Turnkey Solution for New Energy Intelligent Equipment
A battery roller conveyor is a type of material handling equipment used extensively in lithium-ion battery manufacturing lines. It enables the efficient, consistent, and automated transport of workpieces, such as cells, modules, and Packs, across different stages of production. Its application spans the entire value chain—from cell grouping and module assembly to final Pack integration and testing.
Depending on the assembly process and the size/weight of the product being handled, roller conveyors are generally categorized into:
Light-duty roller conveyors, typically used in prismatic battery module production lines.
Heavy-duty roller conveyors, commonly found in Pack assembly lines for electric vehicles and energy storage systems.
These systems play distinct but complementary roles in achieving automation, safety, and throughput consistency in smart battery factories.
Features of Battery Conveyor Systems
Features of Prismatic Module Roller Conveyor
Prismatic modules are mid-sized subassemblies made from stacking or welding multiple cells. These modules need to be transported efficiently through various stations such as gluing, ultrasonic welding, and visual inspection.
Key features include:
Lightweight Load Handling: Engineered to carry modules weighing 10–30kg.
Fast Takt Time Capability: Designed to support fast-paced production cycles with a takt time as low as 6–10 seconds.
Segmented & Modular Construction: Can be built in straight, L-shaped, or U-shaped configurations with quick segment replacements.
High Integration Flexibility: Seamless interface with robots, screw machines, AOI systems, laser welders, and other inline devices.
Cost-Efficiency: Requires low energy consumption, simple control logic, and minimal maintenance, ideal for medium- to high-volume lines.
Optional configurations:
Passive roller sections with gravity feed
Driven roller sections with stepper or servo motors
Side guards and lifting stops for precise positioning
Modular quick-disconnect electrical and signal lines
Pack conveyors are responsible for handling the fully integrated battery Packs, which can weigh 100kg to over 400kg, depending on the application (EV, ESS, or industrial battery system). These systems must prioritize structural durability, positioning accuracy, and safety under high-load conditions.
Key features include:
High Load Capacity: Reinforced rollers and frames capable of carrying 100–300kg (or more) safely and continuously.
Reinforced Drive System: Equipped with dual-chain drive, thick-wall rollers, heavy-duty bearings, and shock-absorbing mounts.
Advanced Safety Systems: Includes anti-backward locks, light curtains, limit sensors, emergency stop buttons, and overload protection.
Interface with Test & Final Assembly: Compatible with high-voltage test platforms, torque systems, EOL testing stations, and warehouse palletizers.
MES and Traceability Support: Barcode scanners, RFID readers, and real-time production data collection can be integrated for full digital factory traceability.
Additional options:
Roller top transfer + lifting tables
Line buffering for 2–3 Packs
Custom roller pitch for Pack dimensions
Static grounding and insulation protection systems
Applications of Battery Roller Conveyor Systems
Module Conveyor Line Applications
Post-Cell Stacking Transfer: Move cell groups to the next gluing or welding station.
Adhesive Curing Transfer: Convey modules through fixed-time curing zones.
Laser Welding Preparation: Position modules accurately for laser welding machines.
Optical Inspection & AOI Integration: Transport modules under cameras or sensors for quality check.
Work-in-Progress Buffering: Temporarily store modules to manage upstream/downstream takt mismatches.
Pack Structure Assembly: Carry base cases, housing shells, and modules for structural integration.
Electrical Busbar & High-Voltage Connection: Stable platform for precision torque and wiring processes.
Function & Safety Testing: Interface directly with automated high-voltage and insulation test benches.
Charge/Discharge Aging Lines: Transport complete Packs to multi-hour or multi-day aging stations.
Final Packaging & Logistics Transfer: Barcode labeling, sealing, and automated warehouse hand-off.
These applications make battery roller lines indispensable to modern battery plants aiming for digital, intelligent, and unmanned production.
Selecting the correct roller conveyor system requires a careful evaluation of your specific production needs and constraints. Here are key criteria to consider:
Factor Recommendation
1. Product Weight Verify the average and peak weight of the module/Pack. Use reinforced designs for >100kg.
2. Production Takt Time Determine the speed requirements of each segment. Faster takt needs servo-driven rollers.
3. Space and Layout Consider U-shaped, linear, or vertical transfer constraints. Use lifting/rotating tables if needed.
4. Device Integration Plan for robot arms, vision sensors, screwing machines, MES systems, etc.
5. Safety Requirements Define needs for safety fences, e-stops, light curtains, and anti-collision features.
6. Traceability & Control If MES tracking is needed, ensure barcode/RFID reading and feedback control are supported.
7. Maintenance & Upgradability Choose conveyors with modular parts, available spares, and remote diagnostic support.
Tip: Work with a system integrator who understands both mechanical engineering and battery process flow, to ensure long-term stability and ROI.
Huiyao Laser (Luoyang) Technology Co., Ltd. is a specialized manufacturer of automated battery manufacturing equipment, serving clients in energy storage, electric vehicles, communication base stations, and consumer electronics.
We provide:
Smart automation integration: MES, AGV, robot arms, EOL
Turnkey system delivery including electrical, mechanical, software
Global support and commissioning with multilingual engineers
Our equipment is designed to meet industrial-grade durability, 24/7 uptime, and international safety standards (CE/ISO compliant).
Whether you need a stand-alone conveyor or a fully integrated smart line, Huiyao Laser can engineer the right solution to drive your manufacturing excellence.
Contact us today to discuss your battery line automation project!
Email: yaolaser@huiyaolaser.com
Head Quarter Address: Huiyao Laser Technology, Building 2, Langxu Industrial Park, Guanlin Road, Science Park Street, Luolong District, Luoyang City, Henan Province, China
Research&Development Center: Room 901-9,Building B1, Phase 1, Southern Area, Baoneng Science and Technology Park, Qinghu Industrial Zone, Gangtou Community, Batian Street, Longgang District, Shenzhen City.
