XWELL XW-BS05 Automatic Cylindrical Battery Cell Sorting Machine

Product Overview

The XWELL XW-BS05 is an automatic cylindrical battery cell sorting machine designed for high-throughput voltage and internal resistance (IR) testing with automated multi-channel sorting. The equipment processes cylindrical cells—including 18650, 21700, 26700, 32650, and 32700 form factors—at a throughput of 2,500 to 3,000 pieces per hour. Tested cells are distributed across five output channels: four channels for accepted cells sorted by parameter ranges, and one channel for rejected (NG) cells.

The system integrates mechanical handling, a feeding mechanism, a testing station, and a programmable logic controller (PLC)-based sorting control architecture. A dedicated PC handles test data acquisition, voltage and internal resistance rating, and data export in CSV format. The mechanical structure is constructed from cold-rolled sheet metal with an aluminum frame, resulting in a unit weight of 200kg and footprint of 1,000 * 1,000 * 1,600mm.

Operating from a single-phase AC 220V / 50Hz supply with a rated power consumption of 1,000W, the XW-BS05 requires compressed air at 0.4–0.6MPa for pneumatic actuation of the sorting mechanism. An optional barcode scanner can be integrated for cell-level traceability, and users may select between HOPE HK3561 and HIOKI BT3561 internal resistance testers depending on precision and budget requirements.

Product Features

• Multi-Format Cylindrical Cell Compatibility: The equipment accepts cylindrical cells including 18650, 21700, 26700, 32650, and 32700 form factors, covering the most common lithium-ion cell sizes used in battery pack assembly.
• Five-Channel Sorting Output: Tested cells are routed to five separate channels—four for accepted (OK) cells sorted by user-defined voltage and IR parameter bands, and one for rejected (NG) cells that fall outside specified tolerance ranges.
• 2,500–3,000 pcs/h Throughput: The automated feeding, testing, and sorting sequence achieves a processing speed of 2,500 to 3,000 cells per hour, suitable for medium to high-volume battery pack production lines.
• Integrated Voltage and IR Testing: Each cell undergoes simultaneous voltage measurement and internal resistance testing at the test station. The tester reads both parameters and transmits results to the controller for real-time sorting decisions.
• PLC and PC Dual-Control Architecture: A motion controller and PLC manage the mechanical sequence—cell feeding, handling, and channel routing—while a dedicated PC handles test data collection, voltage and IR rating, data recording, and CSV export.
• Automated Feeding System: Cells are loaded into the input bin and transported by a roller-driven feeding mechanism to the test position, where spring-loaded probes make contact with the cell positive and negative terminals for measurement.
• PC-Based Data Management: The companion PC software records all test results and supports data export to CSV format, enabling batch traceability and quality documentation for production records.
• Optional High-Precision IR Tester: Users can configure the machine with a HOPE HK3561 or HIOKI BT3561 internal resistance tester, accommodating different accuracy and budget requirements for production or laboratory environments.
• Rugged Mechanical Construction: The chassis and structural components are manufactured from thick cold-rolled sheet metal, with an aluminum frame providing rigidity while maintaining a manageable unit weight of 200kg.
• Optional Barcode Scanner Integration: A barcode scanner can be added to the system for individual cell identification and traceability, linking test data to specific cell serial numbers for quality assurance workflows.
• Adjustable Sorting Parameters: Voltage and internal resistance sorting thresholds are configured through the PC software, allowing operators to define multiple acceptance bands across the four OK channels based on production grading requirements.
• Compact Footprint for Production Line Integration: With dimensions of 1,000 * 1,000 * 1,600mm, the XW-BS05 occupies approximately one square meter of floor space, facilitating integration into existing battery pack assembly lines.

Working Principle

The XW-BS05 operates through a sequential automated workflow that combines mechanical handling, electrical measurement, and pneumatic sorting. The process begins when cylindrical cells are loaded into the input bin. A motorized roller mechanism advances individual cells from the bin toward the testing station, maintaining consistent feed spacing for reliable measurement contact.

