{"id":2907,"date":"2026-10-01T09:14:29","date_gmt":"2026-10-01T09:14:29","guid":{"rendered":"https:\/\/www.cybernetik.com\/blog\/?p=2907"},"modified":"2026-10-01T09:29:12","modified_gmt":"2026-10-01T09:29:12","slug":"two-wheeler-e-rickshaw-battery-pack-assembly-india-in","status":"publish","type":"post","link":"https:\/\/www.cybernetik.com\/blog\/cleantech\/two-wheeler-e-rickshaw-battery-pack-assembly-india-in\/","title":{"rendered":"Two-Wheeler and E-Rickshaw Battery Pack Assembly in India"},"content":{"rendered":"\n<div class=\"wp-block-group has-white-color has-text-color has-background has-link-color wp-elements-6548dd2a37385b784999873b5c4176e8 is-layout-constrained wp-container-core-group-is-layout-800b4e77 wp-block-group-is-layout-constrained\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px;background-color:#12263a;margin-bottom:20px;padding-top:10px;padding-right:30px;padding-bottom:30px;padding-left:30px\">\n<h2 class=\"wp-block-heading has-white-color has-text-color has-link-color wp-elements-19215f1e6a1396f83f0257af42631315\" style=\"line-height:1.4\">Key takeaways<\/h2>\n\n\n\n<div style=\"height:6px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_24e509-72:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_24e509-72 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items2907_24e509-72 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items2907_24e509-72 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-2907_043443-bf .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_043443-bf\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Two-wheeler and e-rickshaw packs face different operating conditions: Scooter packs commonly use 48\u201372 V systems and face water, dust, vibration, heat, and frequent handling, while e-rickshaw packs experience long operating hours, heavy loads, and deep cycling.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_5a2ff5-ef .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_5a2ff5-ef\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">High cylindrical-cell counts make joint quality critical: Many two-wheeler packs contain hundreds of cells and welds, making joining quality and verification important for long-term reliability under continuous vibration.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_c39942-8f .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_c39942-8f\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Removable packs need robust mechanical and environmental protection: Connectors must withstand repeated mating cycles, while enclosures, seals, fasteners, and internal cell structures need to tolerate drops, impacts, water, dust, and rough handling.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_db0159-ad .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_db0159-ad\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Passive cooling increases the importance of cell matching and thermal design: With most two- and three-wheeler packs relying on passive or air cooling, cell grading, internal layout, and thermal layer placement become particularly important in high ambient temperatures.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_aca90c-85 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_aca90c-85\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Line design must balance high volumes, variant flexibility, and verification: Short takt times, multiple voltage\/capacity variants, and cost pressure favor automation of critical steps such as cell testing, joining, and leak testing while maintaining verification of every cell and joint.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_46e0cb-82 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_46e0cb-82\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\">Cybernetik supports flexible two- and three-wheeler battery assembly: Its capabilities include testing every cell, laser and resistance welding with inline weld checks, placement verification, BMS\/TCU programming, air-leak testing, laser marking, and barcode\/RFID traceability with MES connectivity.<\/span><\/li>\n<\/ul><\/div>\n<\/div>\n\n\n\n<p class=\"has-link-color wp-elements-5de8de41be431b9f4610ec66253e26c7 wp-block-paragraph\">A battery pack in an electric car sits bolted into the floor, cooled by liquid, sheltered from the weather and rarely touched for years. A pack in an Indian electric scooter gets pulled out and carried up stairs to charge, splashed through flooded roads during the monsoon, baked in summer heat and shaken over broken surfaces every day.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The scooter pack is smaller and simpler on paper. In practice it lives a harder life, and the assembly line has to build for that life rather than for the specification sheet.