Battery Module and Pack Assembly Process

BATTERY MODULE AND
PACK ASSEMBLY PROCESS

PEM of RWTH Aachen University has been The German Mechanical Engineering
active for many years in the area of Industry Association (VDMA) represents
lithium-ion battery production. The range more than 3200 companies in the
of activities covers automotive as well as mechanical engineering sector, which is
stationary applications. Many national and dominated by SMEs. The battery
international industry projects with production department focuses on
companies throughout the entire value battery production technology. Member
chain as well as leading positions in companies supply machines, plants,
notable research projects allow PEM to machine components, tools and services
offer a broad expertise. in the entire process chain of battery
production: From raw material
preparation, electrode production and
cell assembly to module and pack
production.
PEM VDMA
Chair of Production Engineering of E- Battery Production
Mobility Components Lyoner Straße 18
Campus Boulevard 30 60528 Frankfurt am Main
52074 Aachen
www.pem.rwth-aachen.de www.vdma.org
Authors
PEM der RWTH Aachen VDMA
Dr.-Ing. Dipl.-Wirt.-Ing.
Heiner Hans Heimes Dr. Sarah Michaelis
Chief Engineer Battery Production, Division Manager
Head of E-Mobility Laboratory Sarah.Michaelis@vdma.org
H.Heimes@pem.rwth-aachen.de
Ehsan Rahimzei
Prof. Dr.-Ing. Achim Kampker Battery Production, Project Manager
Ehsan.Rahimzei@vdma.org
Any questions?
Saskia Wessel, M.Sc.
Team Leader Battery Engineering
S.Wessel@pem.rwth-aachen.de Contact us!
Mario Kehrer, M.Sc.

Battery Engineering Frankfurt am Main, December 2018
M.Kehrer@pem.rwth-aachen.de Printed by PEM of RWTH Aachen and VDMA,
3rd Edition
ISBN: 978-3-947920-05-1
Overview
Battery module and battery pack
Battery module Battery pack
Cooling BMS master

Battery cells system
BMS slave and
Sensors contacting system High-voltage
module
Insulation foil Wiring

Module
housing
Coolant connection
Insulation plate
CAN interface Service plug
and electricity
Module production Pack production
Based on the brochure “Lithium-ion battery cell production process", this

brochure schematically illustrates the further processing of the cell into battery
modules and finally into a battery pack.
The individual cells are connected serial or in parallel in modules. Several
modules as well as further electrical, mechanical and thermal components are
assembled to a pack.
Each pack has a different Layout depending on the required performance. Due
to the large number of different product and process variants, common
information on the process parameters cannot be stated and can be specified
in more detail in a joint discussion with the PEM Chair or the VDMA.
Technological Development
of battery modules and battery packs
Product innovation (excerpt) Process innovation (excerpt)
 Mechanical Integration
 Module assembly
• Simplification of the module
• Elimination of cell gluing
housing
process
• Pack housing plastic
• Elimination of module
construction
assembly
 Pack assembly
 Electrical Integration
• Assembly low voltage area
• Relocating of the BMS
• Joining pack cover
• Contacting system
● Todays technology developments will improve the mechanical and

electrical integration of the housings and the overall systems.
● The Research on product and process innovations is primarily
aiming at reducing costs and simplifying the assembly.
Overview
Comparison
Zelle
of battery modules
Pouch cell battery module
Spring tensioning ● It is important to note that the

Cell pouch cells expands/shrinks in its
thickness during the charging or
discharging cycle.
● Each pouch cell is inserted into a
frame.
● Due to the swelling of the cells, the
frames are arrested flexible by
springs.
● Cooling in a pouch module is
optional and can be served by either
convective or liquid coolant.
● For example, pouch cells can be
serial connected and cooled via U-
profiles.
Zelle
Pouch cell battery module
● In the architecture of a round cell

module, the cells are fixed by the
Cell module case.
Module case
● The space between the cells can be
used by a cooling system or direct
cooling.
● The metal housing prevents the cell
from swelling.
● At module level, the cells can be
connected both serial and parallel.
● The cells are contacted via a metal
plate on both sides.
Zelle
Prismatic cell battery module
● Prismatic cells can be installed

