As EV battery technologies continue to evolve, Cell-to-Pack (CTP) has emerged as a key pathway driving both structural innovation and manufacturing efficiency upgrades in battery systems.
Facing demanding requirements for higher integration density, tighter precision standards and more complex manufacturing processes, LeadTech, a subsidiary of Lead Intelligent Equipment (hereafter referred to as LEAD), has launched an integrated intelligent CTP assembly solution for prismatic batteries. Built upon deep automation expertise and advanced digital technologies, the solution fundamentally reconstructs the manufacturing logic from cell to PACK, enabling customers to simultaneously improve efficiency, quality and production flexibility.
The solution upgrades the traditional Cell-Module-Pack process into a streamlined Cell-to-Pack architecture by eliminating conventional module assembly stages. Through the deep integration of advanced 3D + AI vision, AI algorithms, intelligent AGV logistics systems, precision process simulation and system-level simulation technologies, LeadTech has developed a next-generation prismatic battery CTP production line solution featuring high automation, high precision, high modularity and high flexibility. This system enables intelligent and high-efficiency assembly from cell to PACK.
Cell Insertion into Housing
Following cell polarity verification, individual cells are controlled pneumatically and press-fitted to specified dimensions by servos. The entire process follows stringent manufacturing standards to ensure dimensional conformity. The servo press system precisely positions and maintains pressure at target locations while integrating displacement control and pressure monitoring, enabling highly stable and high-precision assembly performance.
Wide-Area Adhesive Dispensing
Through real-time detection and automatic compensation between the dispensing nozzle and housing position, the system maintains highly accurate adhesive path control. With high-flow, high-precision wide-area dispensing technology, it significantly improves dispensing efficiency. Moreover, integrated intelligent flow monitoring and adhesive thickness inspection technologies ensure stable and reliable dispensing quality throughout production.
CCS Laser Welding
Equipped with self-developed in-process 0CT inspection technology and post-weld 3D + 2D vision inspection, the solution combines deep-learning core algorithms to achieve comprehensive and highly accurate inspection of complex welding quality conditions, ensuring both reliability and consistency in welding processes.
Automated Top Cover Tightening
Automated equipment enables efficient and precise bolt tightening for battery PACK top covers. Four tightening spindles can operate simultaneously while uploading real-time production data. The spindle spacing can be adjusted flexibly, while floating mechanisms in the height direction enable adaptive tightening operations. This significantly improves assembly efficiency, precision and overall product quality.
From process innovation to the deep integration of intelligent manufacturing, LEAD’s prismatic battery CTP production line not only delivers high precision and strong consistency across critical manufacturing stages, but also empowers battery production to higher standards through full-process intelligentization. Looking ahead, LEAD will continue to drive innovation and provide competitive intelligent equipment solutions for the new energy industry worldwide, working together with industry partners to accelerate the global energy transition.
