A battery module assembly line is a fully or semi-automated manufacturing line designed to group and connect individual battery cells—typically prismatic, pouch, or cylindrical types—into a standardized module. The purpose of this process is to create a manageable and repeatable sub-unit that can be used in a wide range of battery systems. In the case of prismatic cells, their rigid aluminum or steel casing and high energy density make them especially suitable for module assembly. The line is structured to handle large quantities of cells with high precision and consistency, minimizing human error, ensuring electrical balance, and preparing the modules for subsequent integration into a battery pack.
Features of Battery Module Assembly Line
Battery module assembly lines are characterized by high levels of automation and precision. The lines usually include automated feeding systems for cell loading, followed by integrated testing units for voltage, internal resistance (IR), and capacity sorting. Cells are arranged in a specific configuration (series and/or parallel), then welded using high-precision technologies such as laser welding or ultrasonic welding. The line typically incorporates vision systems and sensors to detect polarity, position accuracy, and welding quality. Additional features include modular design for flexible adaptation to different module types, data traceability systems for process tracking, and inline electrical safety checks. These features contribute to consistent module quality, high production throughput, and reduced operational costs.
Workstations in Battery Pack Assembly Line
Cell Loading Station – Automatically loads and orients prismatic cells into the tray or fixture, ensuring accurate positioning for downstream processes.
OCV Testing Station – Measures the open-circuit voltage and internal resistance of each cell to ensure consistency and screen out defective cells before assembly.
Polarity Detection & Flipping Station – Automatically detects the positive and negative terminals of each cell and flips cells with reversed polarity to ensure correct orientation.
Cell Glue Applying Station – Applies thermal or structural adhesive on the sides of the cells to secure them within the module frame and enhance vibration resistance.
Terminal Pole Photograph Station – Captures high-resolution images of cell terminals to confirm correct alignment, cleanliness, and for traceability or AI-based quality inspection.
Insulation & Safety Inspection Station – Checks for the presence and correct placement of insulation materials; performs dielectric and grounding tests to ensure electrical safety compliance.
Module Terminal Pole Laser Cleaning Station – Uses high-precision laser to remove oxide layers or contaminants from cell terminals, improving conductivity and welding quality.
CCS/BUSBAR Installation Station – Automatically places and aligns current collecting systems (CCS) or busbars onto the cell terminals for efficient current distribution.
Laser Welding Station – Performs high-precision laser welding of busbars to cell terminals, ensuring strong electrical and mechanical connections.
Post-Welding Cleaning & EOL Testing Station – Removes welding residues and performs final inspection, including insulation resistance, voltage, and connectivity checks to validate the module meets end-of-line quality standards.
Applications of Battery Module Assembly Line
Electric Vehicles (EVs)
Hybrid Electric Vehicles (HEVs)
Residential and Commercial Energy Storage Systems (ESS)
Renewable Energy Integration (e.g., solar, wind)
Industrial UPS and backup systems
Rail and aviation auxiliary systems
What Is a Battery Pack Assembly Line?
A battery pack assembly line takes pre-assembled battery modules and integrates them with a Battery Management System (BMS), high-voltage wiring, a thermal management system (such as liquid cooling channels), structural reinforcement, safety components, and a protective enclosure to produce a fully functional battery pack. These packs are ready for deployment in vehicles, stationary energy systems, or industrial applications. Unlike module assembly lines, pack lines require multi-domain integration, including mechanical design, electrical architecture, software communication, and thermal engineering, making the process significantly more complex.
Features of Battery Pack Assembly Line
Battery pack lines are designed for advanced integration and quality assurance. Key features include modular fixture systems to accommodate various pack designs, automated systems for module installation and wiring, robotic screwdriving and adhesive dispensing for mechanical assembly, and smart torque monitoring to ensure reliability. The BMS installation process includes communication line routing, sensor connection, and software flashing. Cooling system assembly involves connecting heat exchangers, pumps, or coolant lines depending on the design. Lines also feature sophisticated End-of-Line (EOL) testing, including insulation resistance, leakage detection, communication checks, and charge/discharge simulation. High-voltage safety measures, grounding verification, and environmental sealing systems (IP65/IP67) are built into the line to ensure safety and durability.
Workstations in Battery Pack Assembly Line
Module Loading Station – Loads tested modules into the pack housing.
Structural Assembly Station – Installs brackets, insulation pads, and spacers.
Busbar & HV Wiring Station – Connects modules using copper/aluminum busbars and high-voltage cables.
BMS Installation Station – Mounts and wires the BMS, voltage sensors, and thermal sensors.
Cooling System Assembly – Installs thermal plates, liquid channels, or fans.
Pack Housing Assembly – Installs upper/lower housing covers, sealing foams, and gaskets.
EOL Testing Station – Full electrical function testing, communication verification, and leak detection.
Labeling and Traceability Station – Final marking, barcode association, and packaging.
Applications of Battery Pack Assembly Line
Battery Electric Vehicles (BEVs), Plug-in Hybrid EVs
Commercial Vehicles and Electric Buses
Solar + Storage Home Systems
Grid-scale Energy Storage Stations
Forklifts, AGVs, and Material Handling Equipment
Marine Propulsion Systems and Aviation Backup Units
While both assembly lines are essential to the battery manufacturing process, they serve distinct purposes and differ in complexity. A battery module assembly line focuses on assembling individual cells into consistent, high-performance modules, with an emphasis on electrical uniformity, welding quality, and basic structural integrity. In contrast, a battery pack assembly line integrates these modules into a complete system that includes power distribution, communication, cooling, and safety mechanisms. The pack line also involves compliance with vehicle-level or grid-level safety and functional requirements. Technically, module lines are cell-centric, optimizing balance and structure at the sub-unit level, while pack lines are system-centric, combining modules into a high-voltage, software-managed, field-ready energy system. The differences also extend to testing methods, product output, and integration complexity—module lines typically conduct voltage and resistance testing at the cell/module level, whereas pack lines include insulation, CAN communication, charge-discharge simulation, and thermal system verification.
Supplier of Battery Module PACK Assembly Line
Huiyao Laser Technology (Luoyang) Co., Ltd. is a high-tech enterprise focusing on the research and development, manufacturing and sales of equipment for the new energy industry. Huiyao Laser provides comprehensive high-performance laser systems designed for the automotive, electronics, medical equipment, aerospace and other industries and committed to providing customers with comprehensive laser welding equipment, battery cell assembly line equipment, module PACK automatic line equipment, battery structural parts automation equipment and other high-end intelligent equipment. It can tailor the most suitable production line solutions according to the different production needs of customer companies
