High-Performance Battery Solutions for Advanced Manufacturing

Industry 4.0 Automation for Battery Cell Testing

Capabilities Demonstrated

Automated Quality Inspection & Testing – Fully automated battery cell test station with robotics and vision-based inspection.
Advanced Industry 4.0 Integration – AI-driven data collection, process control, and automated decision-making.
Precision Engineering & System Accuracy – Designed to reduce inspection time by 80%, significantly increasing production efficiency.
Turnkey Installation & System Optimization – End-to-end solution, from system design to implementation and commissioning.
Scalable Manufacturing Infrastructure – Designed to enhance throughput while ensuring minimal manual intervention and high-quality standards.

The Challenge

A battery pack manufacturer faced a major bottleneck in cell inspection and testing, a labor-intensive process that accounted for 47% of the total build time. The client sought to automate this critical step while overcoming the challenge of integrating battery testing equipment with robotics and machine control systems, which traditionally lacked seamless interoperability.

The manufacturer needed a high-throughput, precision-driven solution that could streamline battery cell inspection, improve quality control, and eliminate manual data entry errors, all while maintaining strict safety and performance standards.

Solution

Re:Build partnered with the client to develop an Industry 4.0 automated battery cell test station, leveraging robotics, vision inspection, and real-time data processing. The fully integrated system enabled seamless orchestration of robot movement, automated testing, and intelligent decision-making.

Key System Features & Technologies

Fully Automated Testing System – Cells are automatically moved through each station, reducing manual handling.
Integrated Edge Computing – The system automatically configures and runs each electrical test, improving efficiency.
Advanced Robotics & Vision Inspection – AI-driven top and bottom visual inspections ensure precise defect detection.
Real-Time Data Collection & Logging – Every test result (voltage, internal resistance, and inspection images) is stored in a centralized database.
Turnkey Deployment & System Integration – The entire system was designed, installed, and optimized to function seamlessly within the existing production environment.

Results

The automated battery cell test station significantly enhanced production throughput, reduced labor dependency, and improved overall manufacturing efficiency.

Key Outcomes

80% Reduction in Inspection Time – Total time to inspect and test battery cells was reduced, cutting overall battery pack assembly time from 170 minutes to 90 minutes.
Elimination of Manual Data Entry Errors – Fully automated data collection and logging ensured error-free reporting and traceability.
Scalable for Future Production Demands – The system is expandable to accommodate higher throughput as production scales.
Higher Quality & Consistency – Improved defect detection and real-time monitoring ensured higher reliability and product consistency.

By implementing this Industry 4.0 automation system, the client transformed its battery manufacturing workflow, achieving higher efficiency, better quality control, and a streamlined production process—positioning the company for long-term scalability and cost savings.

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