Quick answer

This Sunka Lead solution is a high-configuration prismatic LFP energy storage module and PACK production line with a specified cell processing capacity of at least 12 PPM.

In this project, 12 PPM refers to battery cell processing throughput, not 12 finished PACKs per minute.

The line uses a 314 Ah prismatic LFP cell as the reference product and is designed to support 280 Ah, 314 Ah, 587 Ah, 628 Ah and 688 Ah cells. Module compatibility ranges from 1P10S to 1P16S, while the PACK section supports 1P52S and 1P104S configurations. It is also designed to accommodate both liquid-cooled and air-cooled energy storage modules.

Rather than increasing throughput at a single workstation, the solution integrates robotic cell loading, OCV testing, automated taping, robotic stacking, module welding, AGV-based PACK logistics, EOL Testing and MES traceability into one coordinated manufacturing system.

Key project specifications

These values are design specifications stated in the technical agreement rather than claimed operating results.

Why 12 PPM is more than simply running machines faster

For an energy storage battery manufacturer, increasing a line from 6 or 8 PPM to 12 PPM is not simply a matter of increasing robot speed.

Every upstream and downstream operation must keep pace.

Once cell loading is accelerated, barcode scanning, OCV testing, NG rejection, polarity correction and taping must process cells at corresponding rates.

The module section must then balance stacking, compression, steel-strip fitting, terminal positioning, laser cleaning and welding.

At the PACK stage, the product may weigh hundreds of kilograms, so its material flow cannot be treated in the same way as individual cells.

This means a 12 PPM line is fundamentally a line-balancing challenge, not merely a high-speed machine specification.

Sunka Lead therefore designs the cell, module and PACK sections as an interconnected manufacturing system rather than treating each workstation as an isolated unit.

Robotic cell loading establishes the front-end throughput

Incoming cells are delivered on pallets.

After the top packaging is manually removed, the pallet is transferred to the loading position by forklift. A 3D line-scan vision system locates the pallet before a six-axis robot removes the cells and places them onto the production line.

The robot can pick one row of five cells per cycle, and the gripper includes servo pitch adjustment.

Presence detection, drop prevention and a floating protection mechanism are incorporated into the gripper to reduce the risk of cell damage during handling.

Robot repeatability is specified at ±0.06 mm.

For large-format cells, this automation is particularly valuable because higher cell capacity generally means greater handling mass and more repetitive material movement.

OCV testing becomes the starting point of digital traceability

After loading, each cell undergoes barcode identification and OCV/IR testing.

Electrical parameters such as voltage, internal resistance and grade information can be evaluated and associated with the individual cell barcode.

Cells that fail barcode verification or OCV inspection are automatically rejected, while qualified cells proceed to the following processes.

Multiple cell test standards can be stored in the host computer and selected automatically according to production information or switched manually.

The test results are not used only for an immediate OK/NG decision.

They are also stored and uploaded to the production data system.

This makes the OCV station both:

an incoming quality gate and the first data node in the traceability chain.

Automated polarity correction, taping and liner removal maintain process continuity

To support ≥12 PPM cell throughput, the front-end process does not rely heavily on manual handling after OCV inspection.

Cells can be automatically flipped according to the module recipe, followed by automated adhesive application and release-liner removal.

The taping equipment can transfer four cells simultaneously and execute the corresponding process according to the selected module recipe.

A manual taping station is also reserved.

This provides additional process flexibility for maintenance, special production requirements or production adjustments without changing the main automated architecture.

Dual-platform robotic stacking reduces waiting time

After cell preparation, the cells enter the automated stacking section.

A six-axis robot places the cells on the stacking platform according to the module recipe.

The system uses two stacking platforms operating alternately.

While one platform is completing module discharge or transition operations, the other can continue supporting production.

This reduces robot idle time caused by waiting for a single platform to reset.

Robot repeatability is specified at ±0.06 mm. The stacking platform bottom flatness is specified at ±0.1 mm, while side flatness is ±0.3 mm, excluding product-related variation.

Independent error-proofing logic is implemented at both the PLC and robot execution levels.

