packs are assembled with the highest accuracy and efficiency. A partner that offers an integrated approach to testing and assembly also helps guarantee that each battery pack undergoes thorough inspection and performance evaluations before it hits the market. By ensuring compliance with industry standards and regulations, battery manufacturers can produce their designs with confidence and deliver a high-quality battery that consumers trust.

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