Modular Machine Design for Flexible Battery Production

At CMWTEC, we develop intelligent machine solutions tailored to the demands of modern battery manufacturing. Our modular machine design enables maximum flexibility, whether you require a standalone machine or a fully integrated battery production line.

Each machine can be configured individually and combined into complete, customized production systems. This allows for a highly efficient and scalable approach to battery assembly – perfectly aligned with your specific process requirements.

Our technology is used across a wide range of applications, including AGM batteries, SLI batteries, motorcycle batteries, automotive batteries, truck batteries, and industrial lead-acid batteries.

Key Advantages of the CMWTEC Modular System

1. Flexible system configurations – Machines can operate independently or as part of a connected line
2. Scalable automation – Add modules as your production expands
3. Custom engineering – Tailored solutions for unique process requirements
4. Future-proof investment – Designed for long-term adaptability and system upgrades
5. Process transparency – Integrated data acquisition for efficient quality control and traceability
6. Optimized usability – Ergonomic machine designs support smooth operation and maintenance

With CMWTEC, you benefit from a future-ready production environment, capable of adapting to new challenges and technologies. Our experienced engineering team supports you from concept to commissioning – ensuring that each solution integrates seamlessly into your operations.

Discover Our Modular Machine Portfolio

The modular approach at CMWTEC is not just a design philosophy – it’s the foundation of our Premium Line. Selected machines from this product line are specifically developed for modular integration and can be flexibly combined into highly efficient, automated production lines.

From acid filling and level control to plug insertion, electrical testing, and final cleaning – we offer a wide range of machines that work seamlessly together or as standalone units. Our Combination Machines bring multiple process steps together in one compact system, increasing efficiency while reducing floor space and handling time.

Below, you’ll find an overview of the modular machines from our Premium Line and the available combination systems – including detailed technical specifications and application insights.

AUTOMATIC INITIAL ACID FILLING MACHINE

The automatic intital acid filling machine is designed for filling of sulphuric acid into automotive batteries by volume controlling up to the pre-selected volume. The individual batteries supplied through the conveyor of the finishing line are exactly positioned. The fill stroke moves down, and the individual filling heads are lowered into the filling holes of the battery. The volume control by flow meter facilitates the achievement of a quick and exact fill volume. When the pre-selected volume is reached the fill stroke will raise up, the battery will be fed out of the machine, and the next batteries will be fed in.

AUTOMATIC ACID LEVELLING/LEVEL CHECK MACHINE

The automatic acid levelling/level check machine is designed for checking under- and over-filling of sulphuric automotive batteries. The individual batteries supplied through the conveyor of the finishing line are exactly positioned. The fill stroke moves down, and the levelling heads are lowered into the filling holes of the battery. The first station checks the acid level in the battery. If a battery is under-filled it will be topped-up to the level, if a battery is over-filled it removes the acid out of the battery with diaphragm pumps. As a result, the acid level is accurate in all the individual cells by means of tungsten electrode monitoring. The second station will check the levelling unit by lowering the Check heads with a distance measuring system until each electrode gets in contact with acid. The result will be displayed on the HMI for verification. An exact level achievement is guaranteed. If a battery fails it will be rejected on a table

AUTOMATIC PLUG INSERTION MACHINE

The automatic plug insertion machine has been designed for a finishing line following the battery container formation. The batteries filled with sulphuric acid are sealed simultaneously by means of single plugs with an electronic servo motor. Plugs will be screwed in with torque control by a servo driven screw-in device. In a separate plug height control test station before approaching the washing machine the plugs are finally checked if they are applied incorrectly or even missing.

HIGH RATE DISCHARGE TEST MACHINE

The unit can be used for high-rate discharge test of batteries after the formation in the finishing area. The individual batteries supplied through the conveyor of the test machine are positioned exactly. The test stroke is lowered onto the battery terminals. Batteries will be tested by a special electrical measuring system (CHL500). Therefore the individual test clamps will make a tight grip on both terminals, positive and negative.

HIGH VOLTAGE LEAKAGE TEST MACHINE

The machine is designed for high voltage controlling for leakage of batteries in a finishing line. The individual batteries supplied through the conveyor of the finishing line are positioned exactly. Batteries will be controlled by a special digital electric test device system. The positive electrode will be pressed on one of the battery terminals. The four strips of the negative electrode will be positioned round the sealing line between the battery cover and the battery box as well as on the bottom of the battery box. While testing a high voltage (max.12 kV) is being fed. If there is an equalization of the electric potential (i.e. sparks) between the electrodes it indicates a leakage of the battery. By a special function the leakage point can be shown by burning.

