How to Choose Battery Module Assembly Line?

At Re:Build Battery Solutions, we provide turnkey solutions for designing, building, and scaling battery manufacturing facilities. From prototype development to full-scale pack production, our expertise spans the entire battery manufacturing lifecycle. We engineer and integrate cutting-edge automation, real-time process monitoring, and modular production systems, helping battery manufacturers increase efficiency, reduce costs, and improve product quality.

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Whether you are modifying an existing facility, scaling production, or building a new battery manufacturing plant, we deliver fully customized and ready-to-deploy solutions that enhance operational throughput and factory performance.

Re:Build Battery Solutions provides turnkey battery manufacturing solutions, covering facility design, equipment customization, and process optimization to help manufacturers achieve maximum efficiency and scalability. Our end-to-end capabilities span the entire battery manufacturing process, from electrode preparation and cell assembly to module and full pack production. We integrate advanced automation, real-time monitoring, and lean manufacturing principles to engineer high-performance battery assembly lines tailored to customer needs.

Re:Build Battery Solutions has a proven track record in designing, building, and scaling battery manufacturing facilities. Our team of industry-leading engineers, automation specialists, and process optimization experts brings decades of experience in factory design, production automation, and quality control. From cell manufacturing to module and pack assembly, we provide end-to-end solutions that enhance production efficiency, reduce costs, and ensure world-class quality standards. Whether you’re expanding an existing facility or developing a new battery manufacturing plant, we deliver expert-driven solutions tailored to your operational needs.

Our battery assembly line solutions are designed for flexibility and scalability, allowing manufacturers to adapt to evolving production demands. We offer modular, pre-engineered factory systems that enable rapid deployment, as well as customized production lines built for complex, high-volume manufacturing. By integrating advanced automation, robotics, and real-time process monitoring, we help battery manufacturers optimize throughput, reduce waste, and improve overall factory efficiency—ensuring that their production lines are future-ready and built for growth.

At present, most battery pack assembly lines adopt semi-automatic and fully-automated production line. Considering the cost and construction site, SHINHOP assembly line is designed and manufactured based on the principle of practicality, simplicity and efficiency. The production line process requirements are as follows:

1-The cell loading adopts robot automatic loading or manual loading. Incoming materials can be manually delivered to the designated location, and this station is used as a reserved station.

2-The accuracy of battery cell scanning and identification must reach 100%.

3-Regarding the size (height, length, width, and height of the cell pole) and weight of the incoming battery cells, the battery cell thickness measurement tool must be equipped with a pressure sensor, the pressure is ≦N, and the thickness needs to be clearly displayed on the equipment. The thickness interval parameters are adjustable.

4-The voltage and internal resistance are tested and selected according to specified standards. The battery cell voltage detection accuracy requires 0.1mV, and the resistance detection accuracy requires 0.xn--001m-jpd. When the battery cell OCV is detected, the battery cell code is automatically paired with the battery cell voltage and internal resistance. The voltage and internal resistance interval parameters are adjustable, and there is a corresponding operation interface on the touch screen. (The expected voltage range is 3-5V, the accuracy requirement is 0.001V, the internal resistance is expected to be in the range 0.1-0.xn--5m-fcc, and the accuracy requirement is 0.001 mΩ). The equipment is automatically classified and removed the unqualified product to the NG area and retrieved manually.

5-The battery cells in the module are connected in series, and the module code is laser printed on the end plate. The module code is printed on the end plate. The coding range of the coding machine is ≥ 300mm*300mm. The coding accuracy rate must reach 100%, and the coding position deviation should be controlled within ±1mm.

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6-The module consists of end plates on both sides, battery cells and two steel strips.

7-The maximum stacking number of modules is 16 cells. After stacking, the height difference of the poles is less than 0.05mm. The accuracy requirements of the robot are: movement accuracy ±1mm and static accuracy 0.5mm.

8-When the steel strip is placed on the module, the pressure on both sides is ≦N. The pressure on each cell is between 300-500N. The overall length of the module is ≦mm. The module size equipment can be accurately controlled, and the overall length error of the module is ±0.5mm.

9-After the module is formed, conduct insulation testing on the individual cells. Testing equipment for insulation testing needs to be purchased from high-quality well-known brands. The testing tooling must be well-insulated and well-designed to be compatible with multiple products.

10-The qualified module battery poles terminal are laser cleaned, and after completion, the module flows into the bus bar welding station. The gap between the bus bar and the poles is less than 0.2mm.

11-Bus bar welding requirements: the pulling force is greater than N, and the welding station needs to realize automatic laser welding and automatic dust collection.

12-After the bus welding is completed, the module flows into the post-welding inspection station.

13-Insulation withstand voltage test on the module. The insulation test requires (conductive part to insulating layer) 500VDC level, insulation value ≧1GΩ, the withstand voltage test requirement (conductive part to insulating layer) VDC level, withstand voltage value ≦100μA.

14-Conduct bus bar welding inspection on the module, use DCIR current detection, fast charge and discharge of the module, and voltage internal resistance test. It is necessary to add safety protection and equipment emergency safety accident handling plans (equipment self-protection).

15-The PACK line is basically a manual work station, including: cabinet on-line, cabinet pre-processing; module loading into the cabinet; module fixing; BMS installation; wire harness installation, module connection; top cover; chassis Insulation withstand voltage testing, PACK offline testing; chassis offline.

16-The module fixing station is a manual station. The module fixing screws are manually tightened with a tightening gun, and the torque is uploaded to the MES system.

If you are looking for more details, kindly visit Battery Module Assembly Line.