<\/p>\n\n\n\n<p class=\"has-link-color wp-elements-906243e3dbec955e5ce271900d9a6ac5 wp-block-paragraph\">India\u2019s electric vehicle volume sits overwhelmingly in two and three wheelers rather than cars, a pattern covered in the article on <a href=\"https:\/\/www.cybernetik.com\/blog\/cleantech\/ev-battery-production-india-trends-in\/\">EV battery production trends in India<\/a>. This piece looks at what that means for how these packs are actually built.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Smaller Packs, Different Problems<\/strong><\/h3>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th><\/th><th><strong>Electric scooter or motorcycle<\/strong><\/th><th><strong>E-rickshaw<\/strong><\/th><th><strong>Passenger car, for contrast<\/strong><\/th><\/tr><\/thead><tbody><tr><td>Typical system voltage<\/td><td>Commonly 48 to 72 volts<\/td><td>Commonly around 48 to 60 volts<\/td><td>Several hundred volts<\/td><\/tr><tr><td>Pack energy<\/td><td>A few kilowatt-hours<\/td><td>Larger than a scooter, far smaller than a car<\/td><td>Tens of kilowatt-hours<\/td><\/tr><tr><td>Common cell choice<\/td><td>Cylindrical, in high counts<\/td><td>LFP prismatic or cylindrical, chosen for cycle life<\/td><td>Varies widely by platform<\/td><\/tr><tr><td>Cooling<\/td><td>Usually passive or air<\/td><td>Usually passive<\/td><td>Often active liquid cooling<\/td><\/tr><tr><td>Handling in service<\/td><td>Often removed for charging or swapped<\/td><td>Increasingly swapped at stations<\/td><td>Fixed in the vehicle floor<\/td><\/tr><tr><td>Hardest conditions<\/td><td>Water, dust, vibration, heat, drops<\/td><td>Long daily duty, heavy loads, deep cycling<\/td><td>Crash loads and structural duty<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">The last row of that table is the one that shapes assembly most. A car pack is engineered around crash safety and structural duty. A scooter pack is engineered around being handled, dropped, soaked and shaken, and an e-rickshaw pack around being worked hard for long hours every single day. Those are different failure modes, and they call for different emphasis on the line.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Voltage Changes What the Line Needs<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Most two and three wheeler packs run at far lower voltages than car packs, commonly somewhere between 48 and 72 volts. That changes the electrical safety picture on the line compared with a car plant handling packs at several hundred volts.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">It does not remove it. A fully charged pack at these voltages can still deliver very high current into a short circuit, enough to weld a spanner in place or start a fire, and the upper end of that range sits above the level usually treated as safe to touch. The difference is one of degree. Insulated tooling, a defined order for making connections and a clear response to a damaged pack all still apply.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Cylindrical Cells Mean a Lot of Joints<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Many two-wheeler packs use cylindrical cells, and because each cell holds relatively little energy, a pack needs a large number of them. More cells means more joints. A pack that looks modest from the outside can contain hundreds of welds, each one carrying current and each one exposed to vibration for years.<\/p>\n\n\n\n<p class=\"has-link-color wp-elements-c3378b5b2d3c7a1d40ba272e1f8d52c7 wp-block-paragraph\">That shifts the weight of quality control toward joining. The choice between resistance welding, laser welding and wire bonding, and how each is checked, is covered in the guide to <a href=\"https:\/\/www.cybernetik.com\/blog\/cleantech\/laser-welding-vs-wire-bonding-cell-interconnects-in\/\">laser welding and wire bonding for cell interconnects<\/a>. Whichever method is used, a joint count in the hundreds is exactly the situation where sampling stops being meaningful and every joint needs checking.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<figure class=\"wp-block-image size-full has-custom-border\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1920\" height=\"1080\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing.webp\" alt=\"\" class=\"wp-image-2506\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px\" srcset=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing.webp 1920w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing-300x169.webp 300w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing-1024x576.webp 1024w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing-768x432.webp 768w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/08\/How-Automation-Is-Transforming-EV-Battery-Manufacturing-1536x864.webp 1536w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Built to Be Carried<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Removable packs are common on Indian scooters because many owners do not have a charging point where they park. A pack that gets lifted out and carried around faces demands a fixed pack never sees.