Semi-automatic Drone Lithium-ion Battery Pack Assembly Line

Product Overview

ACEY-PAL-UAV Lithium Ion Battery Pack Assembly Line is designed for assembling high-rate lithium pouch battery packs used in UAVs, agricultural drones, inspection drones, mapping drones, and other unmanned aerial systems.

The assembly line covers the main processes from pouch cell capacity grading and OCV/IR sorting to tab cutting, ultrasonic tab welding, BMS testing, comprehensive pack testing, and charge/discharge aging. Each workstation can be configured according to the pouch cell dimensions, battery pack structure, series-parallel configuration, voltage, current, production capacity, and testing requirements.

Process Flow

• Cell Capacity Grading
• OCV & IR Sorting
• Cell Tab Cutting
• Ultrasonic Tab Welding
• BMS Testing
• Pack Comprehensive Testing
• Insulation Film Heat Shrinking
• Inkjet Coding
• Charge/Discharge Aging Testing

Key Features

• Complete semi-automatic solution from individual pouch cell testing to finished battery pack aging.
• Suitable for high-rate pouch battery packs used in drones and UAV applications.
• Modular workstation design allows flexible equipment selection and production layout.
• Supports customized fixtures for different pouch cell sizes and tab spacing.
• Accurate cell capacity, voltage, and internal resistance classification improves pack consistency.
• Ultrasonic tab welding provides reliable connections with low contact resistance.
• BMS and comprehensive testing stations verify major electrical and protection functions.
• Programmable charge/discharge aging supports long-cycle reliability testing.
• Testing voltage, current, channel quantity, and equipment configuration can be customized.

Assembly Process

1. Pouch Cell Capacity Grading

   The pouch cell capacity grading machine performs controlled charging and discharging to measure cell capacity, voltage, and charge/discharge performance. Cells can then be classified according to the preset grading criteria.

   Main Specifications

   Item	Specification
   Equipment	Pouch Cell Capacity Grading Machine
   Model	ACEY-PCT Series
   Number of Channels	64 / 128 / 160 / 256
   Battery Type	Lithium pouch cell
   Cell Fixture	Blue and white clamp
   Fixture Spacing	Customized according to cell dimensions
   Charge Voltage Range	DC 0–4.5 V
   Discharge Voltage Range	DC 4.5–2 V
   Current Range	20 A / 30 A / 40 A / 60 A, customizable
   Power Supply	Three-phase five-wire AC 380 V ±10%, 50 Hz
   AC Current Distortion	≤5%
   Working Temperature	−10°C to 40°C
   Relative Humidity	≤80%

   

2. Pouch Cell OCV and Internal Resistance Sorting

   The pouch cell sorting machine measures cell voltage and internal resistance before automatically classifying cells into different channels. Cells with similar electrical performance can be grouped together to improve battery pack consistency.

   Main Specifications

   Item	Specification
   Equipment	Pouch Cell OCV/IR Sorting Machine
   Model	ACEY-PCSM Series
   Production Efficiency	8–10 PPM
   Equipment Utilization	≥95%
   Sorting Channels	5 qualified and 1 unqualified
   Optional Channels	5–7 channels, customizable
   Applicable Cell Length	50–170 mm
   Applicable Cell Width	20–100 mm
   Applicable Cell Thickness	4–20 mm
   Control System	Industrial PC with embedded control system
   Display	21.5-inch display
   Input Power	1 kW
   Power Supply	AC 220 V, 50 Hz
   Compressed Air	≥0.6 MPa
   Reference Dimensions	1800 × 1570 × 1750 mm
   Optional Configuration	Internal resistance tester and barcode scanner

   

3. Pouch Cell Tab Cutting

   The tab cutting machine trims the positive and negative cell tabs to the specified dimensions. Consistent tab width and position help prepare the cells for subsequent grouping and ultrasonic welding.

   Main Specifications

   Item	Specification
   Equipment	Pouch Cell Tab Cutting Machine
   Model	ACEY-PTC560
   Applicable Battery	Lithium pouch cell
   Positive Tab Width	5–60 mm
   Negative Tab Width	5–60 mm
   Tab Center Distance	12–150 mm
   Maximum Input Power	≤500 W
   Power Supply	AC 220 V ±10%, 50–60 Hz
   Machine Dimensions	450 × 310 × 210 mm
   Machine Weight	Approximately 14 kg

   

4. Ultrasonic Cell Tab Welding

   The ultrasonic welding machine connects the positive and negative tabs of grouped pouch cells. It is suitable for welding aluminum tabs and nickel-coated copper tabs without requiring additional soldering material.

