ASSEMBLY LINE

For Automotive Battery Production

up to 6 BATTERIES
per minute

The Assembly Line is a set of highly flexible ASSEMBLY LINE

machines for assembling up to 6 batteries per
minute.
The automatic Assembly Line is essential for
Different levels of automation can be chosen. consistently reliable battery quality.
Starting from a semi-automatic line to a fully
automatic solution. Based on our long experience, modern engineering,
and proficiency, we offer a market oriented and
The line is optimized for easy and central efficient solution.
adjustment to different battery types, even while
line is in use.

Central line adjustments for all battery types

keep movements of working heads on all stations
simple.

The optional SCADA-System enables central

control and management of the line as well as
running statistics.

All machines fulfil state of the art safety

standards.
 the production process

5
4
3
2
1
Assembly Line
Standard Configuration

The Assembly Process The Assembly Machine

1 Battery Testing and Intercell Welding Short Circuit Tester and

Intercell Welding Machine

2 Placing the Lid Lid Placer

3 Welding the Lid to the Box Heat Sealing Machine

4 Creating the Final Poles Post Welding Machine

5 Leakage Testing and Marking Leakage Control and

Marking Machine

OPTIONS
n Magic Eye Setting Machine
n Assembly Software Support (SCADA)

Based on individual requirements

we offer customized solutions.
Short circuit tester and
INTERCELL welding machine

For Testing and

Intercell Welding
Short Circuit Control Head
For car and truck batteries.

Short Circuit Control Head:

Tester 3,000 V, 100 mA type DHVT 3,000 VAC

Intercell Welding Device:

SAFCO type IP3/S 1650 (one per each head,
max. 3 heads possible)

Parallel Welding Clamps with Strap Aligner

The short circuit control head is equipped with CHARACTERISTICS

automatic height regulation by recipe on the Performance
operator panel. Single Welding Head up to 3 batteries/min.
Double Welding Head up to 4.5 batteries/min.
Triple Welding Head up to 6 batteries/min.
The intercell welding (through the partition) is
Container Length 175 - 500 mm
done by parallel welding clamps.
Container Height 160 - 300 mm
Container Width 125 - 275 mm
Welding clamps are operated hydraulically for
accurate control.
MACHINE DIMENSIONS (single welding head)
Linear movement of welding clamps prevents Length 4,500 mm
undesirable stress on straps.
Width 2,000 mm
Height 2,375 mm
The automatic intercell welding head is
Net Weight 1,800 kg
adjustable on three axes by recipe via the
operator panel.
UTILITIES
The battery conveyor is equipped with Air Pressure 6 bar
synchronizers, guides and stoppers. Uncompressed Air Volume 5.4 m3/h
Electrical Power Consumption 16 kVA
The discarding bench is equipped with an eject Technical data may change.
cylinder and has a capacity of 3 batteries.

Accurate strap alignment for best welding OPTIONS

results. n Up to three electro welding heads
n Second short circuit control machine after intercell welding
n Roller conveyor for battery recirculation after reject bench
n Tools for different battery types
 LID PLACER

AUTOMATIC LID PLACING MACHINE Storage Unit

The lid placer consists of two parts:

The storage and the lid placing unit

One storage unit consists of two buffers with

a total capacity of up to 60 stackable lids.

Lid Placing Unit

A sophisticated rack management system allows LID DIMENSIONS

easy and user-friedly loading during operation. Length 175 - 420 mm
Width 125 - 280 mm
The rotatable lid placing unit is equipped with
pole detection system in order to always place
the lid in correct position. MACHINE DIMENSIONS
Length 4,350 mm

The lid placing machine is equipped with PLC Width 1,700 mm

and operation panel. Height 2,250 mm
Net Weigth 1,000 kg
The storage racks are adjustable according to
customer’s battery range. UTILITIES
Air Pressure 6 bar
Electrical Power Consumption 3 Kw
Uncompressed Air Volume 6 mc/h

OPTIONS
n Post alignment unit
n Post greasing unit
n Additional lid store
Heat sealing machine

For WELDING the Lid to the Box

Homogeneous temperature for the whole heating
plate and innovative design for double heating
plate facilitate a proper sealing process.

