ESS Prismatic Battery Pack Assembly Solution

Complete Turnkey Solution for Energy Storage Battery Pack Manufacturing

As global demand for renewable energy storage continues to grow, manufacturers require efficient, reliable, and scalable production solutions for prismatic battery packs.

Due to their structural advantages, prismatic battery packs are widely used in diverse fields such as consumer electronics, electric vehicles, renewable energy storage, and portable devices.

ACEY provides complete turnkey solutions for Energy Storage System (ESS) battery pack manufacturing, covering everything from battery cell testing to final pack inspection.

Cell capacity grading → Cell Voltage & IR sorting → Module stacking & pressing → Terminal laser cleaning → Module laser welding → BMS testing → Battery pack comprehensive testing → Battery pack aging testing

Our solutions are suitable for:

• Residential ESS
• Commercial & Industrial ESS (C&I)
• Container Energy Storage
• Solar Battery Storage
• Telecom Backup Power
• UPS Systems
• Microgrid Energy Storage
• Utility-scale Energy Storage Projects

Whether you are building a pilot production line or a fully automated smart factory, ACEY can customize the production process according to your battery specifications, factory layout, production capacity, and automation requirements. Our ESS battery pack assembly solutions support mainstream prismatic cells from 100Ah to over 314Ah.

ACEY provides flexible automation levels to match different investment budgets and production capacities.

Semi-Automatic Solution

Advantages:

Lower investment

Flexible production

Easy operation

Faster deployment

Fully Automatic Solution

Advantages:

· Automatic barcode scanning

· Robot handling

· Automatic laser welding

· MES integration

· Production data traceability

· High production efficiency

1. Prismatic cell grading machine

Product Description

Prismatic cell capacity grading machine evaluates and sorts cells based on voltage, capacity, and other key parameters through cyclic charge-discharge testing. This process ensures consistency and reliability in subsequent battery pack assembly.

Product Features

• Multi-channel Operation: Simultaneous testing and grading of multiple cells significantly boosts production throughput.
• Safe & Reliable: Independent channel control protects against overcharge, over-discharge, and short circuits, safeguarding cell integrity.
• Data Traceability: Real-time parameter logging for every cell enables full traceability throughout the production chain.
• Energy-efficient: Integrated energy recovery functionality minimizes power consumption and maximizes overall system efficiency.

2. Battery Sorting Machine

Product Description

Battery Sorting Machine automatically tests and categorizes prismatic lithium-ion cells according to voltage and internal resistance. By grouping cells with matching electrical characteristics, it ensures uniformity and dependable performance during battery pack assembly.

Product Features

• Designed for Prismatic Cells – Compatible with prismatic aluminum-case batteries in a wide range of sizes.
• Flexible Multi-Channel Sorting – Available with 3, 7, or 9 sorting channels, with custom configurations to suit different production capacities.
• High-Precision PLC Control – PLC-based control system with linear modules ensures stable, accurate, and reliable operation.
• Automatic Testing & Sorting – Supports automatic battery testing, barcode/QR code identification, and intelligent cell sorting with minimal manual intervention.
• MES Integration – Connects seamlessly with MES systems for QR code traceability, production data management, and real-time SPC analysis.
• High Throughput – Sorting speed up to 1,000 cells/hour, significantly increasing productivity compared with manual operation.
• Scalable & Easy to Integrate – Optional internal resistance testing and flexible system configuration make it suitable for different battery production lines.

3. Battery Module Stacking and Pressing Machine

Product Description

The Battery Stacking & Pressing Machine is designed for stacking, pressing, and strapping prismatic lithium-ion cells. Driven by a servo motor, ball screw module, and planetary reducer, it delivers a stable pressing force exceeding 500 kg with precise stroke and pressure control. The system offers easy model changeover to accommodate various cell sizes, and incorporates triple-layer protection-software limits, hardware limits, and pressure monitoring-to prevent over-compression, ensuring both operational safety and consistent stacking accuracy.

Product Features

• High-Precision Servo Compression for stable and uniform battery module pressing.
• Up to 500kg Compression Force with accurate pressure control for consistent module quality.
• Compatible with Various Prismatic Battery Sizes for flexible EV and ESS production.
• PLC Touchscreen Control with easy parameter setting and user-friendly operation.
• Triple Safety Protection featuring software, hardware, and pressure limit safeguards for reliable operation.

4. Laser Cleaning Machine

Product Description

The Laser Cleaning Machine is deployed in prismatic lithium-ion battery pack assembly to clean terminals, busbars, connectors, battery modules, housing surfaces, and BMS contact points. By effectively removing oxides, dust, and debris, it ensures robust electrical connections and optimal thermal management.

