From cell selection to final battery pack assembly, discover the full workflow and key machines used in lithium battery PACK production.
The PACK process involves grouping battery cells, welding them into series/parallel configurations, installing a BMS, insulating the pack, and sealing it into a protective shell. This ensures safety, performance, and reliability.
The Battery Management System (BMS) acts as the brain of the battery. It ensures cells are balanced, monitors temperature and voltage, and protects the battery from overcharging, over-discharging, and short-circuits.
Typical steps include:
Cell matching and sorting
Spot or laser welding
BMS installation
Insulation and structural fixation
Functional testing
Sealing and packaging
Spot welding (for nickel strips) and laser welding (for high-precision or automated lines) are commonly used, depending on production scale and cell type.
A typical BMS monitors:
Voltage (per cell & total)
Current (charge/discharge)
Temperature
State of Charge (SOC)
Cell balancing status
Advanced models may also include CAN/UART data output.
When faults are detected (like overheating or voltage imbalance), the BMS cuts off the circuit to stop charging/discharging—preventing dangerous conditions and protecting the system.
In lithium battery manufacturing, PACK refers to the process of assembling individual lithium cells (cylindrical, prismatic, or pouch) into usable battery modules or packs with added structure, electronics, wiring, and protection. The result is a finished battery pack ready to power electric bikes, tools, scooters, or energy storage devices.
This process is not just about physical assembly—it integrates electrical testing, welding, software configuration, and safety measures to ensure long-term performance and compliance.
The PACK process typically starts with cell inspection and ends with final functional testing and labeling. Here’s a streamlined view of how a professional battery pack is built:
| Process Step | Key Equipment | Purpose |
|---|---|---|
| Cell Sorting | Voltage & IR Tester | Ensures cell consistency in voltage and impedance |
| Cell Arrangement | Positioning Fixture | Aligns cells by series/parallel config |
| Nickel Tab Welding | Spot Welder | Connects cells securely for current flow |
| BMS Installation | Manual / Semi-auto Wiring Tools | Connects sensing wires and control circuits |
| Insulation & Wrapping | PVC Shrinking Machine | Adds outer protection, anti-shock cover |
| Aging Test | Cycling Test Machine | Simulates charge/discharge under load |
| Final QC | Multimeter, Load Tester | Verifies voltage, capacity, communication |
Explore the different outer shell materials, structures, and designs available for lithium battery packs—and how they impact durability, cooling, and customization.
The shell, or enclosure, protects the internal battery structure against mechanical damage, water ingress, and thermal risks. Depending on application—such as e-bikes, scooters, power stations, or drones—manufacturers choose from different materials and shapes that optimize safety, installation, and branding.
A well-designed shell ensures not just durability, but also effective heat dissipation, water resistance (IP65–IP67), and user convenience in plug-and-play systems.
We can broadly categorize battery shells into plastic (ABS/PC) and metal (aluminum alloy) enclosures, with hybrid composite options for special cases.
We can broadly categorize battery shells into plastic (ABS/PC) and metal (aluminum alloy) enclosures, with hybrid composite options for special cases.
| Shell Type | Material | Applications | Advantages |
|---|---|---|---|
| Plastic Case (e.g. Hailong) | ABS or PC+ABS | E-bikes, scooters | Lightweight, cost-effective, moldable into brand shapes |
| Metal Case | Aluminum Alloy | Energy storage, high-power tools | Better heat dissipation, high strength, longer lifespan |
| Soft Pack with PVC Wrap | Pouch Cell + PVC Wrap | Compact space, custom shapes | Ultra-lightweight, shape-flexible |
| Rack/Box System | Steel, FRP, or Composite | Industrial, Solar ESS | Customizable module layout, scalable capacity |
Shells often integrate heat-sinking fins, ventilation ducts, or thermal pads to maintain ideal temperature under load. For outdoor or mobile systems, IP65/IP67 sealing, waterproof gaskets, and robust connectors prevent environmental damage.
We also support conformal coating and potting for high-vibration or wet environments.
Shells often integrate heat-sinking fins, ventilation ducts, or thermal pads to maintain ideal temperature under load. For outdoor or mobile systems, IP65/IP67 sealing, waterproof gaskets, and robust connectors prevent environmental damage.
We also support conformal coating and potting for high-vibration or wet environments.
A deep dive into how BMS ensures lithium battery safety, performance, and smart integration in modern power systems.
A Battery Management System (BMS) is the nerve center of every lithium battery pack. It continuously monitors cell voltages, temperatures, charge/discharge currents, and more—making real-time decisions to protect, balance, and optimize the pack.
Without BMS, even the best cells can degrade rapidly, overheat, or become dangerous. For B2B applications—whether powering eBikes, energy storage, or industrial equipment—BMS is a must-have.
A well-designed BMS typically includes the following internal modules:
| Module | Function | Key Components |
|---|---|---|
| MCU (Microcontroller) | Decision-making & logic | ST/TI/NXP chips, firmware |
| Voltage Monitoring | Detects individual cell voltage | Voltage sensing IC, resistive dividers |
| Temperature Sensing | Monitors NTC/PTC sensors | Thermistors, ADC |
| Current Sensing | Measures in/out current | Shunt resistor, Hall sensor |
| MOSFET Control | Disconnects charge/discharge paths | N-channel FETs, gate drivers |
| Balancing Circuit | Equalizes cell voltage | Passive (resistors) or Active (inductor/capacitor switching) |
| Communication Interface | Transmits data externally | UART, CAN, RS485, I²C |
| Protection Logic | Executes cutoffs | Software logic + comparator |
Passive Balancing:
Extra voltage from higher cells is dissipated as heat via resistors. Simple, low-cost, but wastes energy.
Active Balancing:
Transfers charge from higher to lower cells using inductive or capacitive methods. Improves efficiency and longevity.
Comparison Table:
| Balancing Type | Efficiency | Complexity | Typical Use |
|---|---|---|---|
| Passive | Low (~50%) | Simple, low cost | eBikes, tools, small packs |
| Active | High (~90%) | High, needs logic+switches | ESS, EVs, premium industrial packs |
A BMS isn’t isolated—it often needs to talk to controllers (MCU/VCU), chargers, apps, or cloud platforms.
UART: Simple, low-cost. Ideal for debugging or simple display communication.
CAN (Controller Area Network): Automotive-grade, fast, reliable. Used in EVs, robotics, high-end eBikes.
RS485: Good for industrial setups with long-distance, multi-node wiring.
Choosing the right protocol depends on your end-use system architecture.
Bluetooth App: View voltage, SOC, temperature in real-time
GPS Module: Fleet tracking or anti-theft
OTA Firmware: Update features or protection limits remotely
Data Logging: Export performance & diagnostic logs
Smart BMS transforms the battery into a networked energy device, not just a power source.
Lithium battery reliability begins with a precise PACK process and is safeguarded by a smart BMS. During PACK assembly, cells are sorted, welded, and integrated with BMS and protective structures, ensuring electrical stability and structural integrity. The BMS monitors key parameters—voltage, temperature, SOC—and actively prevents overcharge, over-discharge, and imbalance. Together, these systems enable safe, long-lasting, and efficient battery packs ready for real-world demands.
