Sorting Machine

Prismatic Cell Sorting Machine

(Technical Documentation)

1. Product Overview

Prismatic Cell Sorting Machine (also called Square Cell Grading Machine) is core automated equipment in lithium-ion battery manufacturing (especially in PACK assembly lines). It performs high-precision electrical performance testing and automatic classification (grading) for prismatic (square aluminum/steel case) Li-ion cells, ensuring cell consistency, safety, and service life in battery modules/packs.

1.1 Core Functions

High-precision Electrical Testing

OCV (Open Circuit Voltage): Accuracy up to ±0.1mV or higher.

IR (Internal Resistance): ACIR/DCIR measurement, accuracy ±0.01mΩ.

Optional Parameters: K-value (self-discharge rate), thickness/appearance inspection, EIS.

Intelligent Grading/Sorting

Classify cells into 5–20 grades (e.g., 9 OK grades + 1 NG grade) by voltage, IR, etc.

Ensure high parameter consistency for cells in the same batch/module.

Full Automation

Loading → Scanning (ID binding) → Testing → Grading → Unloading → Data storage & MES upload.

2. System Structure

2.1 Mechanical Components

Loading & Conveying System

Manual/automatic loading hopper, servo-driven belt conveyor, positioning & alignment mechanism.

Flexible Gripping: Adaptive soft jaws to prevent cell scratching or deformation.

1.Testing Unit (Core)

Four-wire gold-plated test probes to eliminate contact resistance interference.

High-precision tester (e.g., Hioki BT3561A/3562, Keysight 34461A).

2.Scanning & Control System

Industrial camera/barcode scanner (QR/barcode) for cell ID–data binding.

PLC + Industrial PC for motion control, data processing, and grading algorithms.

3.Sorting & Unloading System

Servo motor + XY ball screw module or robotic arm; positioning accuracy ±0.02mm.

Multi-channel (e.g., 8/10 channels) discharge chutes / bins.

4.Software & Data System

Custom grading rules, data recording, report generation, MES integration.

2.2 Electrical & Control System

Power Supply: AC 220V ±5%, 50/60Hz; Power ≤ 2.0kW.

Control: PLC + Industrial PC (Windows/Linux).

Communication: TCP/IP, RS485; supports MES/WMS connection.

Safety: Emergency stop, overload protection, short-circuit protection, safety door interlock.

3. Working Process

1.Loading: Manually place cells into the feeding conveyor.

2.Scanning: Read unique cell ID (SN/QR code).

3.Positioning: Convey cells to test station with precise alignment.

4.Testing: Probes contact cell tabs; measure OCV / IR.

5.Grading: System compares data with preset ranges and assigns grade.

6.Sorting: Servo/robotic arm places cells into corresponding grade bins.

7.Unloading & Data Storage: Graded cells collected; data saved for traceability.

5. Key Features & Advantages

High Consistency: Improves battery pack cycle life, SOC accuracy, and thermal balance.

High Efficiency: 10× faster than manual sorting; near-zero error.

Full Traceability: All test data bound to cell ID; supports MES.

Flexibility: Quick changeover for different cell models; customizable grading rules.

Safety: Non-damage handling; protection for cells and equipment.

6. Applications

Lithium-ion Battery Manufacturing: Prismatic cell grading before module/pack assembly.

Battery Repair & Recycling: Cell sorting for second-life applications.

R&D: Cell performance testing and classification.

7. Maintenance

Probes: Clean/replace monthly to ensure test accuracy.

Belts/Rails: Lubricate weekly; check for wear.

Calibration: Calibrate OCV/IR tester quarterly.

Software: Back up data; update firmware periodically.