Module/Pack/CTP Turnkey Solutions for Automotive Manufacturing

Module Turnkey Solutions for Automotive Manufacturing

As a global leader in battery equipment manufacturing, LEAD offers a comprehensive suite of services tailored to lithium battery module production. Our services cover factory planning, consultancy, specialized machinery, custom MES, assembly line integration, intelligent logistics warehousing, and module disassembly for various types of production lines including prismatic cells, cylindrical cells, large cylindrical cells, and pouch cells.

Our module line solution encompasses key processes such as cell auto loading and code scanning, cell plasma cleaning, cell AB gluing, cell stacking, laser welding, CCD positioning, and EOL testing. Integrated with LEAD’s proprietary intelligent logistics system and MES system, our production line consistently achieves an overall yield rate exceeding 99% and an availability rate exceeding 95%.

PACK Turnkey Solutions for Automotive Manufacturing

Automotive Pack intelligent production line

LEAD specializes in Battery Pack Solutions, harnessing advanced technologies such as self-developed vision systems, software platforms, comprehensive simulation, laser welding, and big data analysis. We cater to diverse battery types, including cylindrical, pouch, and prismatic cells, providing a spectrum of services from factory modeling and simulation to tailored machinery, MES design for production lines, intelligent warehousing logistics, and complete turnkey solutions.

Our PACK line solution encompasses key processes like lower housing loading, automatic module insertion and tightening, busbar assembly, wire harness connection, EOL testing, upper cover installation, charge and discharge testing, and leakage testing. Leveraging LEAD’s intelligent logistics and MES systems, our production lines consistently achieve a yield rate exceeding 99% and an availability rate surpassing 95%.

CTP Turnkey Solutions for Automotive Manufacturing

Drawing on extensive domestic and international experience in module and pack lines, LEAD has equipped itself with cutting-edge technology for a self-developed CTP production line. Additionally, LEAD has the synchronous engineering capability to co-develop the next generation of CTP products with its customers. The company has achieved an automation rate of over 85% and compatibility with more than five variants on its intelligent production line. This line accommodates various battery types, including prismatic cells, pouch cells, cylindrical cells, and large cylindrical cells. LEAD offers optimal CTP solutions, significantly enhancing product performance while reducing the production line’s footprint.

Comparison Table of LEAD vs others

Item

LEAD MODULE/PACK/CTP TURNKEY SOLUTION

Conventional Prismatic Line (Separately-supplied)

Whole Line Planning & Designing Capability

Taking all aspects of the process into consideration, the on-site connection for customers is smooth, with high automation rates, rapid productivity improvement, and reduced effort on the part of the customer.

The overall layout is well-designed, with seamless integration between each equipment and logistics, ensuring a smooth connection throughout the entire production line.

Standardized design: The entire production line follows unified design standards and modular design, allowing for high interchangeability between components. This reduces the difficulty of debugging and maintenance while minimizing unnecessary spare parts and maintenance costs. All equipment shares consistent standards in appearance, interior design, wiring, and layout.

Using multiple pieced-together equipment requires customers to undertake comprehensive line planning and integration, leading to complex technical and commercial communications. This elongates the setup period, and after production begins, the capacity ramp-up is slow, demanding significant manpower and resources from the customer.

Outsourcing to multiple equipment manufacturers necessitates customer-led collaboration, resulting in difficulties in layout coordination and management. The response efficiency for integration is low, posing challenges in coordination and communication.

Due to the different manufacturers’ designs, standards vary, and interchangeability between components is limited. Additionally, there are inconsistencies in equipment appearance, interior design, wiring, and layout standards, resulting in unevenness and lack of uniformity.

Whole Line Efficiency

The designed production capacity of the LEAD module/PACK/CTP battery assembly line can achieve 30 JPH (Joints Per Hour), with stable output exceeding 30 JPH.

The designed production capacity is above 20 JPH (Joints Per Hour).

Whole Line Comprehensive Availability

On average, achieving over 85%.

The average utilization rate of multi-vendor assembly lines is around 70% to 75%.

Product First Time Yield

The first-pass yield rate of the LEAD production line’s products can reach 99%.

The average utilization rate of multi-vendor assembly lines is approximately 88%.

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Production line requirements

What we supply

Benefit

Production line requirements

Item

280 Prismatic Cell Energy Storage Overview

Cell Model

Cell：71173207
Module：1p13s
Pack：1p52s

Compatibility

Cell：L:30-75，W:170-220，H:80-220
Module：1p8s-1p16s
Pack：1p32s-1p6416s
Container：20inch-45inch

Process

cleaning&gluing，cell stacking，tab welding，module testing，pack gluing，pack busbar assembly&tightening，pack upper housing assembly，container pack insertion，container pack tightening

What we supply