EV Battery Module Line Delivers 500K Units Annually
High-volume battery module assembly with integrated testing and thermal management
Project Overview
The electric vehicle revolution is creating unprecedented demand for battery manufacturing capacity. When a leading EV battery manufacturer secured contracts to supply modules for three major automakers, they needed to build production capability from the ground up—and fast.
AMD Automation was selected to design and build a complete battery module assembly line capable of producing 500,000 modules annually, with the flexibility to scale to 750,000 as demand grows.
Safety-First Design
Battery manufacturing presents unique safety challenges. High-voltage components, flammable electrolytes, and the risk of thermal runaway require careful engineering at every step.
Electrical Safety
- All robot cells rated for work on energized systems (NFPA 70E compliant)
- Automatic grounding verification before any operation
- Hi-pot testing at multiple stages catches insulation defects
- Emergency disconnect systems throughout the line
Thermal Monitoring
- Infrared cameras monitor cell temperatures in real-time
- Automatic rejection of any cells showing thermal anomalies
- Fire suppression systems at critical stations
- Thermal runaway containment in testing areas
Mechanical Safety
- Category 4, Performance Level e safety systems
- Light curtains and area scanners at operator interfaces
- Safe speed monitoring for collaborative operations
- Emergency stop coverage throughout
Process Flow
The line performs complete module assembly from incoming cells to packaged product:
Zone 1 - Cell Preparation - Incoming cell testing and sorting - Polarity and voltage verification - Vision-guided cell stacking
Zone 2 - Module Assembly - Cell-to-busbar laser welding - Weld quality verification - Thermal interface material dispensing
Zone 3 - Electrical Integration - BMS installation and connection - Harness routing and termination - Insulation resistance testing
Zone 4 - Final Test & Pack - Full electrical characterization - Capacity and impedance testing - Labeling and packaging
Scaling for Growth
The modular design allows capacity expansion without major reconstruction:
- Additional cell preparation stations can be added inline
- Parallel test stations accommodate longer test cycles
- Buffer systems smooth flow between zones
- MES integration enables real-time capacity management
Customer Testimonial
"AMD Automation delivered a production line that met our aggressive timeline while exceeding our quality and safety requirements. Their understanding of high-voltage battery manufacturing was evident in every design decision. We're already planning the next line expansion with them."
— Director of Manufacturing, EV Battery Manufacturer
01The Challenge
A major EV battery manufacturer needed to rapidly scale production to meet OEM commitments. The line required handling high-voltage components safely while maintaining the precision and speed necessary for automotive production volumes.
- 500,000 annual production target with growth potential
- High-voltage safety requirements (400V+ systems)
- Thermal runaway prevention critical for safety
- 100% electrical testing and traceability required
- 24/7 operation with minimal downtime
02Our Solution
AMD Automation designed a comprehensive battery module assembly line integrating cell handling, module assembly, welding, testing, and packaging—all with built-in safety systems for high-voltage operations.
Automated Cell Handling
Vision-guided robots sort, orient, and stack cylindrical cells with polarity verification and voltage testing at each step.
Precision Laser Welding
Fiber laser welding system creates reliable interconnects between cells with real-time weld quality monitoring and thermal imaging.
Integrated Test Systems
Each module undergoes insulation resistance testing, hi-pot testing, and capacity verification before proceeding downstream.
Thermal Management Integration
Automated dispensing of thermal interface material ensures consistent heat transfer from cells to cooling plates.
03The Results
The line achieved full production rate within 60 days of installation and has maintained 99.9% uptime through its first year of operation. The integrated quality systems have kept defect rates below 1 ppm.
Technical Specifications
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