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Connectors<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">The connector between pack and vehicle may be mated and unmated every day for years. A connector rated for a modest number of cycles, or one that allows dirt into the contact area, becomes a source of heating and intermittent faults long before the cells wear out.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Drops and knocks<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A pack that gets carried will eventually get dropped. Enclosure strength, how cells are held inside and how well the internal structure absorbs a shock all decide whether a drop is harmless or starts a slow internal fault.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Enclosure robustness<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">A casing that is scuffed, knocked and set down on rough floors every day needs more margin than one that sits untouched under a car. Seals and fasteners have to survive that treatment and still keep water out.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Monsoon and Dust<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Water is the enemy of any battery pack, and Indian roads during the monsoon test that thoroughly. A scooter pack sits low, close to spray and standing water, and waterlogged streets can submerge it briefly.<\/p>\n\n\n\n<p class=\"has-link-color wp-elements-cfc77353bbdfa8baa75e9da6bc34a2d2 wp-block-paragraph\">That makes sealing one of the most important things the line gets right, and leak testing one of the most important checks. How that testing works, and why temperature affects the result so strongly, is covered in the article on <a href=\"https:\/\/cleantech.cybernetik.com\/blog\/battery-enclosure-leak-testing\">leak testing methods for battery enclosures<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Dust matters too, especially for anything with vents, connectors or gaps. Fine dust mixed with moisture forms a conductive paste over time, which is a slower route to the same kind of failure water causes quickly.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Heat Without Liquid Cooling<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Most two and three wheeler packs rely on passive or air cooling rather than liquid systems. Add high ambient temperatures across much of India and the thermal margin gets thin.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Without a liquid system to even out temperatures, the pack depends on its internal layout, the materials between cells and the enclosure, and above all on the cells being well matched. A cell that runs a little warmer than its neighbors ages faster, which makes it warmer still, and in a pack with no active cooling to pull that difference back there is nothing to stop the gap widening.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The practical result is that cell grading and thermal layer placement matter more in these packs, not less, even though the packs are smaller and cheaper.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Vibration and Road Conditions<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Scooters and rickshaws transmit far more road vibration to their batteries than cars do, and many roads add potholes and speed breakers on top. That vibration works on every joint, bracket and cable inside the pack continuously.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A weld that is slightly weak will usually pass every test on the day it is made. Months of vibration are what find it. The same goes for a cable routed against a sharp edge or a cell held a little loosely. These are assembly details, and in this segment they decide whether a pack lasts its expected life.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>E-Rickshaws Are a Different Duty<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">E-rickshaws deserve separate treatment because their use pattern is unlike a private scooter\u2019s.