Tensioning Gluing without remaining gaps.
● The individual cells are glued
Bandage Cell together.
● The adhesive film serves both as
electrical and thermal insulator in
the event of an accident.
● The cells are clamped with a
bandage and/or a plastic or metal
housing.
Pre-Assembly
Module production
Initial inspection Extraction system for

solvent vapours
V
Glue gun
Surface cleaning
Pasted battery
Glue cell
Transportation
system
1000433FG984BH7
Specific conveyor Cell stack

barcode
Pack production
● Goods in (using prismatic cells as an example): Scanning of the product

labels and sorting according to the performance data.
● Receiving inspection to sort out faulty cells (electrochemical impedance
analysis, voltage measurement, capacity analysis, etc.).
● Depending on delivery condition, cleaning and/or activating of the surfaces.
● Joining of the cells (e.g. using liquid or solid adhesives).
● The joining medium must be electrically insulating to prevent from internal
short circuits. Polyurethane-based adhesives with elastomeric properties
after curing are in common use.
● The cells are stacked in a defined way.
● Depending on the joining medium, extraction of solvent vapours.
Process parameters & requirements Technology alternatives [excerpt]

• Exact positioning and secure fixation of the • Glue gun for glue application
cells to each other is necessary
• Application of double-sided adhesive tapes
• Power, charging time and service life
depending on the weakest cell
• Speed of the process strongly depends on
the degree of automation
• Delivery quality of the supplier determines
the amount of inspection
Quality influences [excerpt] Quality features [excerpt]

• Position-accurate cell handling • Precise handling of the cells
• Bonding and pressing method • Adjusted contact pressure during transport
and insertion to prevent electrolyte leakage
Production costs* [excerpt] Invest for machinery and equipment: € 4.0-5.0 million
*PEM study by RWTH Aachen University: Capacity of the pack: 150 Ah, pack voltage: 400 V, production capacity: 4 GWh/a
Insulation and Tensioning
Module production
Pressure Tensioning
F Bandage
plates
F
Preloading Insulation plates
Prismatic cells
Tensioning Gluing
Bandage Cell
Case
Pack production
● Stacked cells are pressed to create a defined stack geometry and minimize
swelling during charge and discharge.
● The pressure is applied onto the stack by a clamping device, a bandage or
by the module body itself.
● Plastic plates or foils are used for heat dissipation and electrical insulation,
which prevent heat transfer and current flow between the cells. These are
intended to interrupt a chain reaction in the event of a cell failure.
● Exact positioning of the components on the module and subsequent gluing
and/or screwing and insertion into the housing.
● For pouch cells, instead of gluing, it is possible to insert them into individual
frames (drawer systems) and then bracing them.

• Max. compression forces in N and N/cm² • Automatic grippers for cell stacking
(depending on cell type and specifications)
• Manually filled cell magazines for feeding
• Uniform contact pressure between the cells for module assembly
insulation plate and module in N/cm2
• Fast process execution and curing times for
potting compounds
• Tightening torques of the connecting
elements, tensions

• Precise handling technology • Precise positioning measures
• Precise pressing • Optimal heat dissipation
• Consideration of the tolerance chains of
cells and module components
Electrical Contacting
Module production
Welding A
machine
Battery module
Holding jig V
Current and voltage
measurement
Laser Ultrasonic Current Screws
Fast / Efficient Gentle Low investment Detachable connection
High heat input expenses Material dependent Contact resistance
Pack
pack production
● Wiring of the cells by electrical connection of the contact tabs / current

collectors. Depending on the module voltage, the cells are contacted to
form one or more parallel strings.
● Contact e.g. by the use of ultrasonic welding (low heat input), laser welding
(high precision) or screw connections (electrical losses due to contact
resistances).
● Checking the joints for conductivity by resistance measurements.
● With a high degree of automation, the welding seams can be inspected
during the welding process by an optical inspection.
• Seams must be free of dust and grease and • Laser welding

have low reflections for laser welding. • Ultrasonic welding
• Ultrasonic welding: frequency: 20-40 kHz, • Screwing
amplitude: 10-50 μm, pressure: 1-10 MPa
• Laser welding: 1000-4000 W
• Low heat input into the cell