COMBINATION MACHINES

The concept of our combination machines based on the technology of premium line automatic machines with the focus on the application process. Space and cost saving with the full benefit of single machines.

Customized for our customer needs.

2-in-1 COMBINATION MACHINE BRUSHING / HRD+ACR

The machine is designed to have 2 different functions units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the combination machine are positioned exactly at each function station. The special designed rotating brushing tool is lowered onto the battery terminal. Brushing is accomplished by means of steel brush inserts mounted in the rotating tool with lead dust suction inside the tool. After this the battery is entering the High-Rate Discharge testing with our new E-Load modules integrated in the machine design. Additional to the HRD the unit can test also ACR (Internal Resistance) The machine is equipped with a reject table for eject batteries which have not passed the HRD test.

2-in-1 COMBINATION MACHINE BRUSHING / HRD

The machine is designed to have 2 different functions units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the combination machine are positioned exactly at each function station. The special designed rotating brushing tool is lowered onto the battery terminal. Brushing is accomplished by means of steel brush inserts mounted in the rotating tool with lead dust suction inside the tool. After this the battery is entering the High-Rate Discharge testing with our new E-Load modules integrated in the machine design. The machine is equipped with a reject table for eject batteries which have not passed the HRD test.

2-in-1 COMBINATION MACHINE HRD/ACR

The machine is designed to have 2 different functions units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the combination machine are positioned exactly at each function station. The first station measures the internal resistance by using clamps which are connected to the electronic test device. After this the battery is entering the High-Rate Discharge testing with our new E-Load modules integrated in the machine design. The machine is equipped with a reject table for eject batteries which have not passed the HRD or Impedance test.

2-in-1 COMBINATION MACHINE BRUSHING / HRD

The machine is designed to have 2 different functions units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the combination machine are positioned exactly at each function station. The special designed rotating brushing tool is lowered onto the battery terminal. Brushing is accomplished by means of steel brush inserts mounted in the rotating tool with lead dust suction inside the tool. After this the battery is entering the High-Rate Discharge testing with our new E-Load modules integrated in the machine design. The machine is equipped with a reject table for eject batteries which have not passed the HRD test. Batteries who need to be retested can easily transport from reject table back to entry by our battery transfer carriage unit (battery shuttle).

3-in-1 COMBINATION MACHINE OCV/ LEVELLING/LEVEL CHECK

The machine is designed for pre-check of open circuit voltage and checking of under- and over-filling of sulphuric automotive batteries. The individual batteries supplied through the conveyor of the finishing line are exactly positioned. The fill stroke moves down, and the levelling heads are lowered into the filling holes of the battery. The first station checks the acid level in the battery. If a battery is under-filled it will be topped-up to the level, if a battery is over-filled it removes the acid out of the battery with diaphragm pumps. As a result, the acid level is accurate in all the individual cells by means of hose sensor monitoring. The second station will check the levelling unit by lowering the Check heads with a distance measuring system until each tungsten electrode gets in contact with acid. The result will be displayed on the HMI for verification. An exact level achievement is guaranteed. If a battery fails it will be rejected on a reject table.

3-in-1 COMBINATION TEST MACHINE

The unit can be used for high-rate discharge test of batteries after the formation in the finishing area. The individual batteries supplied through the conveyor of the test machine are positioned exactly. The test stroke is lowered onto the battery terminals. Batteries will be tested by a special electrical measuring system (CHL500). Therefore, the individual test clamps will make a tight grip on both terminals, positive and negative.

5-in-1 COMBINATION TEST MACHINE

The machine is designed to have 5 different function units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the test machine are positioned exactly at each function station. Post brushing, followed by High-Rate Discharge testing, High Voltage Leakage test, post greasing and finally Needle Marking function unit for date codes. The machine is equipped with a reject table for ejecting batteries which have not passed the HRD or HV test.

CUSTOMIZED EOL AUTOMOTIVE 2-in-1

The machine is designed to have 2 different function units in one main frame with one PLC controller and one HMI. The individual batteries supplied through the conveyor of the test machine are positioned exactly at each function station. High-Rate Discharge testing with our new E-Load modules integrated in the machine design is followed by a High Voltage Leakage test of the cover seal and the box bottom. The machine is equipped with a reject table for ejecting batteries which have not passed the HRD or HV test.