Meet the Demand Shift in Global Battery Manufacturing

The global lithium-ion battery market is undergoing three critical shifts:

Diversification of Technology: Prismatic cells account for over 60% of applications, yet OEMs demand bespoke module sizes and capacities.

Accelerated Time-to-Market: Leading battery manufacturers require production lines to ramp up within 12 months from delivery.

Extreme Cost Pressures: Production costs must drop below $0.08/Wh to remain competitive.

Standardized lines no longer suffice. Customized non-standard production lines are the new industry standard.

SUNKALEAD’s Prismatic Cell Pack Production Line: 5 Core Technological Breakthroughs

Model: Custom Prismatic Cell battery pack assembly line

(Supports 10–300Ah cells | Configurable 12–200pcs/min throughput)

1. Intelligent Front-End Processing System

AI-Powered Vision-Guided Feeding: 100% precision alignment via machine learning

OCV Online Testing: ±0.5% voltage accuracy with automated defect sorting

Dual-Track Barcode Scanning: QR code/RFID traceability for full lifecycle management

2. Ultra-Precision Stacking Technology

6-Axis Robotic Stacking: ±0.2mm alignment accuracy (industry average: ±0.5mm)

Laser Distance Calibration: Real-time error compensation during stacking

Adaptive Compression Mechanism: Pressure control ±5N for optimal cell bonding

3. Advanced Welding & Quality Assurance

Fiber laser welding: Weld strength ≥80MPa | Heat-affected zone <3mm

CCD Polarity Detection: 100% accuracy with <0.01% misalignment rate

Helium Leak Testing: Airtightness up to 1×10⁻⁶ Pa·m³/s

4. Modular & Scalable Design

Plug-and-Play Architecture: 30-minute reconfiguration for new models

Digital Twin Simulation: Real-time production line optimization

MES System Integration: End-to-end data visibility

5. Safety & Sustainability

Explosion-Proof Dust Collection: Particulate concentration <1mg/m³

Energy Recovery System: Welding energy consumption reduced by 35%

ESD Protection: Full-process static discharge monitoring

Four Benchmark Use Cases

Customer Success Stories

Global EV Manufacturer:

Deployed 12+ lines for BEV/HEV/PHEV platforms

Achieved 98.7% first-pass yield at 200pcs/h

European Energy Storage Client:

UL9540A thermal runaway certification passed

Supports 48V/96V/384V multi-voltage architectures

Key Performance Comparison

Metric          Traditional Pack Line     SUNKALEAD Custom Line

Line Flexibility：Fixed module dimensions，12–200pcs/min adjustable

Equipment Uptime：75%–85%，        ≥92%

Data Traceability：Manual logging，      Full digital traceability

Delivery Timeline：18–24 months，      9–12 months (industry-leading)

Why Choose SUNKALEAD?

Tailored Expertise: 200+ non-standard projects delivered across 3C/energy storage/automotive sectors

Rapid Deployment: Three global facilities (China/Europe) enabling 90-day delivery

Full Lifecycle Support: Training, spare parts, software upgrades, and retrofit services

Take Action Today

Free Consultation: Request the Global battery pack line ,

For any inquiries about battery pack assembly line solutions,please don't hesitate to contact us.

 Custom Proposal: Upload your specs for a 72-hour feasibility study

Remote Validation: Access 72-hour digital twin simulation