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A private scooter is ridden for short trips and parked most of the day. An e-rickshaw often runs for long hours with heavy passenger loads and gets drained deeply before charging, day after day. That is a demanding cycle, and it is a big part of why lithium iron phosphate has gained ground in this segment, since it tolerates repeated deep cycling well and stays thermally stable.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The segment has also been moving away from lead-acid batteries toward lithium, which changes what operators expect. A lithium pack costs more upfront and is expected to last much longer, so a pack that fails early does far more damage to trust than a cheap lead-acid battery ever did.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Battery Swapping Raises the Stakes on Identity<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Swapping is growing fastest in exactly these segments, particularly for commercial fleets. A rider pulls into a station, hands over a depleted pack and leaves with a charged one in a couple of minutes.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">That model changes the life of a pack completely. Instead of living in one vehicle, a swappable pack passes through dozens or hundreds of them, each with a different rider and duty. Tracking its health, its history and any fault it has shown becomes essential, because the operator needs to know which packs are aging faster and why.<\/p>\n\n\n\n<p class=\"has-link-color wp-elements-e4e5e027ba13f96f866eade76b3c1403 wp-block-paragraph\">All of that depends on every pack carrying a reliable identity from the day it was built, with its build record attached. How that works on the line is covered in the article on <a href=\"https:\/\/www.cybernetik.com\/blog\/cleantech\/battery-pack-traceability-mes-integration-in\">battery pack traceability and MES integration<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Swapping also pushes toward standard pack sizes and connectors so that one station can serve many vehicles. For manufacturers that means building to tight dimensional tolerances, because a pack that does not fit the slot is useless regardless of its cells.<\/p>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group is-nowrap is-layout-flex wp-container-core-group-is-layout-7387b849 wp-block-group-is-layout-flex\">\n<p class=\"has-text-align-left wp-block-paragraph\" style=\"font-size:29px\"><img decoding=\"async\" class=\"wp-image-503\" style=\"width: 65px\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/Frame-1.svg\" alt=\"\"><strong>&#8220;As battery swapping expands, pack identity and traceability become essential for tracking health, service history, and performance across multiple vehicles.&#8221;<\/strong><\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-group has-luminous-vivid-amber-color has-text-color has-link-color has-medium-font-size wp-elements-6bc6b22d4811b996eac9b48d6a42bdf4 is-horizontal is-content-justification-left is-nowrap is-layout-flex wp-container-core-group-is-layout-e8523bbf wp-block-group-is-layout-flex\" style=\"text-decoration:none\">\n<div class=\"wp-block-group is-content-justification-left is-layout-constrained wp-container-core-group-is-layout-d9c85f36 wp-block-group-is-layout-constrained\">\n<figure class=\"wp-block-image alignwide size-thumbnail\" style=\"margin-top:0;margin-right:0;margin-bottom:0;margin-left:0\"><img decoding=\"async\" width=\"150\" height=\"150\" src=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-150x150.png\" alt=\"\" class=\"wp-image-898\" srcset=\"https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-150x150.png 150w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2-300x300.webp 300w, https:\/\/www.cybernetik.com\/blog\/wp-content\/uploads\/2026\/05\/minus-2.webp 512w\" sizes=\"(max-width: 150px) 100vw, 150px\" \/><\/figure>\n<\/div>\n\n\n\n<p class=\"wp-block-paragraph\"><a href=\"https:\/\/cleantech.cybernetik.com\/\" data-type=\"link\" data-id=\"https:\/\/cleantech.cybernetik.com\/\">Cybernetik Cleantech Automation Team<\/a><\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-group is-layout-constrained wp-block-group-is-layout-constrained\">\n<h2 class=\"wp-block-heading\" style=\"font-size:34px\">See it in action<\/h2>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe title=\"EV Battery Pack Assembly Automation | Cybernetik Robotic Automation\" width=\"800\" height=\"450\" src=\"https:\/\/www.youtube.com\/embed\/GlM4ws-HsZI?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n<\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Line Design for This Segment<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Two and three wheeler pack lines tend to share a few characteristics that set them apart from car pack lines.