JBM Group – Fully Automated Bus Battery Pack Assembly Line for Prismatic Cells- 3.3 GW capacity

Challenges:

• Line suitable for Different size of cell and multi variant battery pack 
• High-Performance and High-Capacity Batteries: The battery packs needed to deliver 35 to 65 kW of power, with high energy density, reliability, and long lifecycle, tailored specifically for electric buses.
• Complexity of Assembly: The scale of the battery packs (65 kW) required advanced automation to handle the large prismatic cells, ensure precision in assembly, and maintain high standards of quality.
• No Precedent in India: As a pioneering project, JBM Group wanted to partner with a company capable of building a fully automated battery pack assembly line for prismatic cells, a solution that was unavailable in India at the time.
• Scalability for Global Markets: The solution had to be designed not just for the Indian market but also for export markets, meeting international standards for battery performance, safety, and quality.

 Solution:

Maestrotech, with its expertise in automation for battery pack assembly, undertook the challenge and delivered a first-of-its-kind fully automated assembly line for prismatic cell-based battery packs at JBM Group’s Bawal plant. The system incorporated cutting-edge technology to ensure both speed and Functionality meeting the specific needs of electric bus battery production.

Key features of the assembly line included:

Automated Cell Sorting and Stacking:
We design unique gripper for handle different size of cells.The assembly line used robotic sorting systems to efficiently sort prismatic cells by type, size, and voltage, ensuring that only the correct cells were used in each battery pack. The system then automatically stacked the cells in precise alignment to form the battery pack. 

Advanced Laser Welding Machines:
Maestrotech installed multiple high-precision Laser welding machines capable of welding prismatic cells. The machines with auto clamping fixture applied exacting force between busbar & cell terminals, ensuring the integrity of each battery pack. This step was crucial for ensuring long-lasting battery performance, especially for large-scale EV applications like buses. 

Battery Pack Testing Stations:
Integrated automated testing systems were installed to verify key metrics such as voltage, capacity, and internal resistance (IR). These real-time tests were crucial in ensuring that every battery pack met JBM Group’s performance and safety standards.

Full Automation with Minimal Manual Intervention:
The entire process, from cell sorting to the final assembly of the battery pack, was fully automated, reducing the need for skill labor and minimizing human error. The automation, pokayoke ensured consistent quality, high throughput, and precision, even during high-volume production.

Modular Design for Scalability:
The system was designed with modular components that allowed for easy upgrades and expansions. As the demand for electric buses and large-scale battery solutions grows, JBM Group can scale the assembly line to meet increased production needs and even adapt it for other applications, such as electric trucks and energy storage systems (BESS).

Quality Control and Data Analytics Integration:
The assembly line incorporated Line Traceability and data analytics platforms with Customised display  to collect real-time data throughout the production process. This enabled JBM Group optimize the overall assembly line efficiency.

Results:

First Fully Automated Battery Pack Line in India for Prismatic Cells:
This was the first fully automated assembly line for prismatic cell-based 65 kW bus batteries in India, making it a milestone project for the Indian EV manufacturing sector. Maestrotech expertise in automation enabled JBM Group to become a leader in the electric bus market, capable of manufacturing world-class batteries locally.

High-Volume Production:
The assembly line was capable of producing high volumes of 65 kW battery packs with 7 to 15 packs per hour output. This ensured that JBM Group could meet the growing demand for electric buses, both domestically and in export markets, with an annual production capacity that supported global scaling.

Increased Efficiency and Reduced Lead Time:
With full automation, the assembly line significantly reduced production lead time, ensuring that JBM Group could ramp up production quickly and meet tight delivery schedules for their electric bus projects.

Consistent Quality and Safety:
Automated testing systems ensured that each battery pack met stringent quality standards, contributing to the reliability and safety of the battery packs, which are crucial for the electric bus market. This also led to a reduction in warranty claims and operational failures.

Cost Reduction and Labor Savings:
The fully automated system significantly reduced the labor costs associated with manual assembly, allowing JBM Group to focus human resources on higher-value activities such as R&D, sales, and customer support. It also minimized the risk of human error, leading to a reduction in production rework and associated costs.

Global Competitiveness:
In collaboration with JBM, Maestrotech proudly completed the bus battery pack assembly line, which is the first of its kind to be fully design & manufactured in India , adhering to global quality standards. With JBM placing their trust in Maestrotech to deliver this advanced line, Maestrotech successfully executed the project, showcasing their capability and expertise. This fully automated production line strengthens JBM’s position as a competitive player in the electric mobility and EV battery manufacturing markets, enabling them to export high-quality batteries to international markets.

Key Metrics:

• Battery Pack Size: 65 kW per pack
• Production Speed: 7 to 15 packs per hour
• Annual Production Capacity: Over 3.3 GWh/year
• Automation Level: Fully automated from cell sorting to final pack assembly
• Plant Location: Bawal, Haryana, India

Conclusion:

The fully automated prismatic cell-based battery pack assembly line implemented by Maestrotech for JBM Group was a game-changer for India’s electric vehicle manufacturing industry. It marked the first-of-its-kind assembly line in India capable of producing large-format, high-capacity battery packs for electric buses.

Maestrotech automation expertise has empowered JBM Group to scale their production, reduce operational costs, and ensure the highest levels of product quality and safety. With this success, JBM Group is well-positioned to serve both the Indian market and international customers, reaffirming its commitment to the Made in India initiative and contributing to the global transition to sustainable electric mobility.

This case study demonstrates Maestrotech’s ability to tackle complex challenges in the EV battery manufacturing sector, delivering cutting-edge, automated solutions that drive efficiency, quality, and scalability.