Battery Assembly

Solutions for Module & Pack Assembly

Highest quality

Ultrasonic Contacting & Dynamic Environmental Simulation

Ultrasonic welding delivers a reliable and highly reproducible joining process for battery modules and packs. Using both torsional and longitudinal technologies, Schunk enables robust welding of critical electrical connections, including busbars, with consistent quality.

Integrated quality monitoring ensures maximum process reliability during welding, without the need for additional positioning aids. Closely spaced welding systems enable multiple welds to be carried out simultaneously, significantly increasing productivity - a clear advantage for series production.

Complementing the joining process, our test chamber solutions for battery modules and packs enable comprehensive environmental simulation under extreme conditions. Designed for high‑energy batteries, they deliver the highest safety standards and can be flexibly adapted to individual test setups for demanding development and quality‑assurance applications.

Ultrasonic Welding - Busbars

Ultrasonic welding is the proven standard for busbar joining in battery production. It enables fast, safe, and high‑strength metal‑to‑metal connections with minimal heat input - ideal for automated high‑voltage applications.

Extremely strong high‑current connections
Perfect for HV busbars, delivering low contact resistance and maximum conductivity.

Fast, robust process for series production
Short cycle times, high reproducibility, and no additional filler materials.

Minimal heat input, even with thick cross‑sections
No structural damage or insulation melting - a process‑reliable solution for e‑mobility production.

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Test Chambers for Battery Modules and Packs

We provide advanced test chamber solutions from 100 liters to 20 m³ for the safe, reproducible testing of battery modules and packs under real‑world and extreme operating conditions.

Comprehensive environmental simulation
Validation of battery modules and packs under thermal, climatic, and mechanical stresses, including heat, cold, humidity, dust, and combined load scenarios.
Integrated safety concepts
Chambers equipped with application‑specific protection features aligned to defined hazard levels, ensuring maximum safety for personnel and test environments.
Flexible, scalable solutions
Available as standardised or custom‑engineered systems, configurable for a wide range of module and pack designs and test specifications.