Product Features

• Non-Contact Cleaning Process: Cleans surfaces without physical contact, eliminating the risk of mechanical damage to battery components.
• High Cleaning Precision: Selectively removes oxides and contaminants while preserving the integrity of the aluminum surface.
• Improved Welding Quality: Delivers clean, uniform welding surfaces that enhance weld strength and consistency.
• No Chemical Consumables: Operates without chemicals or abrasives, offering an environmentally friendly solution with low maintenance requirements.

5. Laser Welding Machine

Product Description

The Laser Welding Machine for lithium-ion batteries is primarily employed in the assembly process of prismatic and pouch cell battery packs. It welds busbars to individual cells and interconnects them in series and parallel configurations to form a complete battery pack, enabling efficient power distribution and internal electrical connectivity.

Product Features

• High-Power 1500W-6000W Fiber Laser Source for fast, stable, and high-quality welding performance.
• High-Precision Welding with a concentrated laser beam, producing narrow weld seams, minimal heat-affected zones, and low workpiece deformation.
• Suitable for Prismatic Battery Packs, ideal for EV, ESS, and lithium battery module assembly applications.
• Maintenance-Free Fiber Laser Design offering high stability, long service life, and low operating costs without optical path adjustments.
• Easy Integration into Automated Production Lines with stable operation and support for high-efficiency, continuous battery pack manufacturing.

6. BMS Tester Machine

Product Description

The BMS Tester employs capacitance to simulate battery charge and discharge, performing a comprehensive suite of protection board tests-including overcharge protection, overcharge recovery, overdischarge protection, overdischarge recovery, standby power consumption, and overcurrent testing.

Product Features

• Supports various BMS types and specifications used in different lithium battery pack applications.
• The number of series is optional from 1-52
• Various protection and recovery function tests
• Can choose the number of sections to be tested according to your own needs
• Test results can be automatically saved

7. Battery Comprehensive Tester

Product Description

The Battery Comprehensive Tester is designed for overall performance evaluation of lithium-ion battery packs. Key test parameters include open-circuit voltage, AC internal resistance, continuous charge/discharge current and voltage, charge/discharge overcurrent protection, short-circuit protection response time, overcurrent delay, and post-test voltage verification.

Product Features

• Multi-parameter integrated testing function

It can simultaneously measure open circuit voltage (OCV), internal resistance (AC/DC IR), charge/discharge performance, and protection functions, providing a one-stop comprehensive battery test solution.

• Compatible with multiple battery types

Suitable for lithium batteries, lead-acid batteries, Ni-MH, and Ni-Cd batteries, offering strong compatibility across different battery systems.

• Full protection function testing capability

Supports testing of overcharge, over-discharge, overcurrent, and short-circuit protection to effectively identify defective batteries.

• High-precision electrical performance measurement

Provides high-accuracy voltage and internal resistance measurement with mV-level and milliohm-level resolution, ensuring stable and reliable test results.

• Supports automation and MES integration

Can be integrated with barcode scanning or automatic identification to start testing, and supports data recording, Excel export, and MES system connectivity.

• Suitable for fast production line screening

Enables rapid pass/fail judgment of batteries, improving production efficiency and reducing defective products in downstream processes.

8. Battery Aging Machine

Product Description

The Battery Aging Machine is used for aging and performance testing of finished battery packs. It supports a wide range of battery chemistries, including ternary lithium, lithium iron phosphate, lead-acid, and nickel-metal hydride / nickel-cadmium batteries. The system is primarily applied to cycle life testing, capacity evaluation, charge/discharge performance assessment, and temperature characteristic analysis of battery packs.

Product Features

• Supports battery pack charge–discharge aging cycle testing

It performs full aging processes including charging, discharging, resting, and cycling to evaluate battery capacity retention and performance degradation over time.

• Compatible with multiple battery chemistries and applications

Suitable for lithium-ion, LiFePO₄, NMC, lead-acid, Ni-MH, and Ni-Cd batteries, widely used in energy storage systems, EVs, and power tools.

• Multi-channel independent testing design

Each channel operates independently or in grouped modes, enabling simultaneous testing of multiple battery packs to significantly improve production efficiency.

• High-precision charge and discharge control

Supports constant current (CC) and constant voltage (CV) charging, as well as constant current discharging, with accurate voltage and current control and stable data acquisition.

• Comprehensive safety protection system

Equipped with over-voltage, under-voltage, over-current, short-circuit, over-temperature, and reverse polarity protection, along with power-off data retention and recovery functions.

• Intelligent data management and remote monitoring

Provides real-time data recording, curve analysis, and Excel export, and supports MES system integration for smart manufacturing and digital production management.