POLYMER BATTERY PACK ASSEMBLY LINE

Why Choose Pouch Battery Packs?

Pouch battery packs feature a lightweight structure, flexible dimensions, and high packaging efficiency. Their adaptable design allows for better space utilization and more compact battery packs, making them ideal for EVs, energy storage, consumer electronics, and drones.

Polymer lithium- ion battery pack include battery cells, protection frames, busbars, end plates, strapping tapes, etc. Depending on the protection frames, there are two typical structures as shown in the figure below. One is a battery protection frame made of plastic material, which uses strapping tapes, covers and trays to fix multiple battery cells in series and parallel to form a module; the other is to use an aluminum protection frame, incorporate multiple series and parallel connections into it, and add end plates at the ends to form a module.

Process Breakdown of Semi-Automatic Line

Common Equipment in the Production Line

The polymer battery pack assembly line typically involves the following key machines:

1. Grading Machine
2. Sorting Machine
3. Tab Cutting Machine
4. Ultrasonic Welding Machine / Laser Welding Machine
5. BMS Tester
6. Comprehensive Tester
7. Aging Machine

Semi-automatic lines combine manual operation with automated stations, providing a flexible and cost- effective solution for polymer battery module production.

They are especially suitable for multi-model, small-to-medium scale manufacturing, where frequent product changeover is required.

Process Breakdown of Full Automatic Line

1. Automatic pouch module assembly line
2. Production mode: Multi-type pouch cell compatibility line
3. High compatibility with multiple pouch cell formats
4. Fixture-based flexible production system
5. Designed for scalable automation upgrade path

The fully automatic module and PACK production line covers the entire process from cell loading, cell testing, and cell taping to module assembly, module welding, and module testing, enabling a fully automated and continuous production workflow from cell to finished battery pack.

Production Line Process Flow

Capacity Grading Machine

Energy Feedback

Different Fixtures Optional

20A/30A/60A/100A/200A/300A Etc

8/16/32/48/64/128/160/256 Channels Optional

Customization Avaliable

 

 

 

Product Description

The grading machine is used to test cell capacity through charge and discharge cycles. Only qualified and well-matched cells proceed to the next stage, ensuring improved module performance and long-term consistency.

Product Selection

Polymer Battery Capacity Grading Machine
Model	5V 10A	5V 20A	5V 30A	Customized
Channels	1 / 2 / 4 / 8 / 128 / 256 / 512 / Customized
Clamp	Open-close clamping fixture with a tray-based design

ACIR & OCV Sorting Machine

HK/HIOKI IR Tester Optional

10-12 PPM

Automatic with Barcode Scanner

Customization Avaliable

 

 

 

Product Description

The sorting system detects each cell’s voltage and internal resistance, automatically classifying them into different channels based on preset value ranges. Cells that do not meet any defined criteria are directed to the NG channel for rejection. This process ensures consistent cell grouping and improves overall module reliability.

Product Selection

Tab Cutting Machine

Simultaneous Positive/Negative Cutting Without Short Circuit

Min Tab Length: 5 mm

Semi-Automatic, Easy Operation

Customization Avaliable

 

 

 

Product Description

The tab length cutting process is used to precisely trim both positive and negative tabs simultaneously, ensuring consistent tab length for each cell. The equipment is designed with a safe cutting mechanism that prevents short circuit during operation, improving both accuracy and process safety.

Welding Machine

Materials: Busbar (Thick Cu/Al Etc)

Power: 1000W/1500W/2000W/3000W/4000W/6000W Optional

Customization Avaliable

 

 

 

Product Description

For polymer battery module welding, two options are available: ultrasonic welding and laser welding. Ultrasonic welding uses high-frequency vibration to join materials and is well-suited for soft or thin materials, while laser welding utilizes a high-energy laser beam and is more suitable for thicker busbars or rigid conductive structures. The selection of welding method depends on the customer’s battery design and structural requirements.

Product Selection

Polymer Battery Welding Machine
Machine Type	Ultrasonic Welding	Laser Welding
Machine Model	20–40 kHz	1500W / 2000W / 3000W
Welding Principle	High-frequency vibration friction	High-energy laser beam melting
Suitable Materials	Soft / thin materials (Al/Cu tabs)	Thick materials / busbars
Heat Effect	Low heat impact	Localized high heat input
Welding Fixture	Optional	Required
Module Picture

Management System Tester

1-52 Series Battery Pack

Support Smart/Hardware BMS

120A-800A Overdischarge Current

With Computer/Temperature Test Function/Can

Customization Avaliable

 

 

 

Product Description

The BMS testing system is used to verify the protection, communication, and electrical performance of battery management systems in assembled packs, ensuring safe and stable operation.

Main Features

Overcharge / Overdischarge protection test

Overcurrent / Short circuit protection test

Temperature protection test

Internal resistance & conduction resistance testing

Self-consumption detection

Communication function verification (CAN / RS485 / I2C) for accurate reading of SOC, voltage, temperature, and other data

Product Selection

Comprehensive Tester

Voltage Range: 60V-200V

Charge Current Range: 30A-300A

Discharge Current Range: 120A-600A

With Computer

Customization Avaliable

 

 

 

Product Description

The battery comprehensive tester is suitable for all lithium-ion battery packs with CH+, P+, CH-, P- ports and is used to evaluate the overall electrical performance and reliability of battery packs. It applies a load or small AC current to measure key parameters such as open-circuit voltage, AC internal resistance, discharge characteristics, discharge overcurrent protection, short circuit protection, charge performance, and charge protection. By setting upper and lower limit values for each parameter, the system can quickly identify and screen out defective batteries from a batch of finished products, ensuring stable and reliable quality control.

Product Selection

Battery Pack Comprehensive Tester
Voltage Range	50/60/100/120V/200V etc			Customized
Current Range	120/200/300/500/600A etc
Machine Picture

Aging Tester

Energy-Feedback Optional

Voltage Range: 20V-1650V

Discharge Current Range: 10A-1200A

Aging Channel: 7-100 Channel Optional

Customization Avaliable

 

 

 

Product Description

The battery pack aging machine is designed for cycle aging tests, functional performance evaluation, and real-time monitoring of charge and discharge data. It supports four test modes including charging, discharging, shelving, and cycling, allowing flexible program configuration to simulate real working conditions and comprehensively evaluate battery stability and reliability.

Product Selection

Battery Pack Aging Testing Machine
Voltage	20V-1650V
Current	10A-1200A
Channels	1/2/3/4/6/7/8/12/16/32 etc
Type	Standard type/with energy regenerative function (optional)
Standard Model	30A 10A 20-12CH	85V 10A 20A 7-CH	100V 20A 40A	Customized
Machine Picture

Polymer battery packs are increasingly widely used across energy storage systems, electric vehicles, and portable electronic devices, driven by their high energy density, lightweight design, and flexible application adaptability.