Key Questions to Ask When Ordering Battery PACK Automation Line

Battery manufacturing is quickly becoming a cornerstone of the green energy market. According to a report by the International Energy Agency (IEA), battery manufacturing has more than tripled in the last three years, and batteries will need to lead a sixfold increase in global energy storage to meet targets identified by the COP28 United Nations Climate Change Conference. Grid battery energy storage systems (BESS) are also playing an integral role in improving grid resilience.

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As battery manufacturers strive to meet this growing demand, it’s crucial to choose the right automation partner. Those with access to an experienced partner will be better suited to optimize product designs for manufacturing, enhance production efficiency, and reduce time to market. Here, we outline key questions to ask a potential automation partner to ensure they can help you navigate battery production now and in the future.

Does the Automation Partner Understand Core Technologies in Grid Battery Manufacturing?

The automation partner should demonstrate a deep understanding of the key technologies involved in grid battery production, such as high-speed assembly. Manufacturers should also consider the partner’s know-how in specific areas like laser welding, safety standards, integrating advanced robotics and high level of flexibility and can adapt to unique manufacturing process. Manufacturers can bring their safety director or plant safety manager to tour the partner’s facility and assess their commitment to safety and regulatory compliance.

Red Flags to Watch For:

• Basic Responses: Answers that lack detailed explanations of how the partner handles specific technologies should raise concerns.
• Inadequate Safety Measures: If the partner’s facility lacks visible protocols, like personal protective equipment (PPE), or they cannot articulate their approach, it may signal an insufficient commitment to safety standards.

Good Answers to Look For:

• Detailed Case Studies: A good partner will share specific samples of previous projects that implemented high-speed assembly, laser welding, or other relevant tech for grid battery manufacturing.
• Technical Expertise: The partner needs to demonstrate they can integrate automation technologies into the manufacturer’s processes to optimize production and ensure product quality. This can be done through tools like digital twins, SolidWorks, or 3D views of demonstrated processes.
• Safety Considerations: Battery manufacturing involves unique safety requirements to protect employees and ensure compliance. The partner should have experience with battery safety protocols, including clear mitigation strategies to prevent electrical shock and manage thermal runaways.

Can the Automation Partner’s Services Reduce the Manufacturer’s Need to Invest In-House?

Manufacturers need to consider how the partner can support the organization, from collaborating with the project team to providing technical expertise the manufacturer may lack. A good partner will offer problem-solving workshops and Kaizen events to develop solutions alongside the manufacturer. This collaborative approach ensures the partner not only supports those internal needs, but also equips the manufacturer with the information and skills needed to sustain the improvements.

Red Flags to Watch For:

• No Specific Examples: If the partner cannot point to past projects where they directly collaborated with customers, they may lack experience in the industry.
• Lack of Comprehensive Offerings: If the potential partner often relies on other suppliers for specific technologies in automation projects, they likely don’t offer turnkey solutions.
• Inadequate Collaboration: If the partner does not emphasize teamwork, they may not approach automation projects with a partnership mindset.

Good Answers to Look For:

• Collaborative Approach: The partner should share how they work with customers, including using Kaizen events to identify and solve challenges early. This shows their commitment to empowering the manufacturer even after the project ends.
• Technical Expertise: The partner needs to demonstrate how they provide solutions for specific challenges, such as laser welding. A good partner will also mention any proof of principle (POP) processes or benchtop models used to validate the solutions.
• Proactive Methods: Engaging a partner with commitment to collaboration can help manufacturers save time and expenses in the long run—from identifying potential manufacturing issues early to comprehensive training.

Can the Partner Deliver Turnkey Automation Solutions?

Manufacturers must consider whether the partner is accustomed to delivering automation offerings — from design to implementation. Manufacturers should inquire about the partner’s experience in integrating various automation technologies, including line and control integration capabilities. By engaging a partner with a comprehensive approach to automation, the manufacturer can optimize production, drive product quality, and better uphold safety standards.

Red Flags to Watch For:

• Limited Services: If the partner only offers a narrow range of services, they likely cannot support the manufacturer’s growing needs effectively.
• Basic Answers: Partners that give vague responses and don’t share how they handle line and control integration is a major red flag.
• Insufficient Resources: If the partner hesitates to let the manufacturer interview their project management team, controls engineers, or technicians, it’s possible they don’t have the necessary resources to deliver turnkey automation.

