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Cell-to-Pack Battery Energy Storage System (BESS) AGV Line
Cell-to -Pack Battery Energy Storage System (BESS) AGV Line by Semco Infratech, featuring automated battery pack assembly, robotic laser welding
Technical Excellence
Cell-to-Pack BESS AGV Line
The Cell-to-Pack BESS AGV Line Process Flow developed by Semco Infratech is designed to deliver efficient and automated production for modern Battery Energy Storage System (BESS) applications. The process begins with cell processing, where battery cells undergo automatic feeding, OCV and internal resistance testing, thickness measurement, sorting, polarity adjustment, and adhesive application to ensure only qualified cells move forward. In the module stacking stage, cells are arranged using automated equipment and secured with steel strip installation for structural stability. Next, during module assembly, stacked modules are transferred through a buffer system, inserted into the pack box, and fixed securely for further integration. The pack box preparation stage includes liquid cooling plate installation, air-tightness testing, and glue application with inspection to ensure proper thermal management and sealing. After that, pack processing integrates safety and electrical systems through insulation testing, engraving and scanning for traceability, terminal cleaning, pole-based addressing, and CCS placement. The line then performs robotic laser welding, providing precise electrical connections followed by post-welding cleaning and inspection. Finally, in the final assembly and testing stage, the system installs the front panel and copper busbars, conducts end-of-line testing, secures the box lid, integrates fire protection and BMS, and performs a pack air-tightness test before the battery pack exits the line ready for energy storage deployment.
Key Fixture Features
- High-Speed Production: Capable of producing up to 16 battery packs per minute for large-scale energy storage manufacturing.
- AGV-Based Automation: Integrated Automated Guided Vehicle (AGV) system ensures smooth and efficient material handling across the entire production line.
- Precision Laser Welding: Advanced robotic laser welding technology provides strong, reliable, and high-precision battery connections.
- Integrated Quality Testing: Multiple testing stages including OCV, IR, insulation, and air-tightness testing ensure consistent battery pack quality.
- Full Process Traceability: Engraving and scanning systems enable complete tracking and data monitoring throughout the assembly process.
- Cell Processing
- Stacking
- Module Assembly
- Pack Box Preparation
- Pack Processing
- Laser Welding
- Final Assembly and Testing
Cell Processing
- Automatic Cell Feeding & AGV Feeding
- OCV / Internal Resistance Test
- Cell Thickness Measurement
- Cell Sorting
- Polarity Adjustment
- Cell Adhesive Application
Stacking
- Automatic Cell Feeding & AGV Feeding
- OCV / Internal Resistance Test
Module Assembly
- Module Buffer Handling
- Module Insertion into Box
- Module Fixation
Pack Box Preparation
- Liquid Cooling Plate Installation
- Liquid Cooling Plate Air-Tightness Testing
- Box Assembly Glue Application & Inspectionn
Pack Processing
- Insulation Testing
- Engraving & Scanning for Traceability
- Terminal Cleaning
- Pole-Based Addressing
- CCS Placement
Laser Welding
- Robotic Laser Welding
- Post-Welding Cleaning & Inspection
Final Assembly and Testing
- Front Panel Installation
- Copper Busbar Installation
- End-of-Line Testing
- Box Lid Securing
- Fire Protection and BMS Installation
- Pack Air-Tightness Testing
- Pack Off-Line Output
Pack EOL Test
Final inspection of battery pack functionality and safety. Certifies the pack for deployment and shipment.
Request a Quote
- Patparganj Industrial Area, New Delhi
- sales@semcoindia.com
- +91-9289038327
Overview
The rapid growth of renewable energy and grid storage systems has increased the demand for high-performance battery manufacturing technologies. To meet this demand, Semco Infratech has developed the 16PPM Cell-to-Pack BESS Assembly Line, a fully automated AGV-based solution designed for efficient and scalable battery pack production.
This advanced assembly line supports the manufacturing of Battery Energy Storage System (BESS) packs, integrating intelligent automation, robotic laser welding, and multiple quality inspection stages.
The system enables manufacturers to achieve high production speed, consistent quality, and improved operational efficiency in energy storage battery production.
Suitable for industries such as:
EV battery production, energy storage manufacturing, battery research labs, electronics assembly, and OEM-based fabrication units.
Product Specifications
Discover Semco Infratech’s 16PPM Cell-to-Pack BESS Assembly Line with AGV automation, robotic laser welding, and advanced testing for efficient battery energy storage system manufacturing.
Cell-to-Pack Battery Energy Storage System (BESS) AGV Line
Cell-to-Pack BESS AGV Line Process Flow
1. Cell Processing
The first stage focuses on preparing battery cells for module assembly while ensuring quality control and accurate sorting.
