Fully Automated Prismatic Cell Battery Pack Assembly Line for Module Integration MES Digital Traceability System

Fully Automated Battery Pack Assembly Line — Module-to-Pack Integration with Full Traceability

The BPA-INT-C is a fully automated battery pack assembly line designed for high-efficiency module-to-pack integration of prismatic cell battery systems. From module loading to finished pack testing and shipment, it delivers ≥99% yield rate with intelligent MES/ERP control and complete digital traceability — purpose-built for EV and energy storage battery manufacturing.

Core Technical Parameters

• Equipment Utilization Rate: ≥90% — engineered for maximum uptime in demanding production schedules
• Yield Rate: ≥99% — multi-stage inline quality control ensures every pack meets specification
• Automation Level: Fully automated from module loading to finished pack output
• Flexibility: Quick model changeover with recipe-based configuration for different pack designs

Production Process Flow

The BPA-INT-C covers the complete pack assembly process from module receipt to finished pack:

• Module Loading & Verification: Automated module feeding with barcode/RFID scanning for incoming quality verification and traceability chain initiation
• Module Placement & Fixation: Precision robotic placement of modules into pack tray/frame with automatic bolt tensioning and torque verification
• Busbar & Wiring Harness Assembly: Semi-automated busbar installation and wiring harness routing with automated continuity and insulation testing
• BMS & Electronics Integration: BMS mounting, connector mating, and communication bus verification with automated CAN/LIN bus testing
• Pack Sealing & Protection: Automated lid placement, gasket application and bolt tightening with IP verification if required
• End-of-Line Testing: Comprehensive pack-level electrical testing, insulation resistance, HiPot, and communication verification
• Pack Coding & Traceability: Laser marking of pack serial number, QR code and certification labels with full production data upload to MES

Intelligent Manufacturing Features

• Digital Production Management: Real-time production monitoring dashboard with key metrics — throughput, yield, utilization, cycle time — visible to operators and managers on the shop floor and remotely.
• Full Data Traceability: Every module, component, torque value, test result and process parameter is logged and linked to the pack serial number. Complete genealogy traceability from finished pack back to individual cell lot — critical for automotive quality standards and warranty management.
• Seamless MES/ERP Integration: Open architecture supporting OPC-UA, REST API and database-level integration with leading MES platforms. Real-time production order management, material consumption tracking and quality data exchange.
• Transparent Analytics: Built-in analytics for OEE calculation, bottleneck identification, quality trend analysis and predictive maintenance alerts. Data-driven decision support for continuous production improvement.
• Reduced Labor Intensity: Automated material handling, robotic assembly and inline testing significantly reduce operator count and ergonomic strain. Operators focus on supervision and exception handling rather than repetitive manual tasks.

Custom Design & Integration

Every BPA-INT-C line is custom-engineered to match the customer's specific pack design, cell format, production capacity target and workshop footprint. HGTECH provides end-to-end project delivery: line concept and simulation → detailed engineering → manufacturing → factory acceptance testing (FAT) → shipping → site installation → commissioning → operator training → production ramp-up support.

Global Support

Comprehensive warranty package with on-site installation, commissioning and operator training. Remote diagnostic support for rapid troubleshooting. Regional spare parts inventory for minimized downtime. Optional preventive maintenance contracts and production optimization consulting available.

Hgstar — Pioneer and Leader in China’s Laser Industrial Applications

Hgstar is a global provider of laser equipment and intelligent manufacturing solutions, recognized as one of the pioneers in China’s laser industrial applications. As a core subsidiary of HGTECH, a nationally listed high-tech enterprise, Hgstar is committed to continuous innovation, technological breakthroughs, and long-term value creation for global manufacturing customers.

Comprehensive “Laser + Intelligent Manufacturing” Solutions

To meet the evolving needs of customers across different industries, Hgstar continuously expands its product portfolio and solution capabilities. By building a complete industry ecosystem centered on “Laser + Intelligent Manufacturing”, we provide integrated solutions covering laser cutting, welding, marking, automation systems, and smart factory upgrades, helping customers improve productivity and manufacturing efficiency.

Strong R&D Capabilities and Industry Expertise

With nearly 50 years of experience in the laser industry, Hgstar has established 4 overseas R&D centers and built a professional team of over 100 senior laser and automation experts. Our R&D efforts focus on core laser technologies, advanced process development, and forward-looking intelligent manufacturing solutions, ensuring our products remain competitive and reliable in real-world industrial applications.

Global Service Network and Reliable Support

Hgstar operates 23 global service centers, providing localized technical support and responsive after-sales service worldwide. Through remote diagnostics, on-site service, and comprehensive training, we help customers minimize downtime and ensure stable, long-term operation of their equipment.

Driving Productivity Through Innovation

Guided by innovation and practical engineering, Hgstar is dedicated to advancing global manufacturing productivity. By enabling full connectivity, real-time perception, and intelligent decision-making, we support the transformation toward smarter, more efficient production systems.

Hgstar — With light as our technology and reliability as our commitment, we continue to empower industries and shape the future of intelligent manufacturing.