Cylindrical Lithium Battery Pack Assembly Solution
Complete Production Solutions for Cylindrical Lithium Battery Packs
Cylindrical lithium-ion battery cells are widely used in power tools, electric bicycles, electric motorcycles, scooters, drones, portable power systems and other battery-powered applications.
ACEY provides customized cylindrical lithium battery pack assembly solutions for different cell sizes, pack configurations and production requirements. The solution integrates cell capacity grading, insulation protection, cell sorting, polarity inspection, spot welding, BMS testing, electrical performance testing, heat shrink wrapping, coding and battery pack aging.
The equipment can be configured as a semi-automatic or automatic battery pack assembly line according to production capacity, battery pack structure, factory layout and automation requirements.
For cylindrical cells such as 18650, 21700, 26650, 32650 ,32700, 32140, 33140, etc. ACEY can provide a complete equipment configuration from cell testing to finished battery pack inspection.
Advantages
Modular & Flexible Design
The production line consists of standalone machines, allowing customizable configurations to meet diverse process requirements.
01
Lower Initial Investment
Compared to fully automated lines, the semi-automatic solution requires lower capital expenditure, ideal for small-to-medium batch production.
02
Easy Operation & Maintenance
Simple machine structure enables quick troubleshooting, low maintenance costs, and short operator training cycles.
03
High Adaptability
Compatible with various cylindrical cells , enabling quick model changeover, ideal for multi-model and low-volume orders.
04
Scalable & Upgradable
Supports phased capacity expansion and future upgrades to full automation, reducing initial investment risks.
05
Cylindrical Battery Pack Assembly Process
|
Process |
Recommended Equipment |
|
Cell Capacity Grading |
Cell Grading Machine |
|
Insulation Protection |
Insulation Paper Sticking Machine |
|
Voltage & IR Sorting |
Battery Sorting Machine |
|
Polarity Inspection |
CCD Tester |
|
Cell Welding |
Battery Pack Spot Welding Machine |
|
BMS Testing |
BMS Tester |
|
Pack Testing |
Battery Comprehensive Tester |
|
Heat Shrink Wrapping |
Heat Shrink Wrapping Machine |
|
Product Coding |
Inkjet Batch Coding Machine |
|
Aging Testing |
Battery Pack Tester |
Battery Cell Capacity Grading
The first step is to evaluate the electrical performance of individual cylindrical battery cells.
The battery cell grading machine performs controlled charge and discharge tests to measure parameters such as capacity and voltage. Based on the test results, cells with similar electrical characteristics can be classified for subsequent battery pack assembly. This process helps improve cell consistency and provides a reliable foundation for battery pack assembly.
Recommended Equipment
Suitable for different channel configurations according to production requirements.
Insulation Paper Pasting
After cell grading, insulation material is applied to the required area of the cylindrical battery cell.
The insulation paper sticking machine can apply barley paper or other insulating materials to the positive or negative electrode area of cylindrical cells. This additional insulation helps reduce the risk of electrical contact during subsequent assembly and welding processes.
Recommended Equipment
Battery insulation paper sticking machine
The Battery Insulation Paper Pasting Machine can be configured for different cylindrical cell sizes and production requirements.
Cell Voltage & IR Sorting
After insulation protection, the cells are sorted according to their electrical characteristics.
The battery sorting machine measures parameters such as open-circuit voltage and internal resistance and groups cells according to preset ranges. Proper cell matching helps improve consistency within the finished battery pack.
Recommended Equipment
The sorting configuration can be customized according to cell type, sorting criteria and production capacity.
CCD Polarity Inspection
Before the cells enter the welding process, the CCD inspection system checks the orientation and polarity of the cells.
The vision inspection process helps identify incorrectly positioned cells and reduces the risk of polarity errors during battery pack assembly. This is especially important for cylindrical battery packs where multiple cells are connected in series and parallel configurations.
Recommended Equipment
The CCD system can be integrated with the spot welding process for improved production consistency.