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Pack counts are high and cell counts per pack are lower, so takt times are short and the pack assembly stages often set the pace rather than cell handling. Variant mix is usually wide, with several voltages and capacities built on the same line, which makes quick changeover valuable. And cost pressure is severe, which argues for automating the steps where consistency matters most, such as cell testing, joining and leak testing, while keeping simpler steps manual where that makes sense.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">What should not be traded away for cost is verification. In a segment where packs take this much punishment, the defects that matter most are the ones that pass on the day and fail in the field, and those are only caught by checking every cell and every joint as the pack is built.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Compliance<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">India\u2019s safety framework for these vehicles tightened considerably after the two-wheeler battery fires of 2022. AIS-156 covers electric power train safety, IS 16893 covers lithium-ion cells and IS 17387 covers battery packs. Together they push manufacturers toward documented testing and records for each pack, which is another reason traceability belongs in the line from the start.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>Cybernetik\u2019s Work in This Segment<\/strong><\/h2>\n\n\n\n<p class=\"has-link-color wp-elements-f9c07266bc2da1acf1d497c946e9a6af wp-block-paragraph\">Much of Cybernetik\u2019s battery work has been for exactly this market, with <a href=\"https:\/\/cleantech.cybernetik.com\/solutions\/battery-pack-assembly.html\">battery pack assembly automation<\/a> delivered for manufacturers including Hero MotoCorp, TVS Motor, Livguard and Matter.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><thead><tr><th><strong>Cybernetik pack assembly capability<\/strong><\/th><th><strong>Specification<\/strong><\/th><\/tr><\/thead><tbody><tr><td>Cell formats<\/td><td>Cylindrical 18650, 21700 and 32140, plus prismatic, pouch and blade<\/td><\/tr><tr><td>Cell diameters<\/td><td>32, 33, 35, 40, 42 and 46 mm<\/td><\/tr><tr><td>Line rate<\/td><td>Up to 6,000 cells per hour<\/td><\/tr><tr><td>Incoming verification<\/td><td>OCV, IR and ACIR testing on every cell with robotic sorting<\/td><\/tr><tr><td>Joining<\/td><td>Laser and resistance welding with inline weld integrity testing on both module faces<\/td><\/tr><tr><td>Placement checks<\/td><td>Insulation detection and polarity checking on every unit<\/td><\/tr><tr><td>Pack assembly<\/td><td>Thermal pads and insulation sheets, BMS mounting, gasket and cover assembly<\/td><\/tr><tr><td>End of line<\/td><td>BMS and TCU programming, air leakage testing, electrical testing and laser marking<\/td><\/tr><tr><td>Module flexibility<\/td><td>Assembly lines adaptable to multiple module configurations<\/td><\/tr><tr><td>Traceability<\/td><td>Barcode and RFID capture with MES connectivity and process logging<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Three parts of that specification line up directly with the points above. Weld integrity testing on both module faces addresses the high joint counts and the vibration that finds weak welds. Air leakage testing on every pack addresses monsoon water. And lines adaptable to multiple module configurations suit a segment where several voltages and capacities often share one line.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Cybernetik has been building automation for more than three decades. It is headquartered in Pune with facilities in Gujarat and Raigad and offices in the United States and UAE, and has installed over 6,000 systems in more than 30 countries, including over 400 custom robotic solutions. More background is on the <a href=\"https:\/\/cleantech.cybernetik.com\/about.html\">Cybernetik about page<\/a>.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Why manufacturers choose Cybernetik<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n\n\n<style>.