As the global battery industry accelerates toward higher production volumes, tighter quality standards, and advanced automation, the role of precision testing and sorting equipment has become more critical than ever. In lithium-ion battery manufacturing, even the slightest variation in cell voltage or internal resistance can significantly impact the safety, performance, cycle life, and reliability of the final battery pack.
To address these challenges, Semco Infratech has developed the Semco SI-ABR 6CH SM (32140-33145) — a high-speed six-channel cylindrical cell sorting machine equipped with barcode scanning and automated testing capabilities. Designed for modern battery manufacturing environments, this machine combines precision measurement, intelligent sorting, and data traceability into a compact and efficient platform.
The Growing Need for Intelligent Cell Sorting
In lithium-ion battery pack manufacturing, cell consistency is one of the most important parameters affecting overall system performance. Cells with mismatched voltage or internal resistance can lead to Uneven charge/discharge behavior, Reduced pack efficiency, Accelerated aging, Thermal imbalance and Increased safety risks.
To ensure reliable pack assembly, manufacturers must accurately test and classify cells before module or pack integration. The Semco 6 Channel Cell Sorting Machine is specifically designed to automate this process with high speed, high precision, and full traceability.
What is the Semco SI-ABR 6CH SM?
The Semco SI-ABR 6CH SM is a universal cylindrical cell testing and sorting machine capable of scanning battery barcodes, measuring internal resistance and voltage, and automatically sorting cells into designated categories based on predefined parameters.
The system supports cylindrical cell formats including: 32140, 33138, 33145 and can achieve sorting speeds of up to 3,000 cells per hour, making it an ideal solution for medium- to high-volume production lines.
Key Features of the Semco Cell Sorting Machine
1. High-Speed Automated Sorting
The machine delivers a sorting efficiency of ≥50 PPM (pieces per minute), enabling battery manufacturers to improve throughput while maintaining testing accuracy.
The six-channel architecture allows the machine to classify cells into: 5 OK sorting grades, 1 NG (No Good) rejection grade. This multi-level sorting capability helps manufacturers group cells with highly similar electrical characteristics for optimized pack balancing and performance.
2. Integrated Barcode Scanning for Full Traceability
One of the standout features of the system is its integrated barcode scanning functionality. The machine uses a high-speed scanner gun to read barcode information from each cylindrical cell before testing.
The barcode data is then linked with the measured parameters, including Open circuit voltage and AC internal resistance. This data-binding process creates a complete digital traceability record for every cell processed through the system.
In modern EV and BESS manufacturing, traceability has become essential for Quality assurance, Production analytics, Warranty management, Root-cause failure analysis and Regulatory compliance.
By integrating barcode traceability directly into the sorting process, Semco enables manufacturers to build smarter and more transparent production systems.
Precision Testing Capabilities
The Semco SI-ABR 6CH SM is equipped with a high-precision automatic testing system capable of accurately measuring:
Open Circuit Voltage (OCV): Accuracy: ±0.10% rdg | Resolution: 0.1 mV
AC Internal Resistance: Accuracy: ±0.5% rdg | Resolution: 0.01 mΩ
These precision levels are critical because small variations in internal resistance can lead to significant thermal and performance imbalances during high-rate charging and discharging.
Intelligent Automation Architecture
The machine utilizes a PLC + HMI control architecture, combining industrial automation reliability with user-friendly operation.
- PLC Functions: Battery feeding | Transportation | Sorting actuation | Collection operations
- Touchscreen HMI Functions: Parameter setup | Data collection and storage | Voltage/internal resistance classification | Battery parameter management
The system is designed for simple operation, minimizing the need for extensive operator training while maximizing production efficiency.
Process Flow of the Sorting Machine
The operating workflow is fully automated after manual loading of cells. The process includes:
- Manual battery loading
- Feeding wheel transfer
- Barcode scanning
- Voltage and internal resistance testing
- Software-based sorting logic
- Conveyor transport
- Pneumatic sorting into designated channels
The machine also includes Automatic shutdown functions, Full material alarms, Fault alarms and Sound and light warning systems. These features improve operational safety and reduce downtime during production.
Compact Design with Industrial Durability
Semco has engineered the machine with a compact footprint and industrial-grade construction to suit modern battery manufacturing facilities. The system is built using high-quality thick cold-rolled sheet metal for structural durability and long operational life.
Machine Specifications:
- Dimensions: 1755 × 800 × 1420 mm
- Weight: ~200 kg
- Power Supply: Single-phase AC220V ±5% / 50Hz
- Power Consumption: ≤800W
- Air Supply Requirement: 0.4–0.6 MPa
The machine is also equipped with universal movable casters, allowing easy relocation within production facilities.
Ideal Applications
The Semco Six Channel Cell Sorting Machine is suitable for a wide range of lithium-ion battery manufacturing applications, including: EV battery pack production, Energy Storage System (BESS) manufacturing, Power tool battery assembly, E-bike and e-scooter battery production, Cylindrical cell grading and matching and Battery R&D and testing laboratories.
As demand for lithium-ion batteries continues to rise globally, intelligent sorting equipment like this becomes essential for maintaining consistent production quality at scale.
Supporting India’s Battery Manufacturing Ecosystem
India’s battery manufacturing industry is undergoing rapid expansion driven by: EV adoption, Renewable energy integration, Grid-scale BESS deployment, ACC PLI initiatives and Domestic manufacturing localization.
In this evolving landscape, Semco Infratech continues to position itself as a leading provider of advanced battery assembly and testing solutions. The company offers complete turnkey solutions ranging from automated manufacturing lines to high-voltage BESS testing systems. With expertise in automation, testing, traceability, and industrial engineering, Semco supports manufacturers in building safer, smarter, and more scalable battery production facilities.
Conclusion
Battery quality begins at the cell level. No matter how advanced a battery pack design may be, inconsistent cells can compromise performance, reliability, and safety. This is why automated cell testing and sorting systems have become a foundational element of modern lithium-ion manufacturing.
By combining testing accuracy, operational efficiency, and data-driven traceability, Semco delivers a future-ready solution for the next generation of EV and energy storage manufacturing.
Contact Semco Infratech to discuss your EV & BESS manufacturing requirements and discover how automatic assembly solutions can enhance your production efficiency, ensure product quality, and accelerate your path to market competitiveness.