At the test position, spring-loaded probe contacts engage the positive and negative terminals of each cell. The connected internal resistance tester—a HOPE HK3561 or HIOKI BT3561 depending on configuration—simultaneously measures the cell's open-circuit voltage and internal resistance. These two parameters form the basis for all downstream sorting decisions. The measurement cycle is synchronized with the mechanical feed timing to maintain throughput without compromising contact stability.

The tester transmits measured values to the system controller, which compares each cell's voltage and IR readings against the user-defined sorting thresholds configured in the PC software. Based on this comparison, the controller assigns the cell to one of five destination channels. The PLC then actuates the pneumatic sorting mechanism to direct the cell to the appropriate output channel—one of four OK channels corresponding to different parameter grades, or the NG channel for cells falling outside all acceptance windows.

The entire sequence, from cell feeding through measurement to channel routing, is coordinated by the motion controller and PLC working in tandem. The PC concurrently logs all test data—cell voltage, internal resistance, assigned channel, and timestamp—into a structured dataset that can be exported to CSV format for batch quality reporting and production traceability.

The pneumatic system operates at 0.4–0.6MPa compressed air pressure to drive the sorting gate actuators, providing the response speed necessary to maintain the rated throughput of 2,500–3,000 cells per hour. The mechanical handling system uses durable contact surfaces to minimize cell casing abrasion during transport through the feeding and sorting stages.

Product Advantages

• Handles five cylindrical cell formats (18650, 21700, 26700, 32650, 32700) on a single machine without changeover tooling
• Five-channel output with four programmable OK grading bands and one dedicated NG channel
• Dual voltage and internal resistance measurement at each test cycle for comprehensive cell quality assessment
• 2,500–3,000 pcs/h sorting throughput supports medium to high-volume production requirements
• PLC-controlled mechanical sequence and PC-based data management operate as independent subsystems for reliability
• User-configurable sorting thresholds through PC software interface with no hardware adjustment required
• CSV data export enables integration with manufacturing execution systems and quality databases
• Optional HIOKI BT3561 tester upgrade path for applications requiring higher measurement precision
• Optional barcode scanner adds per-cell traceability linking test data to individual cell identity
• 1000W power consumption from standard AC220V/50Hz single-phase supply suits most production facilities

Application Industries

• Cylindrical lithium battery cell manufacturing and quality grading
• 18650 battery pack assembly line incoming cell inspection
• 21700 battery module production cell sorting and matching
• Power tool battery pack cell quality screening
• Electric bicycle and scooter battery pack cell grading
• Energy storage system battery module cell parameter matching
• Consumer electronics battery pack cell voltage and IR testing
• Third-party battery cell testing and sorting service providers
• Battery cell recycling and second-life qualification testing
• Battery research and development cell characterization and binning

Why Choose This Machine

Battery pack performance and safety depend heavily on cell consistency. When cells with varying internal resistance or voltage are assembled into a series-parallel pack, current imbalance during charge and discharge accelerates degradation of the weakest cells. The XW-BS05 addresses this by combining automated voltage and IR measurement with five-channel physical sorting, enabling pack manufacturers to group cells into tightly matched parameter bands before assembly.

The dual-control architecture separates mechanical automation from data management. The PLC and motion controller handle the real-time requirements of cell feeding, probe contact timing, and pneumatic sorting actuation. Simultaneously, the PC software independently manages measurement data acquisition, threshold comparison logic, and CSV export. This separation means that data processing load does not impact the mechanical cycle time, and conversely, mechanical adjustments do not disrupt data recording continuity.

The equipment's compatibility with five cylindrical cell formats—18650, 21700, 26700, 32650, and 32700—eliminates the need for multiple sorting machines dedicated to individual cell sizes. This is particularly relevant for manufacturers producing battery packs in multiple configurations or contract manufacturers serving customers with varied cell specifications. The absence of changeover tooling between cell formats reduces setup time and operator intervention between production runs.

With a sorting rate of 2,500 to 3,000 cells per hour, the XW-BS05 matches the throughput requirements of typical small to medium battery pack assembly operations. The optional upgrade path from the HOPE HK3561 to the HIOKI BT3561 IR tester provides flexibility for applications that demand higher measurement precision, while the optional barcode scanner adds cell-level traceability for quality management systems requiring individual cell data records throughout the production lifecycle.

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