Heating plates are equipped with splitting heaters

for easy maintenance of the tool. With one head
you are able to process batteries with a maximum
length of 350 mm.
Single Heating Plate for Truck Batteries

Separated heating systems allow the creation of CHARACTERISTICS

temperature differences of 20 - 30°C between Performance
box and lid. Single Welding Head up to 2.8 batteries/min.
Double Welding Head up to 4 batteries/min.
Triple Welding Head up to 6 batteries/min.
Heating plates are manually changed quickly and 175 - 500 mm
Container Length
easily; automatic change is available as well.
Container Height 160 - 300 mm
Container Width 125 - 275 mm
The welding temperature can be regulated
automatically by recipe on the operator panel.
MACHINE DIMENSIONS (single welding head)
The lid handling system is equipped with Length 4,500 mm
mechanical hooking for quick manual change 2,000 mm
Width
of tools.
Height 2,375 mm
Net Weight 1,800 kg
The battery conveyor within the machine
is equipped with synchronizers, guides and
stoppers. UTILITIES
Air Pressure 6 bar
Uncompressed Air Volume 5.4 m3/h
Electrical Power Consumption 30 kVA
Technical data may change.

OPTIONS
n Automatic change system for heating plate and lid handler
(including pre-heating system)
n Additional set of tools
 Post welding machine

For Creating the Final Poles Rotating Welding Torches

The post welding head is equipped with

oxyacetylene welding torches and welding bushes
with cooling system.

Optionally, we offer post welding with hot-pin

technology.

Hot-Pin Solution

The post welding head is equipped with CHARACTERISTICS

automatic height regulation by recipe on Performance
the operator panel. Single Welding Head up to 4 batteries/min.
Double Welding Head up to 6 batteries/min.

The welding torches are equipped with Container Length 175 - 500 mm

eccentrically adjustable devices. Container Height 160 - 300 mm

Container Width 125 - 275 mm
The water cooled welding shells ensure
optimally controlled thermal conditions.
MACHINE DIMENSIONS (single welding head)
Length 2,650 mm
Gas and oxygen regulation is done manually by
pressure reducers. Width 1,800 mm
Height 2,500 mm
A flow meter with capacity regulation device Net Weight 1,200 kg
and graduated scale for reading the quantity of
gas and oxygen ensures high-quality welding UTILITIES
(option: automatic controlled valves). Air Pressure 6 bar
Uncompressed Air Volume 3 m3/h
Electrical Power Consumption 3 kVA
Technical data may change.

OPTIONS
n Gas heated hot-pin
n Connection conveyor with manual post welding unit
n Automatic gas flow regulation valves
n Automatic post welding machine for car and truck batteries
 Leakage control and
marking machine

For Leakage Testing and Marking

Leakage Control Head
Leakage testing is done in two cycles (cells 1-3-5;
cells 2-4-6).

The standard machine includes a hot marking

unit. In addition we offer dot or laser marking.

OPTIONS
n Second leakage control head
n Pole height control unit
n Dot or laser marker Marking Unit and Pole Height Control Head
n Six pressure-transducer system

CHARACTERISTICS
Performances
The leakage tester is equipped with automatic Single Leakage Head up to 4 batteries/min.
Double Leakage Head up to 6 batteries/min.
height regulation by recipe on the operator
Container Length 175 - 500 mm
interface panel.
Container Height 160 - 300 mm

The manual positioning of the leakage heads is Container Width 125 - 275 mm
done by templates according to the different lid
MACHINE DIMENSIONS (single leakage head)
dimensions.
Length 4,200 mm
Width 1,500 mm
The leakage control head can be equipped with
different nozzles to check “Kamina” lid types as Height 2,200 mm

well as M18 flat lids. Net Weight 1,150 kg

UTILITIES
The leakage testing pressure is adjustable from
Air Pressure 6 bar
0 to 400 mbar.
Uncompressed Air Volume 4.8 m3/h

The marking unit is equipped with temperature Technical data may change.

regulation.
WE CARE ABOUT

H S E
Health. Safety. Environment.
PR 1010940E/02.16

Rosendahl Nextrom GmbH T +43 3113 5100-0 office.bm@rosendahlnextrom.com

8212 Pischelsdorf, Austria F +43 3113 5100-51 www.rosendahlnextrom.com
No liability is accepted for errors or misprints. We reserve the right to modify or improve the design or manufacture of machinery and equipment described herein and to alter specifications accordingly without prior notice.