Leverage cutting-edge technology with TOBGROUP’s prismatic cell manufacturing systems. We offer end-to-end support—from facility build-out to equipment customization—incorporating innovations like solid-state and dry electrode techniques.
TOBGROUP leverages globally leading mass-production experience in prismatic cells to deliver a fully automated, end-to-end prismatic cell production line solution. Focused on large-scale manufacturing of power and energy storage batteries, the solution deeply integrates Industry 4.0 technologies, providing a high-precision, high-consistency, and low-energy intelligent manufacturing platform for LFP, NCM/NCA, sodium-ion, and other battery systems.
● Production Scale: 100–300 PPM (supports phased expansion to 500 PPM)
● Size Compatibility:
(1) Standard models: VDA 355/390/590, compatible with CTP/CTC innovative structures
(2) Thickness range: 20–120 mm, length: 70–1500 mm (custom sizes available)
Core Processes Covered:
Dry/wet electrode → twin-screw continuous mixing → ultra-wide high-speed coating → closed-loop control rolling → high-speed laser slitting → winding/stacking → case laser welding → electrolyte filling & formation → helium leak testing → full-channel aging → AI visual inspection → smart warehousing
TOBGROUP Prismatic Cell Production Line Standard Configuration with Full Customization Support
|
Parameter |
Standard Specification |
Customization Capability |
|
Design Cycle |
200 PPM |
50–500 PPM |
|
Cell Size |
VDA 590 module |
Compatible with CTB/blade/large cylindrical |
|
Process Speed |
Coating: 80 m/min |
Up to 120 m/min (dry electrode) |
|
Precision Control |
Thickness: ±1μm |
Weld seam width: 0.1mm |
|
Environment Control |
Class 1000 cleanroom |
Local Class 100 |
|
Energy Management |
Smart power monitoring |
Integrated energy saving ≥30% |
|
Data System |
MES + SCADA |
Compatible with QMS/ERP |
TOBGROUP Prismatic Cell Production Line: Redefining Efficiency and Precision in Large-Scale Manufacturing
● Full Automation Integration
(1) Robotic cluster coordination (automatic web splicing → electrode roll ASRS → AGV logistics)
(2) Unmanned key processes (welding yield ≥99.8%, filling accuracy ±0.5g)
● Digital Twin Process Control
(1) Real-time monitoring of 2000+ sensor data points (temperature/tension/thickness/weld penetration depth)
(2) CPK dynamic optimization based on big data analysis (electrode areal density fluctuation ≤±1.5%)
● Advanced Process Integration
(1) Dry electrode continuous production (40% lower energy consumption, compatible with solid-state electrolytes)
(2) High-speed stacking technology (0.15s/piece, alignment accuracy ±0.3mm)
(3) Ultra-high-speed linear electrolyte filling (vacuum filling speed ≥3s/piece)
● Zero-Risk Mass Production Transition
(1) Pre-loaded process parameter library with 100+ mature solutions (LFP/NCM/sodium-ion)
(2) Real-time OEE early warning system (response time <15 minutes)
Full lifecycle services from plant planning to mass production efficiency
|
Phase |
Service Content |
TOB Core Value |
|
Demand Analysis |
Product positioning/capacity planning/energy efficiency goals |
ROI simulation & technical feasibility report |
|
Line Design |
Process layout/logistics simulation/smart factory planning |
3D digital factory model (incl. ESD/dry room design) |
|
Equipment Delivery |
Custom core equipment + smart control systems |
Global supply chain integration (European precision mechanisms + Japanese control systems) |
|
Commissioning |
Process locking/yield ramp-up/OEE Reached |
SPC control charts & standard operating procedures (SOP) |
|
Continuous Support |
Remote maintenance/process upgrades/spare parts management |
Capacity expansion retrofit solutions |
Core enablers of technological implementation
Actionable insights from planning to execution
● Structural process: Metal case requires high-precision welding (laser/FSW) instead of pouch heat sealing
● Efficiency bottleneck: Stacking speed > winding efficiency (TOB magnetic levitation stacking breaks this limit)
● Sealing system: Requires helium leak test + top cover welding after filling
Triple control mechanism
● Equipment level: Online β-ray thickness measurement for coating/rolling
● Process level: Real-time warning with CPK ≥1.67 for each process
● System level: MES full traceability (300+ data points per cell)
● Floor load: Rolling area ≥8 T/m²
● Environmental control: Electrode workshop dew point ≤-40°C
● Power capacity: ≥5000 kVA for 100 PPM line
TOB’s unique “Three-Phase Efficiency Model”:
● Phase 1: Basic configuration achieves 80% capacity
● Phase 2: Modular expansion (add stackers/aging cabinets)
● Phase 3: Process upgrade (dry electrode/ultra-high-speed filling)
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.