Cylindrical Battery Pack Spot Welding
Qualified cells are arranged according to the battery pack design and electrically connected using nickel strips. The spot welding machine creates reliable connections between the cylindrical cells and nickel strips while controlling welding parameters according to the battery configuration.
ACEY provides different welding solutions, including manual, semi-automatic and automatic spot welding equipment.
Recommended Equipment
Optional configurations include:
- Manual gantry spot welding machine
- Electric spot welding machine
- Pneumatic spot welding machine
- Automatic single-sided spot welder
- Automatic double-sided spot welder
- Customized welding systems
For 18650, 21700, 26650, 32650 and 32700 packs, the welding system can be selected according to cell structure, nickel strip design and production capacity.
BMS Testing
After cell welding and battery pack assembly, the Battery Management System needs to be tested to verify its protection and control functions.
The BMS tester can test battery management functions such as overcharge protection, over-discharge protection and other electrical protection parameters according to the BMS configuration.
Recommended Equipment
BMS Tester Machine
ACEY can provide different BMS testing configurations according to:
- Number of battery series
- Charge/Discharge current
Battery Pack Comprehensive Testing
The assembled battery pack is then subjected to comprehensive electrical testing.
The battery comprehensive tester can evaluate important electrical parameters of the finished pack, helping manufacturers identify abnormal voltage, current or other performance issues before final packaging.
Recommended Equipment
The testing configuration can be selected according to the voltage, charge current and discharge current of the battery pack.
Heat Shrink Wrapping
After comprehensive testing, the battery pack can be covered with PVC heat shrink film.
The heat shrink process provides an insulating outer layer while improving the appearance and structural protection of the finished battery pack.
Recommended Equipment
Automatic Heat Shrink Wrapping Machine
The heat tunnel shrink wrap machine can be configured according to battery pack dimensions and production requirements.
Inkjet Batch Coding
Product information can be printed on the battery pack using an inkjet coding machine.
Depending on the customer's requirements, the coding system can be used to mark information such as:
- Product model
- Production date
- Batch number
- Voltage
- Capacity
- Manufacturer information
This process helps improve product identification and production traceability.
Recommended Equipment
Battery Pack Aging Testing
The final stage is battery pack aging and charge-discharge testing. The battery aging machine performs programmed charging, discharging, resting and cycling processes to evaluate the performance and stability of finished battery packs.
Testing parameters can be configured according to the battery pack voltage, capacity and application requirements.
Recommended Equipment
This equipment is particularly useful for evaluating finished battery pack performance before shipment.
Build Your Cylindrical Battery Pack Production Line
Looking for a complete cylindrical lithium battery pack assembly solution?
ACEY can help configure the right equipment combination according to your:
- Battery cell type
- Cell size
- Battery pack configuration
- Voltage and capacity
- Daily production target
- Automation requirements
- Factory layout
Contact ACEY to discuss your cylindrical battery pack production project and receive a customized equipment proposal.
FAQ
Q: 1.What is a cylindrical battery pack assembly line?
A: A cylindrical battery pack assembly line is a production system used to assemble cylindrical lithium-ion cells into finished battery packs. The equipment includes Cell Grading Machine, Insulation Paper Sticking Machine, Battery Voltage&IR Sorting Machine, CCD tester, Manual/Automatic Spot Welding Machine, BMS Tester, Battery Comprehensive Tester and Battery Aging Machine, etc.
Q: 2.What cylindrical battery cells can be used?
A: The solution can be configured for cylindrical cells such as 18650, 21700, 26650, 32650 and 32700. Other cell sizes can also be considered according to the equipment requirements.
Q: 3.Can the cylindrical battery pack assembly line be customized?
A: Yes. The equipment configuration can be customized according to cell type, pack structure, production capacity, automation level and factory layout.
Q: 4.Can you provide a semi-automatic battery pack assembly line?
A: Yes. ACEY can provide modular semi-automatic/automatic solutions using individual machines for grading, sorting, welding, testing, heat shrinking and aging.