Key processes include:
Automatic Cell Feeding & AGV Feeding
OCV / Internal Resistance Testing
Cell Thickness Measurement
Cell Sorting
Polarity Adjustment
Cell Adhesive Application
These steps ensure only qualified cells move forward into module stacking, improving pack consistency and performance.
2. Module Stacking
In this stage, prepared cells are arranged and structured into battery modules.
Processes involved:
Module Pre-Stacking
Steel Strip Installation
The stacking process ensures mechanical stability and proper electrical connectivity between cells.
3. Module Assembly
After stacking, modules are transferred into the pack enclosure for further integration.
Assembly steps include:
Module Buffer Handling
Module Placement into Box
Module Fixation
This stage prepares the modules for integration with cooling systems and pack electronics.
4. Pack Box Preparation
Before module integration, the battery pack housing undergoes preparation and inspection.
Preparation processes:
Liquid Cooling Plate Installation
Liquid Cooling Plate Air-Tightness Testing
Box Assembly Glue Application & Inspection
These steps ensure proper thermal management and sealing performance, which are essential for energy storage battery packs.
5. Pack Processing
This stage integrates electrical connections, identification systems, and safety features.
Key operations include:
Insulation Testing
Engraving & Scanning (Traceability)
Terminal Cleaning
Pole-Based Addressing
CCS Placement (Cell Connection System)
These processes ensure electrical safety and complete traceability of each pack.
6. Laser Welding
Automated welding technology ensures high-precision electrical connections within the battery pack.
Processes include:
Robotic Laser Welding
Post-Welding Cleaning & Inspection
Laser welding provides strong electrical conductivity, durability, and minimal thermal impact on battery cells.
7. Final Assembly
The final stage completes the battery pack assembly and performs comprehensive testing.
Final assembly operations include:
Front Panel Installation
Copper Busbar Installation
End-of-Line (EOL) Testing
Box Lid Securing
Fire Protection & BMS Installation
Pack Air-Tightness Testing
Pack Off-Line Discharge
Once all inspections and tests are completed, the BESS pack is ready for deployment in energy storage applications.
Applications
- Lithium-ion battery assembly and production units
- EV battery manufacturing facilities
- QC and testing labs
- R&D facilities
- OEM and contract manufacturing plants
Support & Warranty
The product comes with a dedicated support and service package that includes activation, calibration assistance, and post-installation guidance.
- Standard warranty period
- Spare part availability details
- On-site / online installation support
- AMC (Annual Maintenance Contract) option
- Technical support contact email
Faq
Frequently Asked Questions
Find quick answers to common questions about our BESS Assembly Line, including automation capabilities, supported battery types, customization options, safety standards, and production scalability.
What is a Cell-to-Pack BESS AGV Line?
A Cell-to-Pack BESS AGV Line is an automated battery manufacturing system that directly integrates battery cells into battery packs using AGV-based material handling, robotic welding, and advanced testing technologies to improve efficiency and production speed.
What are the advantages of a Cell-to-Pack BESS assembly line?
A Cell-to-Pack BESS assembly line offers several advantages including higher energy density, reduced production complexity, improved manufacturing efficiency, and lower battery pack costs for energy storage systems.
What is the role of AGV systems in a BESS assembly line?
Automated Guided Vehicles (AGVs) transport battery modules, pack components, and materials between different production stations, ensuring efficient workflow, reduced manual handling, and improved factory automation.
Why is robotic laser welding used in battery pack manufacturing?
Robotic laser welding provides high-precision electrical connections, strong weld quality, and minimal thermal impact on battery cells, making it ideal for lithium battery pack assembly.
What testing processes are included in a BESS assembly line?
A typical BESS assembly line includes OCV testing, internal resistance testing, insulation testing, air-tightness testing, and end-of-line (EOL) testing to ensure battery safety, performance, and reliability.
What industries use BESS battery packs?
Battery Energy Storage System packs are widely used in renewable energy storage, solar and wind power integration, grid stabilization, industrial power backup, and EV charging infrastructure.
How does a Cell-to-Pack design improve battery performance?
The Cell-to-Pack architecture eliminates intermediate modules, allowing more cells to fit inside the pack, which increases energy density, improves thermal management, and reduces manufacturing costs.
What is the production capacity of a Cell-to-Pack BESS AGV Line?
The Cell-to-Pack BESS AGV Line from Semco Infratech is designed for high-speed manufacturing and can produce up to 16 battery packs per minute (16PPM), making it ideal for large-scale Battery Energy Storage System (BESS) production.