With the rapid development of the energy storage market, the battery PACK, as the core component of system integration, is bearing higher quality standards and delivery efficiency requirements, transitioning from “productivity” to “smart manufacturing capability.” Today, let’s step into CHISAGE ESS’s Phase II battery Pack automation production line and explore this “efficient, intelligent, and reliable” new engine of smart manufacturing.
|Accelerating through automation
The Phase II battery PACK production line of CHISAGE ESS is systematically designed around “automation + standardization.” Key processes are fully automated, including cell feeding, cell sorting, module assembly, laser cleaning, safety testing, and final inspection with aging. With highly coordinated equipment, the line achieves a processing efficiency of 10 PPM and a first-pass yield of ≥99.5%, with a final yield of ≥99.8%. This ensures more stable and faster delivery capabilities for customers worldwide.
|Self-developed MES system
The entire production line is equipped with our self-developed MES system, enabling real-time data collection, precise analysis, and efficient transmission throughout the manufacturing process. From the barcode scanning of each individual cell upon warehousing to status updates at every production step, the system records key process parameters in real time. This provides robust data support for production decision-making and quality control, truly realizing a data-driven approach to smart factory management.
|Flexible equipment manufacturing
The automated equipment features high flexibility, compatible with 50Ah to 314Ah cells and mainstream cell models. It fully supports a wide range of applications—from residential energy storage to commercial and industrial liquid-cooled systems—meeting global market demands for diverse capacities, voltages, and integration formats.
|Refining key processes
1. The robotic system in the cell feeding stage is equipped with five grippers and two sets of CCD vision systems, enabling precise cell handling and real-time monitoring. It also performs automatic barcode scanning and data entry, ensuring high feeding accuracy and information consistency.
2. In the laser welding process, CHISAGE ESS adopts top-tier German IPG laser equipment and applies high-energy-density laser welding technology to achieve precise alignment between the aluminum busbars and the cell tabs. This process ensures consistent welding depth and weld width, significantly reduces contact resistance, and enhances the energy transmission efficiency of the battery module. The welding system features a “4+2kW” annular spot design, delivering 4kW at the center and 2kW on the outer ring. The entire welding process is spatter-free with a minimal heat-affected zone, effectively preventing internal damage to the cells and further ensuring the safety and service life of the battery.
3. For commercial and industrial liquid-cooled energy storage products, the production line is equipped with a fully automated enclosure dispensing machine. By using high thermal conductivity adhesive materials, an efficient heat transfer path is established between the enclosure and the battery module. In combination with the liquid cooling plate design, this setup significantly reduces temperature differences between cells and enhances the overall thermal balance and heat dissipation efficiency of the battery pack.
|End-to-end quality control
CHISAGE ESS upholds a rigorous, full-process quality control philosophy that spans its entire product range. Before entering the production line, battery cells undergo OCV testing to sort by internal resistance, voltage, and other parameters, ensuring high consistency within each module. At the final stage, every PACK must pass insulation and withstand voltage tests, along with end-of-line (EOL) functionality checks to comprehensively validate electrical performance and system safety. Additionally, 100% of products undergo aging tests, during which they are deeply integrated and tested with in-house inverters on the company’s self-developed testing platform. This effectively simulates real-world application scenarios, further verifying long-term operational stability and compatibility.
The commissioning of CHISAGE ESS’s Phase II automated battery PACK production line marks not only a leap forward in manufacturing capabilities, but also a strategic upgrade in building a high-standard delivery system for the global market. Looking ahead, CHISAGE ESS will continue to focus on intelligent manufacturing as its core driving force, leveraging data-driven management and technology-driven innovation. With more flexible, efficient, and reliable products and solutions, we are committed to serving diverse energy storage scenarios worldwide and empowering the industry toward a new stage of high-quality development.
