Robotic assembly line

automatedfor weldingfor electric cells

Overview
Automated production lines for EV battery assembly, welding and testing. IPG Photonics Corporation delivers configurable systems that integrate cell loading, singulation, high‑speed fiber‑laser cell‑to‑busbar welding, digital weld testing and module/pack assembly. Lines support prismatic, cylindrical, pouch and blade cell formats and can include process development, custom tooling, installation and service.

Key features

• Fully automated battery assembly, welding and test lines
• Configurable for prismatic, cylindrical, pouch and blade cells
• High‑speed fiber‑laser welding (AMB, single‑mode) and OTF capability
• Integrated process monitoring, digital weld testing and full traceability
• Options for real‑time in‑process weld measurement and NDT

Process flow (typical)

• 1. Cell loading & inspection — incoming cells are singulated, inspected and sorted on a conveyor; conforming cells are placed into module frames, nonconforming cells are rejected.
• 2. Cell‑to‑busbar welding — optimized fiber lasers weld cells to busbars on modules using adjustable parameters to maximize speed while minimizing spatter.
• 3. Digital weld testing — non‑destructive resistance measurements (bed‑of‑nails) verify each weld; 100% of test data is logged for traceability.
• 4. Module assembly & sealing — case assembly and robotic wobble welding or seam welding ensure hermetic seals; sealed packs undergo final functional tests.

Lasers & beam delivery

• Adjustable Mode Beam (AMB) dual‑beam lasers to reduce weld defects while maintaining throughput
• On‑The‑Fly (OTF) welding for precise seams with moving heads (configurations capable of >10 cells/s)
• High‑power single‑mode fiber lasers optimized for reflective metals (copper, aluminum)
• Optional real‑time weld measurement and patented in‑process monitoring for 100% weld QA and process drift alerts

Additional manufacturing capabilities

• Electrode foil cutting and notching
• Drying of electrode slurries on anode/cathode foils
• Laser cleaning for refurbishment, recycling and surface preparation without aggressive chemicals
• Case marking for identification and traceability

Technical specifications

• Product family: EV Battery Manufacturing Lines
• Manufacturer: IPG Photonics Corporation
• Product type: automated battery assembly, welding and testing systems
• Supported cell formats: prismatic, cylindrical, pouch, blade
• Primary functions: cell singulation & inspection; cell‑to‑busbar welding; digital weld resistance testing; module assembly and pack sealing
• Welding technologies: fiber lasers (AMB dual‑beam, single‑mode high‑power), OTF
• Quality: optional real‑time in‑process weld measurement; 100% test data logging for traceability
• Typical performance: welding configured to exceed 10 cells/s depending on cell type and line configuration
• Scope of supply: modular systems to full production lines, process development, custom tooling, installation and service