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_887a43-63:not(.this-stops-third-party-issues){margin-top:0px;margin-bottom:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list:not(.this-prevents-issues):not(.this-stops-third-party-issues):not(.tijsloc){margin-top:0px;margin-right:0px;margin-bottom:var(--global-kb-spacing-sm, 1.5rem);margin-left:0px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list{grid-row-gap:35px;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_887a43-63 .kb-svg-icon-wrap{font-size:10px;color:#ef8e27;}.wp-block-kadence-iconlist.kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap .kt-svg-icon-list-single{margin-right:10px;}.kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap, .kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list .kt-svg-icon-list-item-wrap a{line-height:1.2em;}.kt-svg-icon-list-items2907_887a43-63 ul.kt-svg-icon-list .kt-svg-icon-list-level-0 .kt-svg-icon-list-single svg{font-size:20px;}<\/style>\n<div class=\"wp-block-kadence-iconlist kt-svg-icon-list-items kt-svg-icon-list-items2907_887a43-63 kt-svg-icon-list-columns-1 alignnone kt-list-icon-aligntop\"><ul class=\"kt-svg-icon-list\"><style>.kt-svg-icon-list-item-2907_bceff0-28 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_bceff0-28\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Experience in this exact segment. <\/strong>Lines delivered for two-wheeler and energy storage manufacturers rather than adapted from car plant practice.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_94559e-79 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_94559e-79\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Every joint checked. <\/strong>Weld integrity testing on both module faces, which matters when a small pack holds hundreds of welds.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_257941-b9 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_257941-b9\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Every pack leak tested. <\/strong>Air leakage testing before release, for packs that will meet monsoon roads.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_f73d7c-6b .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_f73d7c-6b\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Built for variant mix. <\/strong>Lines adaptable to multiple module configurations, suiting several voltages and capacities on one line.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_d1aa9d-3a .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_d1aa9d-3a\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Identity for swapping. <\/strong>Barcode and RFID capture with MES connectivity, so each pack carries its build record wherever it goes.<\/span><\/li>\n\n\n<style>.kt-svg-icon-list-item-2907_f989b3-85 .kt-svg-icon-list-text mark.kt-highlight{background-color:unset;font-style:normal;color:#f76a0c;-webkit-box-decoration-break:clone;box-decoration-break:clone;padding-top:0px;padding-right:0px;padding-bottom:0px;padding-left:0px;}<\/style>\n<li class=\"wp-block-kadence-listitem kt-svg-icon-list-item-wrap kt-svg-icon-list-item-2907_f989b3-85\"><span class=\"kb-svg-icon-wrap kb-svg-icon-fas_circle kt-svg-icon-list-single\"><svg viewBox=\"0 0 512 512\"  fill=\"currentColor\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\"  aria-hidden=\"true\"><path d=\"M256 8C119 8 8 119 8 256s111 248 248 248 248-111 248-248S393 8 256 8z\"\/><\/svg><\/span><span class=\"kt-svg-icon-list-text\"><strong>Engineering close by. <\/strong>An Indian engineering base, which shortens response time when something needs attention.<\/span><\/li>\n<\/ul><\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-group has-white-color has-text-color has-background has-link-color wp-elements-ac152bf2f15fc4c7252137b9076b5ae4 is-content-justification-space-between is-layout-flex wp-container-core-group-is-layout-bcf883e7 wp-block-group-is-layout-flex\" style=\"border-top-left-radius:5px;border-top-right-radius:5px;border-bottom-left-radius:5px;border-bottom-right-radius:5px;background-color:#12263a;margin-bottom:20px;padding-top:20px;padding-right:30px;padding-bottom:30px;padding-left:30px\">\n<h3 class=\"wp-block-heading has-white-color has-text-color has-link-color wp-elements-f22099acdeda5e510eedec4b07580a36 wp-container-content-29dca9c1\" style=\"font-size:34px;font-style:normal;font-weight:400;line-height:1.4\">Want to know more about our solution?<\/h3>\n\n\n\n<div class=\"wp-block-buttons wp-container-content-69bc4bdf is-content-justification-right is-layout-flex wp-container-core-buttons-is-layout-88867f99 wp-block-buttons-is-layout-flex\" style=\"border-style:none;border-width:0px;border-top-left-radius:0px;border-top-right-radius:0px;border-bottom-left-radius:0px;border-bottom-right-radius:0px;margin-top:0;margin-bottom:0;padding-top:6;padding-right:6;padding-bottom:6;padding-left:6\">\n<div class=\"wp-block-button has-custom-width wp-block-button__width-100 is-style-fill\"><a class=\"wp-block-button__link has-white-color has-text-color has-background has-link-color has-text-align-right wp-element-button\" href=\"https:\/\/meetings-eu1.hubspot.com\/anand-gaikar\" style=\"background-color:#ee8d26;padding-top:10px;padding-right:20px;padding-bottom:10px;padding-left:20px\">Book a call<\/a><\/div>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:25px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading has-large-font-size\"><strong>Frequently asked questions<\/strong><\/h2>\n\n\n<style>.kt-accordion-id2907_c6c3d8-68 .kt-accordion-inner-wrap{column-gap:var(--global-kb-gap-md, 2rem);row-gap:14px;}.kt-accordion-id2907_c6c3d8-68 .