Forsee Power – Prismatic Cell Assembly Line for 3-Wheeler EVs

Project Overview:

Prismatic Cell Assembly Line for 3-Wheeler EV Batteries
In 2022, Forsee Power approached Maestrotech to implement an semi automated prismatic cell assembly line designed to meet the growing demand for electric 3-wheeler batteries. The goal was to establish a high level safety, high-precision manufacturing line capable of producing batteries that would power electric 3-wheelers while maintaining quality , safety and efficiency.

Challenges:

• First project on prismatic battery pack assembly line .

• Integration with Line Traceability software and Other Applications: The assembly line needed to accommodate different battery types, configurations, and potential future expansion for other types of electric vehicles.

Solution:

Maestrotech delivered a state-of-the-art prismatic cell assembly line tailored to Forsee Power’s specifications. Key features of the solution included: 

Automated Prismatic Cell Sorting and Stacking:
The system included automated sorting mechanisms to organize prismatic cells by voltage, IR & cell quantity with respect to module, ensuring that only the correct cells were fed into the assembly line. 

Laser Welding Systems:
Maestrotech implemented high-precision Laser welding machines designed specifically for busbar as well as side plate welding in single machine. 

Battery Pack Testing Stations:
Integrated automated testing stations were used to validate each battery pack’s voltage, current, Leak testing, DCIR, EOL testing , etc . These tests were critical to ensuring that every battery met the performance standards for the 3-wheeler EV market.

Flexibility for Multiple Applications:
The assembly line was designed to accommodate various battery configurations. The modular design ensured scalability as Forsee Power continued to grow its EV battery production.

Key Metrics:

• Battery Pack Size: 5 to 10 kW per pack
• Production Speed: 10 to 20 packs per hour
• Simple & Moduler System
• Automation Level: Semi automated from cell sorting to pack EOL 
• Plant Location: Pune, Maharashtra, India

Conclusion:

The implementation of the prismatic cell assembly line for Forsee Power was a significant success, enabling the company to meet the increasing demand for electric 3-wheeler batteries in a highly efficient, scalable, and cost-effective manner. Maestrotech’s automation solution not only improved production efficiency and throughput but also ensured that every battery pack met the highest safety, performance, and quality standards required for the EV industry.

Forsee Power continues to benefit from this state-of-the-art assembly line, strengthening its position as a leading supplier of advanced battery systems in the growing electric mobility market.

This case study highlights This is our first prismatic assembly line project, where we gained valuable lessons in prismatic cell handling, the assembly process, and the safety precautions that need to be considered during the assembly process.