Industries / Automotive / HV battery components

Automating production of high-voltage battery components for EVs.

High-voltage battery systems are the core technology of the electric vehicle revolution. Their manufacturing and validation demand an extraordinary level of precision, safety, and quality control.
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Powering the e-mobility revolution.

Pagero's way

Safety-first mentality
We design systems to safely test and handle high-voltage components, protecting your team and ensuring the absolute electrical integrity of every battery unit.
High-volume throughput
Our solutions are engineered for speed and efficiency, enabling you to test, inspect, and palletize battery components at the scale required by modern EV production.

END-OF-LINE HIGH-VOLTAGE TESTING

Validating every volt
with absolute certainty
Our custom-built end-of-line test rigs are designed to perform comprehensive high-voltage (HV) tests with the utmost safety and precision. We automate the entire sequence, from connection to the battery's busbars to the final pass/fail report, validating the electrical integrity of every unit before it leaves your facility.
High-voltage testing up to 2000V
Dielectric strength (Hipot) testing
Insulation resistance measurement
Continuity and isolation checks
Automated safety interlock systems
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PROFILE and GEOMETRY CHECKS

Ensuring a perfect fit
with on-the-fly scanning
This is where the core of the steering gear is built. We deploy advanced robotics and torque-controlled tools to assemble the intricate mechanical components and seamlessly integrate the electronic systems, such as motors and sensors for modern Electric Power Steering (EPS).
In-line 3D laser and structured light scanning
Verification of flatness, parallelism, and key features
Comparison to CAD model for deviation analysis
Automated pass/fail based on GD&T specifications
Complete dimensional data logging for traceability
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MULTI-LINE ROBOTIC PALLETIZING

Safe and efficient
end-of-line logistics
Finished battery packs and components are heavy and require careful handling. We engineer robust, multi-line robotic palletizing systems that safely pick up finished units from multiple production lines and stack them according to a predefined pattern, ready for safe and secure shipment.
Heavy-payload robotic integration
Custom end-of-arm tooling (EOAT) for secure gripping
Integration with multiple conveyor or AGV lines
Automated dunnage and slip sheet placement
Full pallet load tracking and labeling
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Ready to power your EV production?
Let's discuss how our advanced automation and testing solutions
can ensure the safety and quality of your high-voltage battery components.

Frequently asked questions (FAQs)

How do you ensure operator safety during high-voltage (HV) testing?

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We treat it as a single, unified 'mechatronic' challenge. Our process ensures that the mechanical assembly (like gear meshing) and the electronic integration (like sensor placement) are performed with consideration for each other, often using robots with advanced force-feedback to ensure delicate parts are connected correctly and securely.

What is 'on-the-fly' scanning, and how is it different from traditional CMM?

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'On-the-fly' scanning means the measurement is taken as the part moves along the production line, without needing to stop. Unlike a traditional Coordinate Measuring Machine (CMM) which is slow and typically used offline in a lab, our in-line scanning solutions provide 100% inspection at production speed, giving you immediate feedback on every part.

Can your palletizing system handle different component sizes or stacking patterns?

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Yes. We design our robotic palletizing systems to be flexible. Using intelligent vision systems and adaptable software, a single cell can be programmed to handle multiple component sizes and to build different pallet patterns based on the product type it receives from the production lines.

How do you provide data traceability for test and measurement results?

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Every test and measurement we perform is linked to the unique serial number of the component. We create a complete digital record that includes the pass/fail status, all specific measurements (like voltage leakage, dimensional data), and a timestamp. This data can be automatically uploaded to your factory's MES or Quality Management System for full traceability.