Automated assembly and laser welding line
Design and construction of a high-efficiency custom line for the electric mobility sector
THE PROJECT
Bonetto Automation offers extensive, proven expertise in the development of automated lines for the battery sector, with a core specialization in laser welding processes for battery modules and packs.
The proposed line integrates advanced laser welding technologies for busbars, terminals, and critical connections—ensuring precision, joint quality, and long-term reliability within a fully automated system that features comprehensive traceability across all production stages.
THE ADVANTAGES
Full integration of module and pack assembly stages
⦁ Full integration of module and pack assembly stages
⦁ High-level automation throughout the entire process
⦁ Production flow optimization, from cell-level to finished pack
⦁ Distributed quality control across all manufacturing phases
⦁ End-to-end traceability for cells, modules, and battery packs
⦁ Continuous monitoring of critical process parameters
⦁ Superior repeatability in assembly and welding processes
⦁ Waste reduction through in-line inspections and initial sorting
⦁ Advanced laser welding integration for high-precision connections
LAYOUT AND OPERATING STATIONS
The line consists of several functional stations, including:
⦁ Cell Loading & Handling
⦁ Cell Inspection, Classification & Sorting
⦁ Plasma Cleaning
⦁ Cell Stacking
⦁ Contact Tab Welding (Laser or Ultrasonic)
⦁ Busbar Laser Welding
⦁ Terminal & Connector Laser Welding
• Optical Inspection
• BMS Assembly
• TIM & Adhesive Application
• Pack Assembly
• Housing Integration
• Isolation & Leak Test
• End Of Line Test (EOL)
• Labeling & Packaging
• Unloading & Palletizing
QUALITY CONTROL AND TRACEABILITY
Continuous monitoring and process validation
⦁ OCV (Open Circuit Voltage) for State of Charge (SoC) measurement
⦁ ACIR for AC internal resistance measurement
⦁ DCIR for DC internal resistance measurement
⦁ Hi-pot testing for insulation verification
⦁ Post-process optical inspection (e.g., weld inspection)
⦁ Quality control on laser joints (busbars, terminals, connections)
⦁ Insulation and leak testing on the battery pack
⦁ Full End-of-Line (EoL) testing prior to unloading and packaging
EXHAUSTED BATTERY MANAGEMENT, RECOVERY, AND VALORIZATION LINE
Within the framework of our full battery manufacturing lifecycle expertise, the project can integrate dedicated solutions for End-of-Life (EoL) battery management, aligning with the process and control phases already developed.
⦁ Reception and handling of exhausted/spent batteries
⦁ Controlled full discharge of cells
⦁ Safety processes for neutralizing residual energy
⦁ Disassembly of modules and battery packs
⦁ Component separation (cells, busbars, housing, electronics)
⦁ Recovery of reusable components for new production cycles
⦁ Sorted disposal of non-recoverable materials
⦁ Integration with testing and classification processes for potential reuse (Second-Life)
This approach extends assembly know-how into sustainable End-of-Life management, contributing to waste reduction and the valorization of materials.
PROVEN INDUSTRY EXPERTISE
Over the years, BONETTO AUTOMATION has developed numerous brake pad assembly lines installed at major international manufacturers.
The expertise gained allows us to:
⦁ Optimize layouts and cycle times
⦁ Integrate complex in-line processes
⦁ Ensure long-term reliability
⦁ Develop fully customized solutions
The combination of mechanical engineering, automation, and software integration establishes BONETTO AUTOMATION as a leading technological partner in the brake system sector.
Do you have a project in mind?
Contact us at
sales@bonettoautomazioni.com