• Joining Technology / Welding Technology • Large joining area to minimize electrical
resistance
• Monitoring and testing technology
• Cleanliness of the joints
• Positioning accuracy of the clamping device.
• Low thermal load
Invest for machinery and equipment: € 10.5-11.0

Production costs* [excerpt] million
Comparison of Welding Processes
Module production
Laser welding
● A laser optic or a diode laser heats

Laser welding unit the current collector and the contact
plate until they are fused.
● This process takes less than a
second due to the fast energy
Holding jig battery supply.
module ● The space requirement of a laser
system is low.
● Laser welding offers a high degree
of flexibility for subsequent process
adaptation, as it is a contactless
process.
Ultrasonic welding
● The necessary heat of fusion is

Ultrasonic generated by interfacial friction and
welding unit acoustic absorption.
● The subsequent cooling creates a
Battery module homogeneous connection.
sin(ω𝑡)
● Advantageous when welding the
same materials.
● The very high joining precision and
the accessibility of the contact
surfaces for the less flexible
sonotrode with counterholder are
Holding jig limiting factors.
Resistance welding
Electrodes ● In resistance welding, the welding

heat is generated by an electrical
resistance.
● Two opposite welding electrodes are
required for the welding process.
● The suitability of the materials
depends on the thermal conductivity
and the melting point.
Holding jig
Mounting of the Slave Circuit Board
Module production
Central contacting system
Contacting Welding
unit machine
Welded joint
BMS
slave
circuit
board
Voltage
measurement
Temperature
sensor
Pack
pack production
● Positioning the slave circuit board of the battery management system (BMS)
or a complete contacting unit for processing the data and controlling the
sensors.
● Joining the circuit board to the module by welding and/or screwing.
● Mounting of the voltage measuring cables by means of screwed or welded
connections and gluing of the temperature sensors.
● Connection of the sensor system to the circuit board via plug connections.
● Functional test by signal testing and random testing of the weld seams by
X-ray or ultrasonic measurement.

• Damage-free joining of circuit board and • Laser welding
sensors
• Screwing
• Delivery of the parts with defined surface
• Plug-in connection
tensions
• Precise installation and handling of the
highly sensitive sensors
• Low heat input (fire hazard)

• Precision of welding technology • Exact positioning of sensors and circuit
board (risk of short circuits)
• Selected assembly technology
• Quality of the joints
• Exact positioning
• High sensitivity of cell & sensors
Mounting of the housing cover
Module production
Wiring Clips Voltage test
harness
V
Module ready for

connection
Screws
Pack production
● Attaching and fitting cables (power & COM cables).

● Wiring the controller and, if necessary, the cooling system for later
connection to the BMS master.
● Mounting of the lit, fixing with screws or clips.
● Testing the module:
● External irregularities (optical tolerances)
● Functionality of communication and sensors (software test)
● Cell voltage, cell difference (balancing)
● State of Charge (SOC) of the module
● HV strength (resistance measurement)
● If necessary, tightness of the cooling circuit and the module (e.g. gas leakage test,
overpressure test, vacuum test)
● Protective caps, label application and preparation for transport.
• Handling and safety regulations for • Screw driving robot with magazine
employee controls • Clipping of the module cover by plug
connectors
• Installation of the flexible cable harnesses
• Ensuring transport safety (cables,

connections, protective caps, etc.)