For a 12 PPM line, the value of this architecture is not simply having an additional platform.

It is about converting robot speed into effective line throughput by reducing non-productive waiting time.

Module compression and dual steel-strip fitting

After stacking, the module enters the compression and steel-strip fitting process.

Operators install the end plates and pre-position the lower steel strips before the robot transfers the stacked module into the compression equipment.

Servo-driven compression mechanisms bring the module to the specified length.

The stated module compression force range is 100–2,000 kgf.

After compression, the upper and lower steel strips are fitted around the module.

Compression force and module length data can be stored locally and uploaded to MES.

For 587 Ah, 628 Ah or 688 Ah cells, compatibility therefore involves more than whether a fixture can physically accommodate a larger cell.

Stacking position, module length, compression settings and downstream welding coordinates must also remain controllable across different product configurations.

Terminal positioning and laser cleaning create a connected welding workflow

Before welding, the CCD vision system captures the module frame and individual cell terminals to establish terminal coordinates.

A laser distance sensor then measures terminal heights, and the corresponding coordinates, images and height data are associated with the module barcode.

These positioning results can be retrieved by the downstream laser welding station.

The laser cleaning process uses the same positioning logic to process the terminal surfaces before CCS welding.

This creates a connected sequence:

terminal positioning → height measurement → laser cleaning → welding coordinate retrieval

rather than forcing each workstation to independently relocate the product.

Why the line uses a 6,000 W laser welding system

After manual CCS installation, the module enters the laser welding station.

The solution uses a 6,000 W laser welding system with two copper pressing mechanisms at a single station to improve welding efficiency.

Before welding, CCD vision identifies fiducial marks. Height measurements and coordinate data returned from the upstream positioning station are then used for compensation calculations.

The welding mechanism executes the programmed weld according to the resulting coordinates.

Key design specifications include:

• laser power: 6,000 W;
  
• robot positioning accuracy: ±0.02 mm;
  
• terminal pressing force: 0–500 N;
  
• busbar-to-terminal gap after pressing: <0.1 mm;
  
• terminal peel-off force requirement: ≥1,800 N;
  
• specified welding pass rate: ≥99.5%.
  

The station also incorporates an enclosed welding area, fume extraction and related safety protection.

For high-throughput production, higher laser power alone is not enough.

The practical objective is:

faster welding + stable positioning + controlled contact + fewer rework events.

Why the PACK section uses AGV-based logistics

Once production reaches PACK assembly, the product becomes much larger and heavier than an individual cell or module.

A conventional fixed conveyor provides a predefined route, but changes to the PACK process can require changes to the conveyor layout.

In this 12 PPM solution, the PACK section uses AGVs with fixture trolleys for circulating material flow.

The AGV moves the PACK through processes including:

enclosure loading → air leak testing → automatic gluing → module loading → module fixing → busbar installation → BMU harness installation → cover installation → PACK air leak testing → EOL testing → unloading

The technical specification describes a 2,000 kg rated-load AGV using QR-code navigation, together with laser obstacle avoidance, emergency-stop and voice-warning functions.

The purpose of the AGV is not simply to make the factory look more automated.

Its more important role is to decouple PACK transport from a completely fixed conveyor route.

This provides greater flexibility if workstation allocation or PACK process routing changes later.

Automated module loading reduces heavy manual handling

At the module loading station, the AGV positions the PACK enclosure and a robot automatically loads the module into the enclosure.

CCD cameras are used for positioning.

The system also scans module information and completes the data binding between the module and the PACK enclosure.

For large-capacity energy storage modules, automated loading addresses several requirements at the same time:

heavy handling, positioning repeatability, assembly consistency and digital product binding.

High automation does not mean removing every manual operation

Although this is a high-configuration automated production line, several assembly operations remain manual, including selected CCS, module fixing, busbar, harness and cover installation processes.

This is consistent with actual PACK manufacturing requirements.

A 12 PPM cell processing capacity does not mean that every PACK assembly operation must also run at 12 finished products per minute.

