Automatic Cylindrical Cell Sorting Machine with Insulating Ring Pasting, Testing and Barcode Scanning

Automatic Cylindrical Cell Sorting Machine with Insulating Ring Pasting, Testing and Barcode Scanning

The AOAO-4518B automatic cylindrical cell sorting machine integrates insulating ring pasting, high-precision voltage and internal resistance testing, barcode scanning, and multi-channel sorting. Designed for 18650, 21700, 26650, and 32700 cells, it enables efficient sorting, consistency control, and MES data traceability in lithium-ion battery production lines.

In cylindrical battery production, the consistency of internal resistance and voltage directly determines grouping strategy, pack balancing performance, and long-term cycle stability. At the same time, proper insulating ring application is essential to ensure electrical isolation and safety during battery module assembly.

This system integrates these critical processes into a single platform, enabling high-throughput processing, stable classification, and full data traceability for both pilot and mass production environments.

Function

The AOAO-4518B is designed to automatically complete insulating ring pasting, voltage and internal resistance testing, barcode scanning, and multi-level sorting of cylindrical cells through a PLC-controlled workflow.

Cells are loaded into the hopper manually and transported via a conveyor system. The machine automatically applies insulating rings, performs high-precision voltage and internal resistance measurements, scans cell barcodes, and classifies cells into predefined grading channels based on software-defined thresholds.

The system supports up to 10 grading levels (OK bins) plus 1 NG channel (for 1821 and 2632 models), enabling precise cell grouping for downstream battery pack assembly.

In terms of production capacity, the equipment can process approximately 4000–4500 cells per hour for 18650 and 21700 formats, and 3000–3500 cells per hour for 26650 and 32700 formats, ensuring compatibility with both pilot-scale and large-scale manufacturing requirements.

The integrated high-speed testing system provides voltage accuracy up to 0.00001 V and internal resistance accuracy of 0.01 mΩ, ensuring reliable classification and excellent repeatability.

All test data are automatically recorded, stored in the industrial PC, and can be uploaded to MES systems, enabling full traceability and process optimization.

Working Principle and Process Flow

The system operates through coordinated control between a PLC, motion control card, and industrial PC. Mechanical motion is executed by the control system, while the PC manages data acquisition and classification logic.

Process flow:

Manual loading → Conveyor transport → Automatic insulating ring pasting → Voltage & internal resistance testing → Barcode scanning → Sorting into designated channels → Data recording and storage

The insulating ring is applied using a 400W variable frequency motor with a buffering mechanism to prevent mechanical impact on the cells. Dual robotic handling ensures stable transfer throughout the process.

Sorting is executed using servo-driven positioning modules, ensuring accurate placement and high repeatability even at high throughput.

Equipment Structure and Design

The machine features a compact and rational structure with a small footprint, suitable for integration into existing production lines.

The frame is constructed from high-quality cold-rolled steel plates combined with an aluminum profile structure, ensuring mechanical rigidity and long-term stability.

The system is equipped with universal casters for easy movement and layout adjustment. A complete alarm system is included, featuring sound and light alerts, automatic stop after sorting completion, full material alarm, fault alarm, and clearing functions.

The control architecture adopts a motion control card combined with an industrial PC. The motion controller handles feeding, transport, and sorting, while the PC manages testing data acquisition and classification logic. This separation improves efficiency and simplifies operation.

Technical Specifications

Operating Environment

Integration into Battery Production Line

The AOAO-4518B is typically installed after formation and aging processes and serves as a key node for cell grading before module assembly.

Upstream equipment includes formation cabinets and aging systems, while downstream processes involve cell grouping, welding, and battery pack assembly.

By ensuring that cells are sorted based on precise voltage and internal resistance criteria, the system significantly improves pack consistency, reduces imbalance risk, and enhances overall battery performance.

The AOAO-4518B integrates insulating ring application, high-precision testing, barcode traceability, and multi-level sorting into a single system.
With up to 10 grading levels, high testing accuracy, and throughput up to 4500 cells per hour, it provides a reliable and scalable solution for cylindrical lithium-ion battery manufacturing, supporting both pilot production and high-volume industrial applications.