• Assembly technology depending on the • Exterior integrity and technical cleanliness
module concept
• Permitted amount of rework
• Measuring and testing technology
• Transportability (cables, connections)
Insertion of the Cell Modules
Pack production
Gripper
Zop view Output
Battery module
Battery pack Integrated allocated space

housing cooling for the battery module
Cooling plate plates
Module production
● Mount the cooling plates in the bottom of the battery pack tray for cooling
the modules during operation (if necessary also heating function).
● Insert the battery modules into the pack housing by means of appropriate
grippers into the bottom of the pack.
● Repeat these steps until all modules (here schematically three modules per
pack) are inserted.
● The construction and wiring of battery packs vary greatly between
applications and suppliers (e.g. 4S3P, 6S3P, 12S1P etc. / S=Serial,
P=Parallel).
● Two serial module strings are often connected in parallel.
● Fully electric vehicles have high-energy cells. Hybrid vehicles have high-
power cells.

• Protective equipment and high-voltage • Fully automated gripper assembly
safety training required
• Semi-automatic insertion of modules with
• Module connections must be securely manipulators
positioned and must not interfere with the
assembly process.
• Handling of the partly very large radiator
elements by employees (occupational
health and safety)

• Flexible assembly technology for different • Danger of short circuits in module handling
storage geometries
• Damage-free transport due to adapted
contact pressure
• Handling of large housings and coolers
Production costs* [excerpt] Investment for machinery: approx. 1.0 million €
Attachment of the Modules
Pack production
Connected modules
Detailed view
Screw
Pilot hole
Recess in side wall for

mounting
Screws for fixing the cell

modules
Module production
● Fixing the battery modules, e.g. by means of screw connections, in the

places provided in the battery pack housing.
● The additional screw connection can increase the rigidity and additionally
protects against vibrations during operation.
● Ensure the correct position and damage-free installation using suitable
systems (e.g. camera, mounting aids, centering pins, etc.).
● Typical screw sizes depending on structure M6-M12.
● Rotation prevention when tightening the screws must be ensured.

• Precise and damage-free fixing of the • No alternatives available for large series
modules to the floor production
• Fixing by gluing, plugging or screwing the
components together
• Connection to cooler structures
• Tightening torques of the screws according
to module size and screw type

• Integration of supporting assembly aids • Guaranteed tight fit of the modules
(e.g. joining cone in packing body)
• Design of the overall system for possible
• Automation of a flexible production line tolerance variation
• Contact surfaces for heat dissipation
Electrical & Thermal Integration
Pack production
BMS Master
Cooling system
High voltage
Wiring module
Output
Coolant
connection
Service plug
LV power
Plugs / valves
connection
Module production
● Positioning of the cooling system in the holder provided and connecting it

to cooling elements in the pack housing.
● Mounting of the high-voltage module consisting of relay, fuses, pre-charge
& current measuring system, insulation monitoring etc.
● Connecting of HV and LV wiring harness to modules and peripherals.
● Installation and wiring of the battery management system (BMS Master) to
control the cooling system, modules, slave circuit boards and high-voltage
module.
● Installation by specially trained employees if the voltage is above 60 V (work
under voltage, sensitization for battery risk - electrician).
● Connect connections, valves and plugs on the outer housing as preparation
for vehicle integration.

• Cooling system, battery management • Busbar systems for simultaneous
system, high-voltage module are usually contacting and fixing of the modules
pre-assembled brought-in parts.
• Assembly of the flexible cables can only be
carried out by a trained employee and is
difficult to automate.

• Assembly technology and support • Correct positioning and wiring of peripheral
devices
• Poka-Yoke design for protection against
false assembly/mounting • Accessibility of connection points
• High-voltage safety (> 60 V) for employees
Sealing & Leak Test
Pack production
Gas testing Vacuum testing
Screws for lids Opening for pressure test
Valve
bursting disc
bar
Cover with
helium Evacuated
bar
DUT
valve
Leak detector
Sealing cord
or glued seal Helium
Detector
Module production
● Apply the seals (e.g. rubber seal, sprayed or glued seals) to the edge of the
housing or cover.
● Place the upper part of the housing or the cover and connect it (e.g. by
screwing) to the battery pack housing.
● Check the housing for leaks by opening the bursting disc or using a leak
tester.
● If necessary, check the tightness of the cooling circuit using suitable gas
(e.g. helium) or leak detectors.
● Install a bursting disc in the battery pack housing to secure the pressure of
the battery pack and ensure safety during operation.

