TOBGROUP provides comprehensive cylindrical cell battery pack production line solutions. We offer custom pack design, manufacturing, and quality assurance services. Complete services from design to production with performance optimization.
TOBGROUP provides global new energy enterprises with highly flexible, zero-defect cylindrical battery PACK mass production solutions. Focusing on mainstream formats such as 21700, 32140, and 4680, our solutions cover application scenarios including power tools, electric two-wheelers, energy storage systems (ESS), and new energy vehicles (NEVs). We enable fully automated, digitalized, and traceable production from cell to PACK.
Core Value:
● Smart Production Line Design: Compatible with multiple cell types (18650/21700/4680, etc.) and multiple PACK configurations (from 1P4S to 20P24S), supports quick changeover within 72 hours.
● Ultimate Quality Control: Integrates machine vision (0.02mm accuracy), real-time laser monitoring, and big data CPK analysis, achieving key process yield ≥ 99.5%.
● Cost Reduction & Efficiency Improvement: Increases output per person by 300%, improves factory space utilization by 40%, and shortens ROI period to 18 months.
● Green Manufacturing: Incorporates waste heat recovery and zero dust emission design, compliant with ISO 14064 carbon footprint standards.
TOBGROUP Cylindrical Cell Battery PACK Production Line Standard Configuration with Full Customization Support
|
Parameter Item |
Standard Configuration |
Customizable Options |
|
Standard Capacity |
80 PACKs/hour |
50-200 PACKs/hour |
|
Compatible Cells |
18650/21700/4680 |
26650/32140/4695, etc. |
|
PACK Voltage Range |
24V-800V |
12V-1000V |
|
Modularity Rate |
≥95% (Auto changeover) |
100% (No manual intervention) |
|
Data Traceability Points |
1500 points/PACK |
5000 points/PACK (incl. BMS data) |
|
Key Yield Metrics |
Welding yield ≥ 99.8% Leak test yield ≥ 99.9% |
Zero defect target |
|
Energy Consumption Index |
≤1.8 kWh/kWh (PACK) |
PV direct-drive mode (Zero-carbon line) |
|
Delivery Cycle |
36 weeks (Standard line) |
28 weeks (Rush order expedited mode) |
Advanced Cylindrical Cell Battery PACK Production Line Solutions by TOBGROUP.
● Full Domain Automation Architecture
(1) Cell Processing: High-speed sorting machine (2000 pcs/min) → AI grouping (Voltage/IR/Capacity ±0.5%)
(2) Assembly Process: Fully automatic stud welding (yield 99.8%) → CCD positioning and insertion → Laser welding (Aspect ratio ≥ 3.0)
(3) Safety Control: Nanoscale leak test (detection rate ≥ 99.9%) → Multi-frequency EOL testing (Insulation/Withstand Voltage/SOC calibration)
● Industry 4.0 Digital Foundation
(1) Digital Twin System: Real-time production line status mapping, predicts equipment failures (92% accuracy)
(2) AI Quality Hub: Weld penetration depth prediction, thermal runaway simulation, virtual calibration (reduces physical testing by 30%)
(3) Blockchain Traceability: Single PACK data chain (2000+ parameters) covering a 10-year lifecycle
● Flexible Manufacturing Revolution
(1) Modular Workstations: Support seamless switching between CTP/CTC structures
(2) Mixed-Line Production Engine: Compatible with LFP/NMC/Sodium-ion chemistries on the same line
(3) Cloud-Edge Coordination: MES order-driven automatic scheduling, order changeover loss < 15 minutes
From Planning to Cylindrical Cell Battery PACK Production Line: TOB Full Support
|
Phase |
TOB Core Deliverables |
Customer Value |
|
In-Depth Needs Analysis |
Product definition (Energy density ≥180Wh/kg? Cycle life >4000?) Cost model (¥0.03/Wh reduction?) |
Precise alignment with business goals |
|
Cylindrical Cell Battery PACK Production Line Top-Level Design |
Digital factory simulation → Logistics simulation → Ergonomics optimization Poka-Yoke error-proofing network design |
Eliminates over-investment |
|
High-Tech Equipment Cluster |
Supply of TOB self-developed equipment: - 6-axis laser welding robot (0.1ms response) - Multi-physics test chamber (-40℃~85℃ temp. cycling) - Nano-coating insulation treatment system |
Breaks import dependence |
|
Risk-Free Delivery |
30-day continuous ramp-up verification (OEE ≥ 88%) SPC process capability report (CPK ≥ 1.67) |
Profitability upon mass production |
|
Knowledge Transfer |
Training system: Equipment operation (L1) → Process optimization (L3) → AI analysis (L5) |
Independent technical mastery |
Core enablers of technological implementation
Actionable insights from planning to execution
Yes, it supports mixed-line production of all diameters (18-46mm) using TOB patented quick-change fixtures (<10 min changeover), with grouping algorithms automatically adapting to dimensional tolerances.
Utilizes TOB's self-developed coaxial ring welding technology:
● 12-beam laser synchronous irradiation.
● Penetration depth control ±5μm.
● Heat-affected zone < 100μm (1/3 of traditional process).
Standard line (80 PACKs/h): 60m L × 25m W × 6m H (includes logistics aisles). Supports L-shaped/U-shaped layouts for space optimization.
From cell QR code to PACK serial number:
● Process Data: 2000+ parameters (incl. welding temp. profile, pressure holding data).
● Quality Data: Full-size CT scan report (optional).
● Lifecycle Data: Direct connection to customer's BMS cloud.
Key adaptation points:
● Corrosion-resistant welding process (TOB patented coated welding pins).
● Low-temperature potting system (maintains fluidity at -30°C).
● Dedicated EOL test programs (internal resistance characteristics at different SOC ranges).
TOBGROUP delivered a 3000F 60138 supercapacitor pilot line with full equipment, materials, and on-site commissioning support.
TOBGROUP designed a Na-ion battery lab line producing 18650S, 32138S, 32140S cells for advanced research and development.
TOBGROUP delivered a full-cycle 5MWh pouch cell production line for Li-ion and Na-ion, enabling European energy storage production.