   The welding process provides high efficiency and low connection resistance, making it suitable for high-capacity and high-discharge-rate drone battery packs.

   Main Specifications

   Item	Specification
   Equipment	Pouch Cell Tab Ultrasonic Welding Machine
   Model	ACEY-SWM-20-6000
   Applicable Material	Aluminum and nickel-coated copper tabs
   Base Material Thickness	0.2 mm
   Welding Configuration	Two-layer tab welding
   Typical Welding Material	Two layers of 0.2 mm aluminum or nickel-coated copper
   Welding Area	20 × 4 mm
   Welding Head Direction	Horizontal, four-surface design
   Welding Time	0.1–0.8 s; programmable up to 60 s
   Welding Pressure	0.1–0.6 MPa
   Ultrasonic Frequency	20 kHz ±200 Hz, automatic tracking
   Manual Head Stroke	10–15 mm
   Maximum Input Power	6000 VA
   Welding Modes	Time, energy, and segmented modes

   

5. BMS Protection Board Testing

   The BMS tester checks the protection parameters and communication functions of the battery management system before final pack testing. It can be configured for different series counts and current levels.

   The system supports both conventional hardware BMS boards and smart BMS boards with UART, CAN, or RS485 communication.

   Main Specifications

   Item	Specification
   Equipment	BMS Protection Board Testing Machine
   Model	ACEY-BP Series
   Supported Series	20S / 24S / 32S and other customized configurations
   Overcharge Voltage	500–5000 mV, accuracy ±1 mV
   Overdischarge Voltage	500–5000 mV, accuracy ±1 mV
   Overdischarge Protection Current	120 A / 200 A / 300 A / 400 A / 500 A / 600 A
   Maximum Charge Current	50 A / 100 A / 200 A / 300 A
   Maximum Output Voltage	5000 mV per cell simulation channel
   Resistance Test Range	0–999 mΩ, accuracy ±1 mΩ
   Short-Circuit Protection Time	0–5000 μs, accuracy ±1 μs
   Communication	UART / CAN / RS485
   BMS Type	Hardware BMS and smart BMS
   Standard Configuration	Industrial PC and equipment cabinet

   

6. Battery Pack Comprehensive Testing

   The battery pack comprehensive tester verifies the electrical and protection performance of the assembled drone battery pack. It can test pack voltage, internal resistance, charging and discharging current, short-circuit protection, overcurrent delay, and temperature sensor resistance.

   Main Specifications

   Item	Specification
   Equipment	Battery Pack Comprehensive Testing Machine
   Model	ACEY-BIT Series
   Voltage Range	60 V / 100 V / 120 V / 150 V
   Internal Resistance Range	0–2000 mΩ
   Charge Current	30 A / 50 A / 100 A
   Discharge Current	120 A / 200 A / 300 A / 400 A / 500 A
   Short-Circuit Time	0–2000 μs
   Overcurrent Delay Time	0–30 s
   NTC Test Range	0–100 kΩ
   R1 Test Range	0–100 kΩ
   Power Supply	AC 200–240 V
   Standard Configuration	Industrial PC and equipment cabinet

   

7. Battery Pack Insulation Film Heat Shrinking

   The heat shrinking machine is used to tightly wrap the assembled drone battery pack with insulation film. Controlled heating shrinks the film evenly around the battery pack, providing electrical insulation, surface protection, and a neat finished appearance.

   The heating temperature and conveying speed can be adjusted according to the battery pack dimensions and heat-shrink film material.

   Main Specifications

   Parameter	Specification
   Item No.	ACEY-5035C
   Power supply	380V50-60HZ
   Power	15KW
   Tunnel Dimensions	Shrinking tunnel size: L1800 x W500 x H350mm
   	*Effective size: W400 x H300mm
   Transporting velocity	0-15m/min
   Conveying material	Mesh
   Conveyor loading	25kg max
   Machine size	2100mm x750mm x1620mm (L* W * H)
   Weight	around 200kg
   Shrink film	PE,POF,PVC,PP

   

8. Battery Pack Inkjet Coding

   The inkjet coding machine prints production information on the battery pack surface or insulation film after heat shrinking. Printable information includes the product model, production date, batch number, serial number, voltage, capacity, barcode, and QR code.

