Automatic Screw Fastening Line for New Energy Battery Modules

In new energy battery module assembly, screw fastening and structural part assembly are among the stages with the largest number of operations and the highest consistency requirements. A module's long edge often needs dozens of screws, takt times are tight and torque consistency requirements are strict, so manual fastening struggles both to guarantee yield and to meet the data traceability required for volume delivery.

Process challenges

· A large number of screws and long fastening travel demand feeding stability and high batch takt;
· The module, end plates and busbars form a multi-layer structure, so hole position tolerance and the risk of floating screws must be intercepted on the line;
· Bolt torque needs to be traceable so it can feed into the overall pack quality traceability system;
· Product models iterate quickly, so the line must support fast changeover between variants.

Solution composition

For these working conditions, Honred Technology provides a module assembly solution built around automatic screw machines. A typical configuration includes:

1. In-line automatic screw fastening platform: links with upstream and downstream conveyors, single track with dual heads or multiple heads, and CCD cameras to compensate for positioning deviation.
2. Closed-loop torque control: servo screwdrivers support multi-stage torque and speed settings and collect torque-angle curves in real time, judging stripped threads, floating screws and missed screws on the line and raising alarms.
3. Feeding system: vibratory bowl or screw feeder, with blow feeding or vacuum pick selected according to the screw length-to-diameter ratio.
4. Data and traceability: fastening data is uploaded in real time, with MES integration and barcode traceability.

Line integration points

· Size the stroke and frame according to the largest module, leaving room for later models;
· Design fixtures for a repeatable workpiece attitude; use vision only to compensate incoming variation;
· Confirm the signal interface with adjacent equipment (board in, board out, fault stop) at the solution stage;
· For multiple models, build a recipe library and call up the corresponding program and fixture at changeover.

Service process

Honred Technology is a source manufacturer of non-standard automated assembly equipment and supports sample testing and process validation: the customer sends real workpieces and screws, and Honred carries out actual fastening validation using a sample machine or trial fixture, reporting fastening results, torque data, yield and takt. Batch manufacturing begins only after validation passes. Direct supply from the manufacturer makes lead times and overall cost more controllable.