Scope Definition (What “Full Automatic” Really Means)

A fully automatic prismatic LFP line typically includes:

Cell processing (post-formation)

Module assembly

Pack / BESS pack assembly

Inline testing + traceability (MES)

Manual work is limited to:

Material loading (cells, busbars)

Quality sampling

Maintenance

PROCESS FLOW – END TO END

A. Cell Incoming & Preparation

(Cells are already formed & aged)

Cell OCV / IR Testing

Barcode / QR code scanning

Automatic cell sorting & grading

Cell insulation film wrapping

Cell cleaning & polarity inspection

Automation level: 95–100%

B. Prismatic Module Assembly (FULL AUTO)

Automatic cell stacking / alignment

End plate loading

Compression (servo / hydraulic press)

Busbar positioning (Cu / Al)

Laser welding or ultrasonic welding

Weld seam inspection (vision + resistance check)

Module BMS (slave) installation

Module EOL testing

Key tech used:

Fiber laser welding

Vision alignment ±0.1 mm

Torque-controlled compression

C. Pack Assembly (EV / BESS)

Pack shell loading

Automatic module insertion

Module interconnection (busbars / cables)

Main BMS installation

Contactor, fuse, HV connector mounting

Liquid / air cooling assembly (if applicable)

Insulation resistance (IR) test

Hi-Pot & continuity test

Pack sealing (glue / gasket)

Final EOL test & data upload

KEY MACHINES LIST (ITEM-WISE)

Cell Handling

Cell sorting & grading machine

Automatic wrapping / insulation machine

Cell stacking robot

Welding

Laser welding system (2–6 kW IPG / Raycus)

Ultrasonic welding (optional for Al tabs)

Assembly

Automatic module press machine

Robotic busbar assembly

Automated screw fastening (torque monitored)

Testing

OCV / IR tester

Hi-pot tester

Pack EOL tester

Leak test (for liquid cooling packs)

Software

MES system

Traceability (cell → module → pack)

TYPICAL CAPACITY RANGES

Example:

280Ah LFP prismatic cell

1P16S / 1P20S module

EV pack: 50–100 kWh

BESS pack: 100–320 kWh

COMPATIBLE CELL FORMATS

100Ah / 150Ah / 173Ah

280Ah / 306Ah / 314Ah (most common for BESS)

Short blade & long blade prismatic formats

UTILITIES & FOOTPRINT (Typical 5 GWh Line)

Area: 5,000 – 8,000 m²

Power: 800 kW – 1.5 MW

Cleanliness: Class 100k–300k

Operators: 25–40 per shift

OEE: 90%+

APPLICATIONS

✅ EV (2W / 3W / LCV / Bus)

✅ BESS (C&I, Utility, Containerized 5MWh)

✅ Telecom & UPS

✅ ESS container OEMs