AITO – New Energy Battery Pack Conveyor Line
Turnkey heavy-duty battery pack conveyor line for AITO — safe, cleanroom-compatible, fully integrated with MES for real-time traceability.
Background
AITO is a fast-growing Chinese new energy vehicle manufacturer known for its premium electric SUVs. To support the ramp-up of its latest EV platform, the company required a dedicated battery pack conveyor line capable of handling large, high-voltage battery assemblies through multiple production stages.
Challenge
Battery pack handling presents unique requirements not found in traditional automotive conveying:
- Heavy payload — Each battery pack weighs several hundred kilograms, demanding robust conveyor design and precise positioning
- High-voltage safety — The conveying system needed to maintain strict isolation and safety protocols throughout the line
- Cleanroom compatibility — Battery pack assembly requires a controlled environment with minimal particle generation from the conveyor itself
- Seamless process integration — The line needed to connect multiple stations including assembly, tightening, electrical testing, and end-of-line inspection
- Mixed-model flexibility — The system had to accommodate different battery pack variants for various AITO vehicle models
Solution
Hongbo designed and delivered a complete turnkey battery pack conveyor line, integrating:
- Heavy-duty roller conveyor system — Precision-ground rollers with individual load capacity exceeding the maximum battery pack weight, ensuring smooth and stable transport
- Automatic lift tables at each station — Pneumatic lift tables positioned at every workstation to facilitate ergonomic operator access and automated equipment interface
- Pallet-based workpiece carriers — Custom-designed pallets with locating pins and anti-static surfaces, providing repeatable positioning accuracy and protecting sensitive battery components
- Cleanroom-compatible construction — Low-particle-generation materials and enclosed roller bearings to meet battery assembly cleanroom standards
- Integrated safety system — Light curtains, emergency stops, and high-voltage isolation zones integrated into the conveyor control logic
- Full MES connectivity — Each pallet RFID-tagged for real-time tracking, with conveyor status, station dwell time, and product genealogy recorded per battery pack
The entire system was pre-assembled and run-off tested in Hongbo’s workshop before shipment, minimizing onsite disruption.
Results
- Conveyor line delivered and fully operational, meeting the client’s production ramp-up schedule
- Smooth, stable battery pack transport with zero positioning errors since commissioning
- Mixed-model capability confirmed — the line handles multiple battery pack variants with automatic pallet recognition
- Cleanroom particle count maintained well within specification, with no contamination-related quality issues
- Full MES traceability from pack assembly through final test, supporting the client’s quality audit requirements
- Line capacity aligned with the client’s target production volume for the new EV platform
Key Equipment Delivered
- Heavy-duty roller conveyor system
- Automatic lift tables at all assembly and test stations
- Custom anti-static pallet carriers with RFID tags
- Pallet return loop with automatic stacker/destacker
- Integrated safety system (light curtains, interlocks, zone control)
- MES interface and real-time production monitoring dashboard