   The coding content can be edited through the control system and connected to the production management system when traceability is required.

   Main Specifications

   Parameter	Specification
   Item No.	ACEY-CPM-2
   Printing	1-41ines(7x5matrix)
   	1-51ines(5x5matrix)
   	Maximum speed=450m/min@5x5,350m/min@7x5,100m/min@16x16
   Character display size	5x5,7x5,9x7,12x9,16x11,19x14,24x17,32x22,cn12x12,16x16
   Character height	1-15mm
   Printing distance	2-20mm
   Optimum distance	10mm
   Printing direction	360°
   Operating system	QBGenL Chinese and English are available
   Printable Characters	English, simplified Chinese, Arabic numerals, serial number, bar code, time, date, trademark pattern, special font
   Communication port	SDCard, synchronizer interface, alarm input / output interface, RS485
   Save information:	68 pieces of printing information & 50 pieces of pattern information
   Sprinkler	60um constant temperature gemstone nozzle, automatic cleaning
   Degree of protection	IP55
   Temperature/Humidity	0-45℃,0-95%
   NW.	24kg
   Chassis	304 Stainless steel body

   

9. Battery Pack Charge/Discharge Aging

   The battery pack aging machine performs programmable charging and discharging cycles under controlled conditions. It is used to evaluate battery pack capacity, cycling performance, energy efficiency, temperature behavior, and long-term stability before shipment.

   Main Specifications

   Item	Specification
   Equipment	Battery Pack Charge/Discharge Aging Machine
   Model	ACEY-BA Series
   Single-Channel Voltage	60 V / 100 V / 120 V / 150 V / 200 V / 300 V / 750 V
   Charge/Discharge Current	50 A–1000 A, customizable
   Number of Channels	1 / 2 / 4 / 8 / 16 / 32
   Channel Operation	Each channel operates independently
   Charging Modes	CC / CV / CCCV
   Discharging Modes	Constant current / constant power / constant resistance
   Cut-Off Conditions	Time, voltage, current, capacity, −ΔV, cell voltage and RSOC
   Accuracy	±0.05% FS + 0.05% RD
   Maximum Cycle Count	9999
   Maximum Programmable Steps	9999
   Nested Loops	Up to 10 levels

   

Customizable Configuration

• Pouch cell length, width, and thickness
• Cell capacity and discharge rate
• Battery pack series and parallel configuration
• Pack voltage and rated capacity
• Maximum charging and discharging current
• Cell sorting channel quantity
• Capacity grading channel quantity
• BMS communication protocol
• Testing voltage and current range
• Aging channel quantity
• Production capacity and factory layout
• Manual worktables, fixtures, and material handling requirements

Why Choose This Assembly Line?

The line combines cell consistency control, reliable tab connection, BMS verification, finished-pack electrical testing, and programmable aging in one modular solution. It helps manufacturers establish a controlled and traceable production process for high-rate pouch cell drone battery packs while retaining flexibility for different battery designs and production volumes.

FAQ

What type of cells can this assembly line process?
The standard solution is designed for lithium pouch cells. Cell fixtures, sorting channels, and tab cutting parameters can be customized according to the actual cell dimensions.

Is the line suitable for different drone battery voltages?
Yes. The BMS tester, comprehensive tester, and aging machine can be configured according to the battery pack’s series count, operating voltage, and current requirements.

Can it test smart BMS boards?
Yes. The BMS testing equipment supports hardware BMS boards and smart BMS boards using UART, CAN, or RS485 communication.

Is the entire production process automatic?
This is a semi-automatic, modular workstation-based solution. Equipment performs the key processing and testing operations, while cell transfer, pack positioning, wiring, and some assembly operations can be completed manually or equipped with customized auxiliary fixtures.

Can the equipment configuration be changed?
Yes. The equipment models, channels, voltage ranges, current ranges, fixtures, and production layout can be customized according to the battery pack design and capacity target.