COENG Energy Storage PACK Production Line: An Illustrative Project in Germany

Project Overview

• Customer:  German energy storage system integrator
• Customer contact: Markus Weber Head of Manufacturing Engineering
• Location: Baden-Württemberg, Germany
• Application: Local battery PACK manufacturing for stationary energy storage projects
• Equipment: COENG Semi-Automatic Energy Storage PACK Production Line 01
• COENG business manager: Caro Yang
• Project scope: Requirements review, line configuration, shipment planning, installation, commissioning and operator handover

Customer Requirements: Connecting Module Production with PACK Assembly

In this illustrative scenario, the customer planned to establish a coordinated battery PACK assembly process for its stationary energy storage business.

The engineering and procurement teams wanted to connect prismatic cell processing, module laser welding and final PACK testing while retaining manual operations at selected assembly stages.

Their purchasing priorities included:

• Compatibility with the selected prismatic aluminum-shell cells.
• Clear equipment boundaries and manual workstation responsibilities.
• A layout suited to the available factory space.
• Defined welding, electrical inspection and airtightness testing procedures.
• Documented shipment, installation and acceptance arrangements.

The project therefore centered on selecting an energy storage battery production line that matched the intended product, facility and operating requirements.

Requirements Coordination with Caro Yang

Caro Yang, COENG’s business manager with extensive experience in energy storage and new energy products, served as the commercial coordination point in this scenario.

She organized the exchange of cell specifications, module drawings, PACK enclosure designs, production targets and factory layout information between the customer and technical team.

The review distinguished equipment functions from project-dependent requirements. The brochure’s reference dimensions of 45 × 3.5 × 2.2 m were used as an initial planning input, with additional consideration given to maintenance access, material movement and operator work areas.

The brochure also lists 10–12 PPM. Because it does not define the counting basis, the project review required clarification before translating this figure into finished-PACK output.

This approach gave procurement managers and engineering contractors a clearer basis for comparing scope, capacity assumptions and acceptance requirements.

Production Functions Selected for Review

The proposed semi-automatic battery pack production line covered two connected manufacturing stages.

Battery module assembly

The module workflow included automatic feeding, OCV sorting and scanning, manual adhesive application and pre-stacking, cell compression and bundling, terminal cleaning and positioning, and manual CCS installation.

Laser welding was followed by weld residue cleaning, weld inspection, internal resistance testing, insulation and withstand voltage testing, and data acquisition.

Energy storage PACK assembly

The PACK workflow included liquid-cooling plate cleaning, automatic adhesive application, module insertion into the enclosure, BMS subassembly, and busbar and BMS pre-installation.

Low-voltage wiring connections, upper enclosure installation, end-of-line testing, airtightness testing and gantry-assisted unloading completed the listed process.

These functions allowed the customer to assess the equipment as a connected manufacturing workflow, with defined checks between processing stages.

Illustrative Shipment Process

Before dispatch, the scenario included a factory acceptance review using agreed samples and a documented inspection checklist.

The teams reviewed equipment operation, supplied tooling, component identification, outstanding items and the installation documentation. Any unresolved items were recorded with an assigned action owner.

The line was then divided into transportable sections. Sensitive components were protected, equipment sections were labeled, and packing records were matched to the installation layout.

Caro Yang coordinated the packing list, commercial documentation, shipping arrangements and customer receiving schedule. A proposed sea-freight route to Hamburg, followed by inland transport to Baden-Württemberg, provided the logistics framework.

The customer’s receiving team checked package condition and equipment identification against the packing records before moving the sections into the installation area.

Installation and Commissioning

Installation began with verification of the prepared floor area, unloading access, utilities and workstation positions.

The equipment sections were positioned and aligned before qualified personnel completed the required connections and safety checks. Commissioning progressed from individual station checks to dry runs and then sample-based process trials.

The engineering team reviewed cell positioning, welding fixtures, conveyor transfers, electrical test settings and PACK handling interfaces. Operators received instruction on routine operation, changeover tasks, inspection points and fault reporting.

Site acceptance was based on agreed tests and documented results, rather than assuming that brochure specifications automatically represented the customer’s operating conditions.

Illustrative Challenges and Solutions

Challenge 1: Factory access differed from the initial layout

A structural column restricted a planned material-handling route.

Resolution: The teams revised the peripheral staging and operator access arrangement before final positioning. They checked maintenance clearances and confirmed that the revised layout preserved the intended process sequence.

Challenge 2: Sample cells required a fixture adjustment

The supplied cell samples showed dimensional variation that affected repeatable positioning.

Resolution: The technical team reviewed the sample drawings and fixture contact points, adjusted the positioning arrangement, and repeated sample trials before approving the setup.

Challenge 3: A PACK sample failed the initial airtightness check

The first trial indicated leakage, but the source was not immediately clear.

Resolution: The team checked the test fixture seals and connections separately from the PACK enclosure. After correcting the fixture sealing issue, they repeated the test using the agreed method.

Challenge 4: Production-rate expectations used different counting units

The customer initially interpreted the brochure’s PPM figure as finished PACKs per minute.

Resolution: Caro Yang coordinated a technical clarification of the counting unit and process boundaries. The teams then reviewed output expectations against the module design, PACK configuration, manual operations and testing cycle.

Handover and Follow-Up

The illustrative handover package included the agreed equipment list, operating instructions, maintenance guidance, commissioning records and an open-item register.

Caro Yang remained the coordination contact for follow-up questions, connecting the customer with the relevant technical personnel and tracking unresolved actions.

For international buyers, this scenario highlights the importance of defining equipment scope, shipment responsibilities, installation readiness and acceptance criteria before committing to a battery manufacturing project.

 Customer Feedback  Actual Testimonial

“The most useful part of the process was the clear connection between our PACK design and the proposed equipment scope. Caro Yang kept commercial and technical questions organized, while the commissioning review helped us clarify fixture requirements, testing procedures and production assumptions.”

— Markus Weber, Head of Manufacturing Engineering

Discuss Your Battery PACK Manufacturing Project

Evaluating a semi-automatic energy storage PACK production line for an overseas manufacturing facility?

Share your cell specifications, module and PACK drawings, factory layout and target output with COENG. Caro Yang can coordinate the requirements review and help define the questions needed for a project-specific configuration and quotation.