Good Answers to Look For:

• Proven Integration Capabilities: The partner needs to show how they integrate automation technologies into one system. This demonstrates their ability to manage complex projects.
• Resource Availability: The partner should be able to mention the number of technicians and controls, design, and electrical engineers on staff, underscoring their capacity to handle large-scale projects. As well as the ability, to expand and contract resources quickly.

Can the Partner Scale with the Company as Demand Grows?

Manufacturers must consider whether the potential partner can handle automation for high-volume production and—eventually—deliver sufficient gigafactory equipment, and support parallel development of multiple locations. As demand grows, it’s critical for manufacturers to evaluate the partner’s ability to support global programs, manage extensive resources, and adapt to increasing production needs.

Red Flags to Watch For:

• Limited Space or Resources: If the partner has only one facility, a small team, and cannot currently expand operations, they may not be able to support major automation programs.
• Hesitant to Provide Information: If the partner doesn’t facilitate interviews with their project management team, engineers, or technicians, they might not be able to adequately deliver gigafactory equipment.
• Poor Partnerships: Smaller partners that lack established relationships with suppliers may not be able to scale effectively.

Good Answers to Look For:

• Demonstrated Scalability: An experienced partner can explain how they successfully scaled operations and personal in previous projects and show they can tackle increasing production needs.
• Capacity for Expansion: The potential partner would highlight their ability to expand operations, including their network of facilities and partnerships.
• Proven Track Record: A good partner will talk about how they’ve created, built, and delivered large-scale automation programs. This gives the manufacturer confidence the partner can support the company as it grows.

Can the Partner Overcome Challenges in Battery Manufacturing?

Manufacturers must consider whether the partner has solved common challenges associated with optimizing battery manufacturing and meeting critical timelines. This involves assessing the partner’s ability to handle complex manufacturing tasks and their understanding of the time it takes to optimize production.

Red Flags to Watch For:

• No Proactive Approach: If the partner does not leverage design for manufacturability (DFM) and can’t say how they’ve delivered automation systems on time, they may lack industry experience.
• Limited Understanding of Schedules: If the partner does not understand the time it takes to optimize critical processes, they won’t be well-equipped to support the manufacturer’s operations.

Good Answers to Look For:

• Demonstrated Expertise: A good partner will show they have successfully overcome specific battery manufacturing challenges. Examples include validating processes through rigorous testing methods and developing unique material handling situations.
• Ability to Meet Timelines: The partner should understand the time required to implement the solution. An automation company that prioritizes POP processes and DFM principles will help the manufacturer solve potential issues early —minimizing recalls, downtime, and costs.

Battery manufacturers looking to scale their operations as global demand grows need the right automation partner at their side. An ideal partner will not only bring a wealth of industry know-how — they’ll also work collaboratively, helping ensure your product designs are optimized for manufacturability. By leveraging the partner’s experience and global resources, manufacturers can enhance production efficiency, save critical time and expenses, and achieve market success.

Pouch cells are a popular choice for battery manufacturers. That’s because the cell is highly efficient—achieving 90-95% packaging efficiency, one of the highest among battery packs. These cells are often used to make batteries for electric vehicles (EVs), but they can also be used in consumer electronics such as cell phones and tablets, or small devices like drones. Pouch cells differ from cylindrical or prismatic cells due to their flexible and lightweight design. This allows for a higher energy density and better space utilization than cylindrical cells.

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However, the assembly and testing of pouch cells presents its own set of challenges, from the cells’ fragile, flexible structure to their sensitivity to high temperatures. Through meticulous handling, early validation, precision welding, and quality checks, battery manufacturers can ensure their product’s performance now and in the future. 

Common Challenges in Pouch Battery Assembly & Testing

Assembly of pouch batteries presents several unique challenges that require careful handling and special processes to ensure their reliability. Some of these challenges include:

• Fragility: Pouch cells are delicate and lack the dimensional stability of cylindrical or prismatic cells. These layered batteries, which are enclosed in foil—which is less robust than the rigid cases used in cylindrical and prismatic cells—are more susceptible to damage during handling and assembly in comparison.
• Material Handling: Special considerations are needed for material handling to prevent damage. Vacuum handling is often used to manipulate pouch cells to avoid distorting the foil seam or stressing the tabs.
• Tab Handling: The interface between the tab and the cell internals is also fragile. Manufacturers must take care when bending or forming the tabs to avoid causing damage or stress.
• Compression: During the compression process, the cells are subjected to controlled pressure to ensure they remain flat and uniform. This is essential for the batteries’ performance and longevity, as it helps eliminate air gaps or inconsistencies within the cell layers, which could affect cell efficiency and stability.
• Welding and Bonding: It’s critical to ensure stable electrical connections through welding and bonding. However, the area where the weld needs to occur can often be fragile. Excessive weld power will quickly penetrate thin pouch cell tabs and potentially damage substrate material. Too little power, and the bond won’t form correctly. This process requires precision and testing to avoid compromising the cell’s integrity.

