CELL-TO-PACK (CTP) ASSEMBLY LINE

Capacity: 500 MWh (Expandable to 1 GWh)

1. Project Description

This document defines the complete scope of supply for a Prismatic Cell-to-Pack (CTP) Battery Assembly Line, designed for an initial capacity of 500 MWh per annum, with seamless expansion capability up to 1 GWh per annum.

The line covers cell receiving, module manufacturing, pack assembly, end-of-line (EOL) testing, material handling, automation, and MES integration, suitable for EV and ESS applications.

2. Technical Overview

Battery Cell Type: Prismatic (LFP / NCM compatible)

Assembly Concept: Cell-to-Pack (CTP)

Automation Level: Highly automated with industrial robotics

Traceability: Full cell–module–pack traceability via MES

Design Philosophy: Modular, scalable, future expansion ready

3. Detailed Scope of Supply

3.1 Cell Incoming Inspection & Pre-processing Section

Cell scanning and barcode reading

Open Circuit Voltage (OCV) testing

Cell thickness measurement

Blue film (insulation film) presence & integrity detection

Polarity detection and matching

NG cell automatic discharge and replenishment

Cell flipping and orientation correction

Qualified cell buffering and conveyor systems

Industrial PC, HMI, PLC-based control system

3.2 Cell Gluing & Vision Inspection Section

Automated adhesive dispensing for prismatic cells

Four-axis robotic handling system

Glue strip placement and transfer mechanisms

Release paper peeling mechanism

CCD-based vision inspection for glue position & quality

Secondary positioning platforms

Integrated safety covers and machine frames

3.3 Module Stacking & Formation Section

Industrial stacking robot for prismatic cells

Robot base and protective fencing

High-precision stacking grippers

Automated cell alignment and stacking control

Industrial PC, HMI, and PLC control

3.4 Module Stacking Positioning Platform

Precision translation mechanisms

Multi-position clamping and positioning units

Module temporary holding and alignment fixtures

Auxiliary fixtures and supports

3.5 Module Clamping & Transfer System

Module clamping and pressurizing tables

End-plate loading and positioning platforms

Module forming mechanisms

High-precision pressure sensor system

Module transfer robot with dedicated gripper

Mobile module assembly stations

3.6 End Plate Processing & Identification

End-plate laser marking system

Module polarity detection and confirmation

Automated transfer and handling mechanism

Barcode scanning and data binding

3.7 Polarity Addressing & Height Measurement

Servo-driven positioning module

Vision inspection system for polarity alignment

Keyence-based height & distance measurement

NG discharge conveyor integration

3.8 Polarity Laser Cleaning Section

High-power laser cleaning of polarity areas

Dust extraction and filtration system

Vision inspection after cleaning

Servo-controlled positioning mechanism

3.9 Busbar Laser Welding Section

Tri-axis laser welding system

High-power fiber laser source (ring-shaped)

Galvo scanning system

Welding pressing mechanism

Vision system for positioning and inspection

Distance measurement & weld height control

Cooling and fume extraction systems

3.10 Slag Removal & Post-Weld Cleaning

Servo-controlled slag removal mechanism

Vacuum-based residue extraction

Automatic lifting and positioning unit

3.11 Weld Quality Inspection (CCD)

CCD-based solder joint and weld inspection

Vision-based defect identification

Automated NG discharge system

3.12 Module Electrical Testing

Module communication and continuity testing

Module DCIR testing

Dedicated test fixtures

Data collection and test result binding

3.13 Module Conveying & Logistics System

High-speed double-layer module conveyor system

Speed-doubling chain mechanism

Flow carriers and material pallets

KBK overhead crane system with fixtures

NG module handling trolleys

ESOP electronic display boards

3.14 PACK Assembly & Cabinet Integration

PACK assembly conveyor line

Cabinet installation workstations

Torque tools for mechanical fastening

Liquid-cooled plate leakage testing

Cantilever cranes for cabinet and cover installation

Pre-assembly workbenches

Barcode printing and scanning systems

3.15 PACK End-of-Line (EOL) Testing

PACK-level electrical & functional testing

Safety and performance verification

Final data binding and report generation

3.16 MES & Digitalization Scope

Production line MES system

Cell / Module / Pack traceability

ESOP management system

Dashboard & real-time production monitoring

Server, UPS, network switches and displays

4. Engineering & Services Scope

Mechanical design & engineering

Electrical design & schematics

Automation & PLC software development

MES configuration and integration

Factory assembly & internal debugging

System integration testing

Documentation and manuals

5. Delivery Scope Clarification

Included:

All machines and subsystems described above

Standard safety enclosures and protections

Standard software licenses for supplied systems

Excluded (Unless Otherwise Agreed):

On-site installation & commissioning at customer site

Export certifications (CE / UL / others)

Wooden packing, freight & insurance

Utilities supply (power, water, air) at site

Civil works and building modifications

6. Expansion Capability

The line is designed for future expansion up to 1 GWh by:

Addition of parallel stations

Duplication of bottleneck processes

Expansion of conveyor and MES architecture