Production · Manufacturing
Automation, precision and control at every station.
Lines ranging from manual to fully automatic stations, to produce anything from a single custom system to large orders with the same quality.
Production capacity
Lines for every type of order.
Several production lines coexist at the centres: manual lines for short runs and special projects, and automatic lines for large volumes.
- 40GWh
- annual production capacity of the centres
- 90s
- to complete a 1P52S pack on the automatic line
- 1/10,000
- defective product rate
- 2
- production centres, in Luoyang and Lianyungang
Manufacturing process
Six stations that make the difference.
Automation is not an end in itself: it ensures every unit comes out the same as the last.
01
Cell loading
A robot arm with distance measurement places each cell in position: precision, safety and a steady pace, with no manual handling.
02
Module handling
A CCD vision system locates the reference marks on each module and corrects the manipulator's position before picking it up.
03
Module to pack
Automatic insertion of the modules into the pack enclosure improves precision and eliminates the risk of impacts.
04
Automatic adhesive dispensing
Robotic adhesive application with a precision better than 0.5 mm, fed from 55-gallon drums so the line never stops.
05
Automatic screwdriving
Every screw is located and tightened to the torque specified for its position. Torque and angle are recorded.
06
On-the-fly laser welding
On-the-fly welding adapts the bead shape, improves its strength and works in any direction without stopping the head.
Technology
On-the-fly laser welding, monitored in real time.
A poorly welded joint means resistance, heat and lost service life. That is why every bead is inspected in-line before, during and after welding.
Conventional welding
The head stops at every joint
On-the-fly welding
Welds on the move, without stopping
The ring beam surrounds the weld spot and stabilises the melt pool: it reduces spatter by more than 90% and, with it, porosity and material loss.
- 01
Before welding
- Bead position: misalignment and excessive gap
- Part height: deviations, clamping faults or deformation
- 02
During welding
- Penetration depth: excess, shortfall or fluctuations due to instability
- 03
After welding
- Surface: excess thickness, pores or sinking
- Bead width and part deformation
Smart factory
A manufacturing execution system (MES) that records everything.
Every product is logged as it is built, with the materials and components it contains, from cell to module to pack. If a fault appears, it is traced back to its source.
Process engineering control
Parameters for every station set, versioned and monitored.
Production traceability
Every cell, module and pack is linked to the unit's serial number.
Product quality control
A station with a non-conforming result stops the part from moving on.
Production process control
Real-time line status to optimise pace and yield.
Traceability
Every unit has its own history, starting from the cell batch.
The serial number of a BK system links to its cell batch, every pack, every rack and the result of every test. If anything needs checking, we know exactly where and when.
- Serial-number logging at every station
- Test results archived with the unit
- Quality dossier delivered with every system
Unit · Power Pro BK241
BK-PP241-2609-0147
Integrated in Lianyungang · 24/09/2026
Cells · 240 LFP cells, 314 Ah
Batch C-2608-A
OCV and impedance measured · 5 homogeneous groups
Packs · 5 × 1P48S packs
P-0147-01 … 05
Weld inspected · EOL test passed
Rack · 1P240S rack + high-voltage box
R-0147
Insulation and polarity verified
FAT · Final system test
FAT-0147
Cycling, protections and communication with BK EMS
Shipping · Quality dossier issued
DQ-0147
Destination: site in Spain
Want to see the line in action?
We organise technical visits to our production centres and to installations in operation.