Pouch Battery Assembly Steps and Considerations

Incoming Pouch Cell Validation

The first step in pouch assembly is incoming cell validation. This step ensures the quality and reliability of the cells before they proceed to further stages of assembly. Cell validation involves a series of inspections and tests to verify the cells meet the required specifications and standards.

Critical aspects of incoming cell validation include:

• Checking for physical defects.
• Measuring cell dimensions.
• Conducting electrical tests to assess the cell’s capacity, voltage, and internal resistance.

By validating incoming cells, battery manufacturers can identify and address issues early on. This can reduce the risk of defects downstream and improve the overall performance and safety of the final battery pack.

Pouch Cell Tab Trimming & Formation

Tab trimming and formation are critical to present the tabs within the required parameters for success downstream. If this critical process is not executed properly, the risk dramatically increases a thermal runaway event. Poor electrical connection or physical damage during final tab assembly steps are all present risks that can lead to significant safety concerns.

In this process the tabs, which extend from the pouch cell, are carefully trimmed to the required length and shape.

Pouch Cell Sequencing & Stacking

Another essential step is sequencing and stacking. This is especially important for applications requiring multiple cells, such as EVs. During sequencing, cells are arranged in a specific order to optimize performance and balance within the battery pack.

Stacking involves carefully aligning and layering the cells to form a cohesive battery pack. Precise stacking mitigates misalignment and secures proper cell connections.

Pouch Cell Compression

Compression maintains the shape and integrity of pouch cells. During this step, the cells are subjected to controlled pressure to ensure they remain flat and uniform. An adhesive and compression absorbing layer is often applied between the cells, which helps secure them in place and keep them aligned during the compression process.

Pouch Cell Busbar Assembly & Tab Formation

At the module stage, forming electrical connections for pouch cells involves using busbars to create stable and reliable connections between the cells. This process ensures the cells function as a unit. Meanwhile, series connectors link multiple cells together, allowing for the desired voltage output of the battery module.

Pouch Cell Busbar Welding

Busbars are typically welded or bonded to the pouch cell tabs to maintain a secure and stable electrical connection. During busbar assembly, the tabs of the pouch cells are carefully bent or shaped to fit the battery pack’s specific design requirements. Correctly aligning and securely connecting the busbars minimizes the risk of mechanical stress or damage and maintains performance and reliability.

Precision in welding also helps battery manufacturers avoid compromising the cells’ integrity and ensures durable connections. The welding process must be carefully controlled to prevent damage to the fragile interface between the tab and the cell internals.

Thermal Interface Material Dispensing & Cooling Plate Considerations

Managing the heat generated by pouch cells during operation increases the longevity of the battery. Thermal interface material (TIM) dispensing and cooling plates are a common solution, applied between the cells and cooling plates to improve thermal conductivity and heat dissipation. Proper dispensing ensures uniform coverage and prevents air gaps, which can cause hotspots and lower performance.

Battery Assembly Quality Checks & Pack Assembly

The final stage of pouch assembly involves a series of rigorous inspections and tests to verify the modules meet the required specifications and standards before enclosing them in the pack for further quality checks.

Key aspects of these quality checks include:

• Visual inspections for physical defects.
• Thorough weld quality inspections.
• Electrical tests to assess capacity.
• Voltage and internal resistance.
• Thermal evaluations to ensure proper heat management.

By conducting thorough quality checks, battery manufacturers can address issues before deploying the batteries, ensuring the final product’s safety and efficiency. Often, battery assembly lines will have both in-line and end-of-line tests. In-line tests help reduce scrapped parts and identify process steps that need refinement. End-of-line tests are focused on ensuring only the best quality batteries are used in the final product.

Charging Up Pouch Assembly & Testing Lines

The assembly and testing of pouch cells are intricate processes that require meticulous attention to detail and precise handling. From incoming cell validation to final quality checks, each step plays a crucial role in ensuring the reliability and performance of the battery.

By collaborating with an automation partner that understands the challenges and considerations involved in battery assembly and testing using pouch cells, battery manufacturers can optimize their processes early on and produce higher-quality batteries that meet the demands of rapidly evolving technologies.

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