TOBGROUP provides comprehensive prismatic cell battery pack production line solutions. Complete services from design to production with performance optimization. Custom design, assembly, and testing services for various applications.
TOBGROUP is dedicated to providing global power battery and energy storage system manufacturers with highly flexible, high-precision, and low-energy consumption prismatic cell battery pack production line solutions. By deeply integrating smart manufacturing technology with battery process know-how, we cover the entire process—including cell sorting, module assembly, pack integration, and End-of-Line (EOL) testing—to help customers achieve large-scale, high-consistency, low-cost, and safe battery system production.
● High Capacity: 0.5 - 5 GWh/year (supports phased expansion, compatible with passenger/commercial vehicle and energy storage applications)
● Cell Compatibility: Prismatic aluminum shell (thickness: 20-80mm, height: 70-220mm, compatible with blade/long cell customization)
● Core Processes:
(1) AI-powered cell sorting (multi-parameter matching: voltage/internal resistance/capacity)
(2) High-speed module assembly (automatic stacking, busbar laser welding, end-plate tightening)
(3) Fully automated pack assembly (CTP/CTB integration, structural adhesive dispensing, cold plate installation, enclosure assembly)
(4) Intelligent EOL testing (leak testing, insulation withstand voltage, charge-discharge, BMS communication calibration)
TOBGROUP Prismatic Cell Battery PACK Production Line Standard Configuration with Full Customization Support
|
Parameter Item |
Standard Specification/Range |
Customization Options |
|
Annual Prismatic Cell Battery PACK Production Line Capacity |
2 GWh |
0.5 - 5 GWh (adjustable based on cell capacity) |
|
Compatible Cell Dimensions |
150mm L × 40mm W × 120mm H |
80-600mm L × 20-80mm W × 70-220mm H |
|
Prismatic Cell Battery PACK Production Line Cycle Time |
20-30 PPM (module section) |
Up to 45 PPM (CTP 3.0 architecture) |
|
Overall Automation Rate |
≥95% |
Upgradeable to "lights-out factory" standards |
|
Key Precision Control |
Welding ±0.1mm, tightening ±3% |
Supports real-time nano-level compensation |
|
MES Data Traceability Points |
500+ |
Expandable to 2000+ (with AI analysis interface) |
|
Factory Requirements |
Length≥80m, height≥5m, load≥5t/m² |
Supports multi-floor facilities/retrofitting |
|
Delivery Time |
8-12 months |
6-18 months (depending on automation level) |
Advanced Prismatic Cell Battery PACK Production Line Solutions by TOBGROUP.
● Industry 4.0-Level Integrated Production Line
(1) Digital twin-based production line design enabling equipment interoperability (OPC UA protocol) and real-time data traceability (MES + SCADA)
(2) Redundant design for critical stations (e.g., dual welding stations) ensuring OEE ≥ 85%
(3) AGV + roller conveyor flexible logistics supporting mixed-model production (changeover time ≤ 15 minutes)
● Ultra-Precision Process Control
(1) Laser welding: 0.2mm repeat positioning accuracy, real-time penetration monitoring (PPK ≥ 1.67)
(2) Tightening system: 100% torque & angle curve traceability, ±3% error
(3) Adhesive dispensing inspection: 3D vision real-time monitoring of width/thickness to prevent poor adhesion
● Comprehensive Quality Assurance
(1) AI cell sorting: multi-parameter dynamic grouping, ≤10mV variation within modules
(2) Online X-Ray inspection: 100% weld defect screening (void/crack detection accuracy: 0.1mm²)
(3) EOL big data analysis: failure mode prediction, SPC process control
● Green Intelligent Manufacturing
(1) Energy consumption intelligent monitoring (kWh/pack visualization)
(2) Thermal management system automated assembly (precise application of thermal adhesive/water-cooling plates)
(3) Centralized exhaust treatment (welding fume purification efficiency ≥ 99%)
From Planning to Prismatic Cell Battery PACK Production Line: TOB Full Support
● In-Depth Requirement Analysis
Product specifications (cell dimensions/pack structure/performance metrics), capacity planning, automation level, investment budget
● Digital Twin Production Line Design
3D production line simulation (logistics simulation/cycle time validation), equipment layout optimization, energy consumption modeling
● Customized Supply of Core Equipment
(1) High-precision cell sorting machine | 6-axis module stacking robot | 3000W fiber laser welding station
(2) Fully automated FDS tightening system | CTP structural adhesive dispenser | Negative pressure leak testing station
● Turnkey Project Delivery
On-site installation and commissioning by TOB engineers, PPAP validation (capacity/yield/OEE compliance)
● Lifelong Technical Support
Smart maintenance system (predictive equipment maintenance) | process upgrade services | tiered personnel training
Core enablers of technological implementation
Actionable insights from planning to execution
Yes, flexible production is supported via quick-change fixtures (≤30 minutes), robotic vision recalibration, and MES recipe switching, accommodating cell lengths of 80-600mm.
Includes four phases: ① production line simulation (1-2 months); ② custom equipment fabrication (4-6 months); ③ installation and commissioning (2 months); ④ PPAP mass production validation (1 month). Higher customization may extend the timeline.
TOBGROUP’s smart energy management system includes: ① variable frequency technology to reduce idle power; ② waste heat recovery for dry rooms; ③ digital twin-optimized equipment start-stop strategies, reducing energy use by ≥15%.
Three-tier training: ① equipment operation/maintenance (2 weeks); ② process parameter optimization (1 week); ③ data analysis and troubleshooting (1 week), with TOB-certified engineer certification.
Yes, with CE/UL/ISO-certified equipment and experience in 50+ countries (North America/EU/Southeast Asia/South America), providing localized installation teams and spare parts support.
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.
