Car battery assembly line

For decades, lead-acid has been the dominating technology in the car battery market. Although that has started to change, most analysts predict that demand for starter and other lead-based car batteries will remain stable in the near future – in fact, it may actually rise due to regional differences in the pace of adoption of electric vehicles (which mostly rely on lithium- or hydrogen-based batteries).

As with any mature technology, battery manufacturers expect an automotive battery assembly line to be highly dependable and work on an almost nonstop basis. For companies with a wide product portfolio counting many different battery types, with ranges that can go from 38 or 40 to 200 Ah, it is of critical importance that changeover and adjustment are as efficient and straightforward as possible.

With over 30 years of experience in the field, BTS can easily meet those requirements. Our semi. and fully auto. car battery assembly lines are designed according to modular design principles and are particularly compact, allowing our customers to save valuable space on the factory floor.

Like most BTS equipment, they are tailor-made to each customer's requirements, and include many clever solutions for reducing changeover time and improving product quality:
• We offer advanced testing systems for use both before and after the welding of the inter-cell connections, allowing to detect COS and welding issues.
• For inter-cell welding, customers can choose between three different technologies: pneumatic, hydraulic or our most advanced servo-controlled welding jaw. An exclusive, patented formula, developed by our engineers and fine-tuned for each customer’s batteries, is used to control weld squeeze distance and pressure settings. An optional terminal alignment system can be added for even more accurate results.
• Our single touch detection function automatically detects the most suitable heat sealing settings for each battery type. With an optional pre-heating station, it is possible to heat 2 sets of tooling simultaneously.
• BTS pole burning machines are designed for efficiency, allowing to achieve excellent results with the lowest possible consumption.
• A combined leak test and (if required) coding machine rounds up the line and can perform both negative and positive pressure tests. It can check each cell individually and is capable of detecting leaks between cells.

Like all newer BTS machines, our car battery assembly lines use a state-of-the-art, network capable PLC and can be upgraded with our optional Industry 4.0 feature package, which includes automatic data export functions, remote access capabilities and our exclusive mobile apps for production monitoring and maintenance purposes.
Car battery assembly line
Auto. car battery post burning machine
Auto. car battery post burning machine
Auto. car battery TIG welding machine
Auto. car battery leak test and coding machine
Auto. car battery leak test and coding machine
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