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EV Battery Pack Assembly

Electrical Vehicle (EV) Battery Assembly Line
Battery is the heart of Electric Vehicles (EVs)! With technology enabling longer range batteries in a world obsessed with cutting emissions, EVs are gaining increasing acceptability. Cybernetik lends you the edge with rapid, precise, and efficient assembly lines for cylindrical and prismatic EV batteries.

Cybernetik is an industrial automation company that blends experience with innovation to design, build, and install end-to-end, customised automation solutions for the food, pharmaceutical, chemical, and manufacturing industries across the world.

Grow Your Business

Bring the power of industrial automation to your EV business.
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Assembly Line

Prismatic
Cylindrical

We develop efficient Turnkey Solutions for your EV business

Cybernetik_Chocloate_Scroll_Mobile
Prismatic Battery Assembly Line_For Website
Grinding
Cocoa Beans Unloading
Blending
Moulding
Separator / Aligner
Secondary Packaging
Tertiary Packaging
Carton Erector

The Cybernetik Advantage

Quality Check

  • High-speed vision and magnetic metal detectors
  • Detection for incorrect orientation, chip off, and metal ingress
  • In-line row rejection

Vibratory Conveyor

  • High capacity and speed
  • Bulk and overhead transfer to minimize footprint
  • Up to 30-deg upward conveying
  • Precise feed rate control via vibration frequency modification
  • Up to 6m product elevation

Grinding

  • Rapid, high-speed operation at 2000-6000 rpm
  • Inbuilt durability and redundancy
  • Easy maintenance-replacement
  • Air cooled Seals and high-performance Bearings
  • Silencers and Inlet Magnets for smooth functioning
  • Hi-tech Polymer Belt for Drive Motor
  • Hygienic, cGMP built

Cocoa Beans Unloading

  • De-dusting Mechanism
  • Magnetic Metal Separator of 10,000 - 12,000 (± 500) gauss
  • Safe and ergonomic loading system
  • Hygienic, cGMP built
  • In-built Hopper

Blending

  • Dust free, smooth operation
  • Flavour preservation for authentic taste
  • Texture control via particle size control
  • Tamper-proof storage
  • Resident time control for required flavour and texture
  • Thorough blending

Moulding

  • Maintains texture through temperature control, preheating of moulds, and vibration table.  
  • Integrated granule dosing unit and granule-chocolate mixer for chocolates with granules.   
  • Automatic or semi-automatic.  
  • Mould material options: Plastic, polycarbonate, or rubber moulds.  

Separator / Aligner

  • Precise row-based separation.  
  • In-line live belt aligners and feeders.  
  • Metal detector and in-line row rejection.  
  • Product singling by 45-deg conveyors.  
  • International standard compliance.  

Roasting

  • Real time Brix checks for rapid operation
  • SCADA for total parameter (temperature, pressure, Brix) control
  • High-strength limpet / dimple jacket design
  • In-built mechanisms to prevent burn-on, mix thoroughly

Primary Packaging

  • Hygienic, cGMP built
  • Precision: Tracking systems for pick-place on moving conveyors
  • High speed: Up to 120 naked chocolates pick-place per minute
  • Orientation based packaging with incorrect position-orientation detection
  • Versatility: Handles various chocolate types and sizes
  • Optimized flow wrapper feeding and distribution

Secondary Packaging

  • Programmable with user-friendly HMI
  • High speed: Servo/Pneumatic end-of-arm customized grippers for palletizers
  • Precision: Weight-based, metered filling systems
  • Large payload capacity
  • Pneumatic holding, fail safe clamping, and stitching / sealing arrangement for bag packing
  • Hygienic, cGMP built

Tertiary Packaging

  • High speed: Servo/Pneumatic end-of-arm customized grippers
  • Heavy duty construction
  • Customized pallet matrix formation
  • Modular, purpose-built design with upstream-downstream integration
  • Flexibility: Automatic, end-of-arm tooling change
  • Multiple unit palletizing in some cases 

Carton Erector

  • Customized pallet matrix formation
  • Servo/pneumatic end-of-arm customized grippers for high speed
  • Multiple cartons simultaneously palletized
  • Optional automated pallet storage and dispensing system
  • Integration with empty pallet dispensing station
  • Integration with slip sheet pick and place for top sheet and bottom sheets
Cybernetik_Chocloate_Scroll_Mobile
Cylindrical Battery Assembly Line_For Website 1
Grinding 1
Cocoa Beans Unloading 1
Blending 1
Moulding 1
Separator / Aligner 1
Secondary Packaging 1
Tertiary Packaging 1
Carton Erector 1