• Dust tightness and resistance • Check the components to ensure the final
• Seal must be suitable for temperature tightness.
changes • No complete alternative available in large
• During the test, the housing may burst in series production
the event of overpressure.
• Bursting disc necessary for safety protection
during battery operation

• Flexible assembly technology • Ensure tightness of the pack despite
ventilation
• leak test
• Definition of permitted reworking
• Service capability for opening the housing
Charging & Flashing
Pack production
Thermal imager
Flashing
Thermal image
Voltage converter
Tasks
• Establish state of charge
• Functional test of thermal management
Module production
● Connect the BMS to a computer and flash with the latest software through
a system analysis program.
● Check the correct functioning of all systems using the analysis program.
● Establish the desired consistent state of charge of all cells.
● If necessary, monitoring of the welded joints and the thermal management
functions during operation by means of a thermographic measuring
system.

• Installation of the latest software for battery • No alternatives available for large series
management systems for corresponding production
vehicle variants (variant creation via
software versions)
• Stick to functional tolerances
• Prevention of gas formation or ignition
during the charging process due to
negative pressure and housing

• battery management software • Functionality of all components
• Measuring and testing technology • Heat development during charging process
• Protection against errors from previous
production steps
End of Line
Pack production
Final
inspection
V Optical
inspection Output
Testing
approved 
100FGBH43V9
Warning signs Product label
Module production
● Connect the test devices to the respective cable connections or lines.

● Inspection of the entire electronics by test software and optical inspection
by an employee.
● Testing the functionality of the BMS and its subcomponents (temperature
sensors, slave circuit board, etc.).
● Charging/discharging the battery according to a defined performance
profile and establishing a desired state of charge (SOC) for storage or
vehicle assembly.
● Apply labels and warnings and mark as "tested" and release the pack.
● Packaging and transporting the battery pack.

• Final process with subsequent storage in • Upstream balancing of the modules in
workpiece carriers incoming goods department or in holding
• Catalogue of criteria for comprehensive positions within the production line
testing (no uniform regulation)
• Good employee training necessary
• Defined delivery condition in coordination
with vehicle assembly (holder, connections,
software versions, etc.)

• Choice of measurement and test • Fulfilment of all quality features
technology
• Definition of permitted rework
• Danger due to high voltage (> 60 V) for
employees
Integration of the Battery Pack
Vehicle assembly
High voltage
Manual screwing and
cables
fastening of the Data cable
connections at the
vehicle
Mounting for
modular assembly
at vehicle
Coolant pipe
Top view
Charger Vehicle control Electric engine
connection system
Coolant circuit
Screws for fixing

to the battery
pack Inverter
Battery pack
Module production Pack production Vehicle integration
● A high-voltage system and high-performance electronics for motor control

are required to ensure operation of the charge control system.
● The use of high-voltage technology additionally increases the safety
requirements, especially in the event of crashes.
● Since the connections for to the vehicle wiring harness are flexible, the
process can hardly be automated and must be carried out by an employee
with assembly aids.
● The mechanical connection of the battery pack is made e.g. by mountings
in the base module and corresponding screw connections (M10-M14).
● Mountings are used to mount the same accumulators in different vehicle
derivatives.

• Production line must be adapted to the • No alternatives available for large series
needs of electric vehicles production
• High battery weight requires modified
front/rear module design. Purpose-Design
vs. Conversion Design (conversion of
combustion vehicles)
• Adaptation of test & maintenance
techniques (e.g. to power supply with 400V)

• Production of electric vehicles on old • Assembly processes for batteries and cables
production lines vs. production on specially • Accessibility of cables and connections
adapted production lines
• Serviceability of the components
(disassembly, interchangeability, etc.)
Battery Lifecycles
Second use, remanufacturing & recycling
Second use Remanufacturing Recycling
1
Disassembly of
Used modules the Sorted battery
with adapted cells Emission
components control
BMS and Case
Furnace and
pelletizing
Test / Analysis
If necessary, feed Slag (building
Refining alloys
into the power grid industry)
solar collector Nickel Copper Cobalt

