testing a lithium battery

Advanced Automatic Formation and Grading System for Cylindrical Lithium-Ion Batteries – High-Efficiency, Smart Manufacturing Solution

This state-of-the-art automated production line is engineered specifically for high-volume manufacturing of cylindrical lithium-ion cells such as 18650 and 21700 formats. Designed with seamless integration of intelligent logistics, ultra-precise battery testing, and modular adaptability, this system delivers up to 1.3 million units per day while maintaining exceptional consistency, traceability, and energy efficiency. It represents a cutting-edge solution for modern battery factories seeking to optimize throughput, reduce operational costs, and support next-generation battery development.

Key Features That Set This Line Apart:

At the heart of this system lies a fully integrated smart material handling architecture powered by 16 AGV robots and 12 MCR composite manipulators. These components ensure continuous pallet movement at 4.17 turnovers per hour and enable rapid tooling changes—reducing setup time by 40% compared to conventional setups. With 3D vision positioning accuracy within ±0.5mm using QR code recognition, material boxes are precisely aligned, minimizing errors and boosting overall equipment effectiveness (OEE). The system supports load capacities up to 2000kg, making it ideal for large-scale industrial operations.

The formation and grading segment includes a 500-pin bed capacity sorting unit and four high-speed OCV testers capable of real-time voltage and internal resistance measurements across 12 critical parameters. Each cell undergoes multi-level classification (OCV0/1/2), ensuring pass rates exceeding 99.9%. Advanced four-wire measurement technology ensures contact resistance below 1 milliohm, enabling micro-level parameter adjustments essential for performance validation in R&D environments. Additionally, regenerative energy systems achieve charging efficiencies above 80% and discharging efficiencies over 70%, reducing annual electricity consumption by more than 30%—a major advantage for sustainable manufacturing practices.

Integrated with an MES-based production management platform, every battery’s journey—from raw input to final grade—is tracked through more than 20 process variables. This full-process traceability enhances quality control, accelerates root cause analysis, and meets stringent compliance standards required in automotive-grade and energy storage applications. The modular design allows fixture and probe components to be replaced independently in under three hours, supporting flexible production runs for different cell sizes and chemistries without costly downtime.

Optimized for Real-World Applications:

This system excels in mass-producing power batteries for electric vehicles, portable electronics, and grid-scale energy storage solutions. Whether deploying standard 18650 or emerging 21700 configurations, the line adapts quickly to varying output demands. For research and development teams, its precision data capture capabilities provide reliable insights into electrode materials, electrolyte behavior, and cycling stability—accelerating innovation cycles. It also supports specialized processes like forming large-format cells over 100Ah, ensuring uniformity and safety in high-capacity packs used in residential and commercial storage systems.

User Feedback Highlights:

Operators worldwide praise the intuitive interface, minimal manual intervention, and consistent product quality. One facility manager noted that after implementing this system, their daily yield increased by 35%, and maintenance incidents dropped significantly due to predictive diagnostics embedded in the software. Another user emphasized how the intelligent logistics reduced bottlenecks during peak production periods, allowing smoother transitions between batches—a key factor in meeting tight delivery schedules.

Frequently Asked Questions:

Is this system suitable for small batch production? Yes, thanks to its modular structure and quick-change fixtures, it can efficiently handle both high-volume and low-volume orders with minimal reconfiguration time. Can it accommodate custom cell formats beyond 18650 and 21700? Absolutely—the design supports various cylindrical dimensions, enabling manufacturers to scale production based on evolving market needs. How does it contribute to sustainability goals? Through regenerative energy recovery and optimized power usage, it lowers carbon footprint while increasing productivity. What kind of technical support is available? A dedicated global service network offers 72-hour response times and lifetime software updates to keep the system operating at peak performance and aligned with technological advancements.