The Cybernetik Advantage tab 2

Quality Check

  • High-speed vision and magnetic metal detectors
  • Detection for incorrect orientation, chip off, and metal ingress
  • In-line row rejection

Vibratory Conveyor

  • High capacity and speed
  • Bulk and overhead transfer to minimize footprint
  • Up to 30-deg upward conveying
  • Precise feed rate control via vibration frequency modification
  • Up to 6m product elevation

Grinding

  • Rapid, high-speed operation at 2000-6000 rpm
  • Inbuilt durability and redundancy
  • Easy maintenance-replacement
  • Air cooled Seals and high-performance Bearings
  • Silencers and Inlet Magnets for smooth functioning
  • Hi-tech Polymer Belt for Drive Motor
  • Hygienic, cGMP built

Cocoa Beans Unloading

  • De-dusting Mechanism
  • Magnetic Metal Separator of 10,000 - 12,000 (± 500) gauss
  • Safe and ergonomic loading system
  • Hygienic, cGMP built
  • In-built Hopper

Blending

  • Dust free, smooth operation
  • Flavour preservation for authentic taste
  • Texture control via particle size control
  • Tamper-proof storage
  • Resident time control for required flavour and texture
  • Thorough blending

Moulding

  • Maintains texture through temperature control, preheating of moulds, and vibration table.  
  • Integrated granule dosing unit and granule-chocolate mixer for chocolates with granules.   
  • Automatic or semi-automatic.  
  • Mould material options: Plastic, polycarbonate, or rubber moulds.  

Separator / Aligner

  • Precise row-based separation.  
  • In-line live belt aligners and feeders.  
  • Metal detector and in-line row rejection.  
  • Product singling by 45-deg conveyors.  
  • International standard compliance.  

Roasting

  • Real time Brix checks for rapid operation
  • SCADA for total parameter (temperature, pressure, Brix) control
  • High-strength limpet / dimple jacket design
  • In-built mechanisms to prevent burn-on, mix thoroughly

Primary Packaging

  • Hygienic, cGMP built
  • Precision: Tracking systems for pick-place on moving conveyors
  • High speed: Up to 120 naked chocolates pick-place per minute
  • Orientation based packaging with incorrect position-orientation detection
  • Versatility: Handles various chocolate types and sizes
  • Optimized flow wrapper feeding and distribution

Secondary Packaging

  • Programmable with user-friendly HMI
  • High speed: Servo/Pneumatic end-of-arm customized grippers for palletizers
  • Precision: Weight-based, metered filling systems
  • Large payload capacity
  • Pneumatic holding, fail safe clamping, and stitching / sealing arrangement for bag packing
  • Hygienic, cGMP built

Tertiary Packaging

  • High speed: Servo/Pneumatic end-of-arm customized grippers
  • Heavy duty construction
  • Customized pallet matrix formation
  • Modular, purpose-built design with upstream-downstream integration
  • Flexibility: Automatic, end-of-arm tooling change
  • Multiple unit palletizing in some cases 

Carton Erector

  • Customized pallet matrix formation
  • Servo/pneumatic end-of-arm customized grippers for high speed
  • Multiple cartons simultaneously palletized
  • Optional automated pallet storage and dispensing system
  • Integration with empty pallet dispensing station
  • Integration with slip sheet pick and place for top sheet and bottom sheets

The Cybernetik Advantage

  • Total quality parameters tracking ensures long battery life
  • Complete operational integration from cell testing and stack formation to end-of-line testing
  • SCADA for customized recipe handling
  • ESD Workbench for safety against electrostatic shocks
  • Servo, Robots, Vision System, and Fixtures for accuracy and speed
  • Poka Yoke for error proofing
  • Regenerative discharging saves electricity

Applications 

Automotive
Battery Manufacturing
Energy
Battery Assembly
Electronics

Automate your battery manufacturing / assembly line

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Types of Lithium-ion Batteries:
Lithium Nickel Manganese Cobalt Oxide is premised on the nickel-manganese synergy in the nickel-manganese-cobalt cathode. Manganese reduces internal resistance and covers up for nickel’s limited stability. Nickel counters manganese’s low specific energy.

