Electric Vehicle Power Assembly Systems

First in India: The first automatic battery pack assembly line ever made in India.

Jendamark made it: Delivered to the country’s most valuable and well-recognised car manufacturer.

Layout: In this Type 1 prismatic battery pack assembly line, the battery pack busbar is of the bolted type.

Key features: All types of battery packs for various vehicles, ranging from three-wheelers and cargo to sedan and SUV, are all built on this line.

Highlights: 100% process security, data traceability and operator guidance

Jendamark made it: For our customer making three-wheeler and two-wheeler battery packs.

Layout: In this prismatic battery pack assembly line, the battery pack busbar and side panel will have laser welding. This line is designed to manufacture 20,000 battery packs per year (in two shifts per day).

Key features: Automation leader Jendamark supplied a unique cell checking and sorting solution which ensures the right cells being used every time.

Highlights: Quality gates at every step ensure that each assembly leaving the line is as per product specifications.

Jendamark made it: Our standard assembly line can be customised as per customer requirements.

Layout: Individual cells are grouped together to form a module or pack of cells. Jendamark provides the complete solution along with traceability for each cell.

Key features: Important parameters include open circuit voltage, barcode scanning, bulging, polarity of the terminal and glue dispensing.

Jendamark made it: We provide the solution along with the traceability of each module. After the pack assembly, Jendamark seamlessly integrates all the testing machines into its database, so that the customer does not have to look into multiple reports to track product data.

Layout: This layout is for module-to-pack assembly, where several modules are put together to form a pack.

Key features: Important parameters include leak testing, glue dispensing, Battery Management System (BMS) testing, all torquing application monitoring and checking.

Jendamark made it: We designed this line to produce battery packs for two-wheelers. The entire machine is manufactured in our own factory using collaborative robots (cobots) to eliminate human error and intervention. We have developed our own machine for cylindrical cell sorting as per OCV/ACIR and AH values.

Layout: This is a cylindrical battery pack assembly line, in which the battery pack busbar will have resistance spot welding. The line has the capacity to produce 50,000 battery packs (in two shifts) per year.

Key features: Important parameters include leak testing, glue dispensing, Battery Management System (BMS) testing, all torquing application monitoring and checking.

Jendamark made it: In the above assembly line Jendamark provides the solution along with traceability of each cell according to key parameters, which can be customised as per customer requirements.

Layout: In this line, individual cells are grouped together to form a module or pack of cells.

Key features: Important traceability parameters include Open Circuit Voltage (OCV), barcode scanning, polarity of terminal and glue dispensing.

Jendamark made it: In the above assembly line Jendamark provides the solution along with traceability for each module according to required parameters.

Layout: In this line, modules are grouped together to form a pack, or bunch of modules.

Key features: Important required parameters include leak testing, glue dispensing, BMS testing, all torquing application monitoring and checking.

Jendamark made it: We have provided assembly line solutions for making DC-AC inverters and DC-DC inverters.

Layout: This inverter assembly line was designed for commercial vehicles and variations are underway for two- and three-wheelers. It features Jendamark’s own integrated Industry 4.0 software solution – ODIN Manufacturing.

Key features: Auto-tightening with bolt feeder to prevent human error, and auto sealant dispenser for applications like thermal paste, adhesive and meter mixing.

Jendamark made it: We supplied this line for India’s leading electric vehicle manufacturer. Correct assembly of motor control units, vehicle control units and similar electronic assembly components is critical due to the inherent small size of the child parts.

Key features: Auto-tightening with bolt feeder to prevent human error, and auto sealant dispenser for applications like thermal paste, adhesive and meter mixing.

Highlights: This low-volume line has all the process security and data traceability solutions, powered by Jendamark’s own ODIN Manufacturing ecosystem.

Jendamark made it: We have provided assembly line solutions for EV motors – for every vehicle from two- and three-wheelers to passenger and commercial vehicles. We provide solutions for complex and challenging assembly requirements such as motor winding, handling the magnets and insertion of the stator into rotor housing

Layout: This assembly line solution includes high-precision automatic stator insertion into the rotor. The most challenging part of a motor line is the insertion of stator in rotor housing with strong magnets. This is resolved using a precise gantry system and float arrangement.

Key features: We also provide high-potential current testing of the motor to check motor winding, as well as a laser marking machine for generating a unique serial number for every part.

Jendamark made it: This axial flux motor assembly line is for two-wheeler vehicles. We have provided a solution that features a winding press with 30-ton force.

Layout: In the above assembly line, the machine for dispensing permanent magnets is the most crucial operation – and Jendamark has mastered it.

Key features: We also provide high-potential current testing of the motor to check motor winding, as well as a laser marking machine for generating a unique serial number for every part.

Jendamark made it: We have manufactured a line for the assembly of rotors – ensuring the right solution at the right time and at the right cost.

Layout: The complexity of this line involved design, development and manufacturing of stainless-steel fixtures to hold the permanent magnets in position during insertion and baking process.

Key features: This line has automatic magnet dispensing, auto sealant dispensing, magnet pasting fixture and a baking area for curing sealant.

Jendamark made it: We provided an EV gear box assembly line for a reputable Indian brand.

Key features: State-of-the-art automatic backlash checking of gear box, cotter pin insertion and other innovative solutions to meet customer product requirements.

Highlights: Flaring machine, oil seal press machine, automatic sealant dispensing machine, and laser marking machine for generating unique serial numbers for every part.