Mondragon Lithium Battery Assembly Line

A used semi-automatic Battery Module assembly line is available for the production of lithium-ion battery modules based on prismatic cells.

The line is designed for the assembly, testing, welding and end-of-line validation of battery modules with up to 16 prismatic cells per module, with a nominal configuration of 100 Ah cells / 5.12 kWh module.

The equipment is manufactured by Mondragon Assembly and includes a two-level pallet transfer system with elevators, manual assembly stations, robotic cell handling, laser cleaning, laser busbar welding, quality inspection and EOL testing.

Main technical data

• Product type: prismatic lithium-ion battery modules
• Line type: semi-automatic production line
• Cell configuration: up to 16 prismatic cells per module
• Cell capacity reference: 100 Ah
• Module energy reference: 5.12 kWh
• Module weight: approx. 37–40 kg
• Gross cycle time: approx. 45 seconds per cell / 12 minutes per module
• Operators required: 3 operators + shift leader
• Total line length: approx. 16.3–16.5 m
• Total width: approx. 5.5 m
• Maximum height: approx. 2.9 m
• Pallet system: two-level closed-loop pallet transfer with elevators
• Supply voltage: 400 VAC / 50 Hz
• Installed power: approx. 40 kW
• Power consumption: approx. 25 kW

Line composition

The line includes the following:

Pallet transfer and elevators
Two-level pallet circulation system with elevators for pallet movement between working and return levels.

Initial manual assembly station
Manual loading of bottom insulation sheet, front and back casing plates and related insulation components.

Robotic cell station
FANUC robot cell for handling prismatic cells, including:

• manual cell loading
• Datamatrix code reading
• OCV / IR testing
• polarity check
• charge–discharge testing
• thermal inspection
• thickness inspection
• foam pad loading and application
• rejected cell unloading

Laser cleaning station
Enclosed laser cleaning station for electrode surface preparation before welding, with X–Y gantry system and 32 cleaning positions.

Manual busbar and PCBA preparation station
Manual placement of plastic cap, busbars, flexible PCBA and welding mask, with camera-based position verification.

Laser busbar welding station
Laser welding station for busbars and flexible PCBA, including:

• X–Y–Z gantry system
• external chiller
• vacuum cleaner
• automatic safety doors
• camera-based weld inspection

Final assembly station
Manual final assembly of the battery module housing, side plates, BMS, wiring and bolted connections using controlled screwdriving operations.

End-of-line station
Station for final battery module validation, including:

• OCV / IR test
• charge–discharge test
• label printing and verification
• module unloading by crane / manipulator

The line is available for sale as a complete package. Inspection and further technical information can be arranged upon request.