For this reason, this battery type has achieved immense success and is utilized in e-bikes, power equipment, and electric powertrains. Customizability further spikes their utility – designers can purpose build it for larger energy or greater power capacity.  

Adding silicon to anode increases battery capacity (measures in milli-ampere-hour or mAh) but lowers discharge current (measured in amperes). This also cuts down battery life as silicon causes alternate expansion-contraction of anode during charging-discharging.
Lithium Iron Phosphate batteries have low resistance with better electrochemical properties. They also cope up better with long duration exposure to high voltage and full charge situations. And, these are amongst the safest lithium ion batteries.

On the down side, these have reduced nominal voltages and larger self-discharges. These batteries are also highly intolerant of moisture. All these features make them useful mainly for energy storage applications.
Lithium Manganese Oxide batteries charge quickly and discharge high current. They also possess better safety and thermal stability which makes them useful in electric vehicles, medical devices, and power equipment.

At the root of its merits is the 3D spinel framework of the cathode made from lithium manganese oxide that cuts internal resistance thereby boosting ion flow on the surface of electrode.

Lower lifespan is a major drawback of this battery type. Design engineers can customize it for high specific power to deliver large currents, higher duration life, or greater energy capacity.
Lithium Nickel Cobalt Aluminium Oxide batteries are an advanced version of lithium nickel oxide batteries with the addition of aluminium imparting greater stability. Applications include industrial, medical, and powertrain.

These deliver fairly large specific power and elevated specific energy over a longer duration. Such features make them comparable to lithium nickel manganese cobalt oxide batteries. Their cost and safety features are not so attractive.
Lithium Cobalt Oxide batteries find use in laptops, mobile phones, and electronic cameras due to their high levels of specific energy. These have an anode made of carbon graphite and a cathode of cobalt oxide.

Overloading and rapid charging overheats them. The type also has low specific power that limits their capacity to deliver high current levels. Besides, they have short lives that result from lithium plating and anode thickening when charging at low temperatures and high speed.
Lithium Titanate batteries last for more number of cycles, can provide ten times the rated capacity discharge current, charge rapidly, discharge well at low temperatures, and are safe. More thermally stable than lithium cobalt oxide batteries, these are also free from the lithium plating issue that plagues the latter.

Anodes are made of lithium titanate while cathode material can be lithium nickel manganese cobalt oxide or lithium manganese oxide. With all these advantages, their cost is bound to be higher. Applications include uninterrupted power supply, powertrains, and solar-driven street lighting.

CASE STUDIES

BLOGS

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About Cybernetik

Successfully delivering turnkey automation solutions since 1989.

Cybernetik is an industrial automation company that blends experience with innovation to design, build, and install end-to-end, customized automation solutions for the food, pharmaceutical, chemical, and manufacturing industries across the world.

Cybernetik was set up as a consultancy in 1989 by a group of engineers from the Indian Institute of Technology (IIT)-Madras, India and the State University of New York at Buffalo, USA.

From 10 people operating in less than 100 sq.m. workspace, our footprint in India has expanded to 30,000+ sq.m. across four units, two each in Pune, Maharashtra and Nadiad, Gujarat.

Our global operations are based out of three international offices:

Vietnam (for Southeast Asia), Dubai (for Middle East and Africa) and United States (for North America).

 

READ IN DETAIL

EV battery pack assembly is an essential part of battery production automation. Making up up to 60% of the cost of an electric vehicle (EV), the battery is the heart of an EV. Just like the engine is for an internal combustion (IC) engine. This makes EV battery manufacturing a crucial operation. 

Battery production automation speeds up the process of EV battery pack assembly: As it is, EV battery manufacturing is a complex operation that includes the following tasks:

  • Cell to pack and pack to module formation.
  • Individual cell testing and possible classification of cell into multiple types based on test results.
  • Plasma cleaning of cell electrodes. 
  • Battery pack insertion in housing. 
  • Resistance or laser welding followed by weld testing. 
  • Adhesive, structural foam, and insulation foam application under pressure. 
  • Regenerative discharging for optimizing electricity use. 

By decarbonizing an area that has traditionally been tough to do so – transport, EVs present humankind with an effective weapon to fight the cancerous menace of Climate change. 

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