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;background:#ffffff;padding-top:var(--global-kb-spacing-md, 2rem);padding-right:var(--global-kb-spacing-sm, 1.5rem);padding-bottom:0px;padding-left:var(--global-kb-spacing-sm, 1.5rem);}.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;border-top-left-radius:0px;border-top-right-radius:0px;border-bottom-right-radius:0px;border-bottom-left-radius:0px;background:#ffffff;font-size:var(--global-kb-font-size-md, 1.25rem);line-height:1.5em;letter-spacing:-0.1px;font-weight:400;text-transform:capitalize;color:#12263a;padding-top:14px;padding-right:10px;padding-bottom:16px;padding-left:16px;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap .kt-blocks-accordion-icon-trigger:before{background:#12263a;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger{background:#12263a;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68 .kt-blocks-accordion-header:focus-visible{color:#12263a;background:#ffffff;border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:before, body:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-blocks-accordion--visible .kt-blocks-accordion-icon-trigger:after, body:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle ) .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:before{background:#ff6900;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger, body:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger{background:#ff6900;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:hover .kt-blocks-accordion-icon-trigger:before, body:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:after, body:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}.kt-accordion-id2907_c6c3d8-68 .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{color:#12263a;background:#ffffff;border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basiccircle ):not( .kt-accodion-icon-style-xclosecircle ):not( .kt-accodion-icon-style-arrowcircle )  > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:before{background:#ff6900;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger{background:#ff6900;}.kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:after, .kt-accordion-id2907_c6c3d8-68:not( .kt-accodion-icon-style-basic ):not( .kt-accodion-icon-style-xclose ):not( .kt-accodion-icon-style-arrow ) .kt-blocks-accordion-header.kt-accordion-panel-active .kt-blocks-accordion-icon-trigger:before{background:#ffffff;}@media all and (max-width: 1024px){.kt-accordion-id2907_c6c3d8-68 .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;}}@media all and (max-width: 1024px){.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;}}@media all and (max-width: 1024px){.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68 .kt-blocks-accordion-header:focus-visible{border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}}@media all and (max-width: 1024px){.kt-accordion-id2907_c6c3d8-68 .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}}@media all and (max-width: 767px){.kt-accordion-id2907_c6c3d8-68 .kt-accordion-inner-wrap{display:block;}.kt-accordion-id2907_c6c3d8-68 .kt-accordion-inner-wrap .kt-accordion-pane:not(:first-child){margin-top:14px;}.kt-accordion-id2907_c6c3d8-68 .kt-accordion-panel-inner{border-top:0px solid transparent;border-right:0px solid transparent;border-bottom:0px solid transparent;border-left:0px solid transparent;}.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header{border-top:0px solid #949494;border-right:0px solid #949494;border-bottom:1px solid #abb8c3;border-left:0px solid #949494;}.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header:hover, \n\t\t\t\tbody:not(.hide-focus-outline) .kt-accordion-id2907_c6c3d8-68 .kt-blocks-accordion-header:focus-visible{border-top-color:#474747;border-top-style:solid;border-right-color:#474747;border-right-style:solid;border-bottom-color:#474747;border-bottom-style:solid;border-left-color:#474747;border-left-style:solid;}.kt-accordion-id2907_c6c3d8-68 .kt-accordion-header-wrap .kt-blocks-accordion-header:focus-visible,\n\t\t\t\t.kt-accordion-id2907_c6c3d8-68 > .kt-accordion-inner-wrap > .wp-block-kadence-pane > .kt-accordion-header-wrap > .kt-blocks-accordion-header.kt-accordion-panel-active{border-top-color:#abb8c3;border-top-style:solid;border-right-color:#abb8c3;border-right-style:solid;border-bottom-color:#abb8c3;border-bottom-style:solid;border-left-color:#abb8c3;border-left-style:solid;}}<\/style>\n<div class=\"wp-block-kadence-accordion alignnone\"><div class=\"kt-accordion-wrap kt-accordion-id2907_c6c3d8-68 kt-accordion-has-19-panes kt-active-pane-0 kt-accordion-block kt-pane-header-alignment-left kt-accodion-icon-style-none kt-accodion-icon-side-right\" style=\"max-width:none\"><div class=\"kt-accordion-inner-wrap\" data-allow-multiple-open=\"false\" data-start-open=\"0\">\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-1 kt-pane2907_2c5363-4a\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">How is a two-wheeler battery pack different from a car battery pack?