Cycle-time logic, product weight and assembly complexity are different at each stage.

The line therefore combines:

high-speed automation for repetitive and quality-critical operations + manual flexibility for selected assembly tasks + AGV transport between PACK stations.

This is more practical than treating “fully automatic” as the only measure of production-line capability.

Compatibility extends beyond cell capacity

The technical agreement specifies compatibility with both liquid-cooled and air-cooled energy storage modules.

This matters because different energy storage applications may use different thermal-management architectures.

If a PACK line is built around only one fixed cooling configuration, changes in customer orders may require substantial retooling or additional equipment.

Sunkalead therefore extends production flexibility beyond cell capacity to module and PACK thermal-management configurations.

For manufacturers planning multiple energy storage products, this can provide greater long-term value than simply increasing nominal throughput.

MES turns high-speed production into traceable production

As throughput increases, production data becomes more important.

When an abnormality occurs, manufacturers need to determine:

which cell was involved, which module it entered, which PACK contains it and what happened at each process step.

The line is equipped with a line-level MES system.

Cell-section incoming and OCV data can be uploaded; module data can be bound through barcode scanning; and the production process is managed across cell, module and PACK sections.

Traceability can be performed through product or material barcodes.

Interfaces are also reserved for connection to the customer's central control or downstream systems.

When individual equipment operates independently, data can be stored locally.

The MES therefore connects:

product identity → process parameters → inspection results → welding information → PACK data

into one production data chain.

What does this 12 PPM line actually solve?

On paper, this is a:

≥12 PPM prismatic energy storage module and PACK production line.

In engineering terms, however, the solution addresses five different manufacturing requirements.

1. Throughput

Robotic loading, automated cell preparation, dual-platform stacking and high-power welding support higher front-end production rates.

2. Large-capacity cell compatibility

The line is designed for 280–688 Ah prismatic LFP cells and 1P10S–1P16S modules.

3. PACK flexibility

The PACK section supports 1P52S and 1P104S configurations and both liquid-cooled and air-cooled modules.

4. Heavy-load logistics

AGVs and fixture trolleys support circulation between PACK workstations.

5. Digital traceability

MES connects cell, module and PACK production data.

For this reason, the Sunka Lead 12 PPM solution is not simply a conventional energy storage line running faster.

It is a production architecture balancing throughput, compatibility, automation, logistics and digital manufacturing.

Frequently asked questions

1.What does 12 PPM mean on this production line?

It refers to a specified battery cell processing capacity of at least 12 cells per minute, not 12 finished PACKs per minute.

2.Which cells can the line support?

The solution uses a 314 Ah cell as the reference product and is designed for 280 Ah, 314 Ah, 587 Ah, 628 Ah and 688 Ah prismatic LFP energy storage cells.

3.Which module and PACK configurations are supported?

The line supports 1P10S–1P16S modules and 1P52S / 1P104S PACK configurations.

4.Why does the PACK section use AGVs?

AGVs provide flexible heavy-load transport between PACK workstations and reduce dependence on a completely fixed conveyor route.

5.Is the line fully unmanned?

No. Key repetitive and quality-critical operations are automated, while selected assembly processes remain manual to preserve practical production flexibility.

6.What laser power is used for CCS welding?

The technical solution specifies a 6,000 W laser welding system combined with CCD positioning, height measurement and pressing mechanisms.

7.Does the production line include MES?

Yes. A line-level MES is included for production data collection, process control and traceability, with interfaces reserved for external system integration.

8.Can the line support both liquid-cooled and air-cooled energy storage modules?

Yes. The technical specification explicitly includes compatibility with both cooling architectures.

About the solution provider

Sunka Lead is the international brand of Guangdong Songke Leading Intelligent Equipment Co., Ltd.

The company specializes in the design, engineering and manufacturing of lithium battery module and PACK production equipment, providing customized solutions for prismatic, cylindrical and pouch battery applications.

From cell processing and module assembly to laser welding, PACK assembly, testing and MES integration, Sunka Lead provides production equipment and turnkey line solutions for lithium battery manufacturers worldwide.