Clean-up
2 Liq. nitrogen Burning
-196°C
hydrogen
Preparation Precipitation
NaOH
lithium
Plastics
Metals
Remanufacturing Reaction
Stationary energy storage Shredder stages
Module production Pack production Vehicle integration
● Batteries can only be used economically for electric cars up to approx. 80% of their
capacity (wear is not linear and strongly dependent on environment and use).
● Decision for type of further use depending on performance data.
Second use:
● Further use in other areas (e.g. stationary energy storage for solar systems) with
adapted control units.
Remanufacturing:
● Preparation for further use of individual components.
Recycling of cells:
● Sorting of batteries by type and removal of peripherals.
● Mechanical preparation (crushing under protective gas) and/or pyrolysis (strong
heating) for "deactivation of the cells".
● Recycling by means of hydro- or pyrometallurgical processes and recovery of raw
materials (especially nickel, cobalt, aluminium and copper).
● Minimum recycling efficiency: 50% of the average battery scrap mass.
Potentials [excerpt] I. Sample process* II. Example process*

• No distinct recycling • Cells are melted down in a • Cryogenic decomposition of
infrastructure established yet pyrometallurgical furnace lithium batteries
• Recycling can counteract price • Burn lithium, aluminum, • Cooling by liquid nitrogen to
fluctuations and dependencies electrolyte, separator and approx. -196°C to reduce
for raw materials graphite & accumulate in the reactivity
slag or leave process with
• Simultaneous recycling of • Battery cell shredding and
exhaust gas
secondary batteries from the shearing
entertainment industry • Slag is made available to the
• Reaction with sodium
construction industry
• In particular, the recycling of hydroxide (NaOH) and burning
cobalt, copper and nickel is • The Co,Ni,Cu,Fe alloy of the released hydrogen at
already proving economically produced during melting is the surface
viable. granulated and hydro-
• Lithium and lithium salts are
metallurgically processed.
precipitated & removed in
solution in a targeted manner
*Source: F. Treffer: Lithium-ion battery recycling in R. Korthauer (Hrsg.), Lithium-Ion Batteries: Basics and Applications, Springer-Verlag 2018

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BATTERY MODULE AND

PACK ASSEMBLY PROCESS

Mario Kehrer, M.Sc.

Battery module Battery pack

Cooling BMS master

Insulation foil Wiring

Module production Pack production

Based on the brochure “Lithium-ion battery cell production process", this

● Todays technology developments will improve the mechanical and

Pouch cell battery module

Spring tensioning ● It is important to note that the

Pouch cell battery module

● In the architecture of a round cell

Prismatic cell battery module

● Prismatic cells can be installed

Initial inspection Extraction system for

Specific conveyor Cell stack

● Goods in (using prismatic cells as an example): Scanning of the product

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Laser Ultrasonic Current Screws

Fast / Efficient Gentle Low investment Detachable connection

High heat input expenses Material dependent Contact resistance

● Wiring of the cells by electrical connection of the contact tabs / current

Process parameters & requirements Technology alternatives [excerpt]

• Seams must be free of dust and grease and • Laser welding

Quality influences [excerpt] Quality features [excerpt]

Invest for machinery and equipment: € 10.5-11.0

● A laser optic or a diode laser heats

● The necessary heat of fusion is

Electrodes ● In resistance welding, the welding

Central contacting system

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Module ready for

● Attaching and fitting cables (power & COM cables).

Process parameters & requirements Technology alternatives [excerpt]

• Ensuring transport safety (cables,

Quality influences [excerpt] Quality features [excerpt]

Zop view Output

Battery pack Integrated allocated space

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Production costs* [excerpt] Investment for machinery: approx. 1.0 million €

Recess in side wall for

Screws for fixing the cell

● Fixing the battery modules, e.g. by means of screw connections, in the

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

● Positioning of the cooling system in the holder provided and connecting it

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Process parameters & requirements Technology alternatives [excerpt]

Quality influences [excerpt] Quality features [excerpt]

Warning signs Product label