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">It is smaller and runs at a much lower voltage, commonly between 48 and 72 volts, but it lives a harder life. Many are removed and carried for charging, sit low enough to meet monsoon water, rely on passive cooling in hot weather and take far more road vibration. Assembly has to prioritize sealing, joint quality and robustness accordingly.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-2 kt-pane2907_cf2759-5d\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Why do two-wheeler packs have so many welds?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">Many use cylindrical cells, and each one holds relatively little energy, so a pack needs a large number of cells to reach its capacity. More cells means more joints, and even a modest pack can contain hundreds of welds, each carrying current and exposed to vibration for years. That is why every joint needs checking rather than a sample.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-3 kt-pane2907_bf22fa-88\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Why is LFP common in e-rickshaw batteries?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">E-rickshaws often run long hours with heavy loads and are drained deeply before charging, day after day. Lithium iron phosphate handles that kind of repeated deep cycling well and stays thermally stable, which suits the duty better than chemistries optimized for maximum energy density.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-11 kt-pane2907_a903b6-a8\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">How does battery swapping affect pack manufacturing?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">A swappable pack moves through many vehicles instead of living in one, so operators need to track each pack\u2019s health and history. That depends on every pack carrying a reliable identity with its build record from day one. Swapping also pushes toward standard sizes and connectors, which means building to tight dimensional tolerances.<\/p>\n<\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-kadence-pane kt-accordion-pane kt-accordion-pane-18 kt-pane2907_d3d044-4e\"><div class=\"kt-accordion-header-wrap\"><button class=\"kt-blocks-accordion-header kt-acccordion-button-label-show\" type=\"button\"><span class=\"kt-blocks-accordion-title-wrap\"><span class=\"kt-blocks-accordion-title\">Which safety standards apply to two and three wheeler batteries in India?<\/span><\/span><span class=\"kt-blocks-accordion-icon-trigger\"><\/span><\/button><\/div><div class=\"kt-accordion-panel kt-accordion-panel-hidden\"><div class=\"kt-accordion-panel-inner\">\n<p class=\"wp-block-paragraph\">AIS-156 covers electric power train safety for these vehicles, IS 16893 covers lithium-ion cells and IS 17387 covers battery packs. The framework tightened after the two-wheeler battery fires of 2022 and pushes manufacturers toward documented testing and records for each pack.<\/p>\n<\/div><\/div><\/div>\n<\/div><\/div><\/div>\n\n\n\n<p class=\"has-white-color has-text-color has-link-color wp-elements-c645e628e62f8fbab9d9726851472d16 wp-block-paragraph\"><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>A battery pack in an electric car sits bolted into the floor, cooled by liquid, sheltered from the weather and rarely touched for years. A pack in an Indian electric scooter&#8230;<\/p>\n","protected":false},"author":4,"featured_media":2864,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[9],"tags":[29],"class_list":["post-2907","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cleantech","tag-cleantech"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.1 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Two-Wheeler and E-Rickshaw Battery Pack Assembly | Cybernetik<\/title>\n<meta name=\"description\" content=\"How two-wheeler and e-rickshaw battery packs are built in India: lower voltages, high weld counts, monsoon sealing, passive cooling, swapping and variant mix.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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