A Cell Contact System (CCS) is a critical assembly within a battery module, combining electrical interconnections with voltage and temperature sensing functions. Depending on the CCS design, its manufacturing process may involve two important joining technologies: pulse hot riveting and laser welding.
Although these processes are often used within the same production line, they serve different purposes. Understanding their differences is essential when specifying a CCS production line, because the joining sequence, positioning methods, testing requirements, and inspection systems all influence the final equipment configuration.
This guide explains how pulse hot riveting and laser welding work in CCS manufacturing, how they can be integrated into a production process, and which technical parameters battery manufacturers should confirm before selecting a CCS automated production line.
What Is a Cell Contact System (CCS)?
A Cell Contact System (CCS) is an electrical interconnection and sensing assembly used inside a battery module. Depending on the product design, it typically includes several components:
- FPC or FFC sensing harness: Transmits voltage and temperature signals.
- Busbars: Provide electrical connections between battery cells.
- Nickel sheets: Serve as conductive joining components in applicable designs.
- Connectors: Connect the sensing circuits to the battery management system (BMS).
- Insulating film or carrier structure: Supports component positioning, insulation, and protection.
Because a CCS combines electrical connection and sensing functions, the reliability of each joint is important to the overall performance of the battery module.
Positioning errors, incomplete welds, damaged sensing circuits, or incorrectly assembled connectors may affect electrical continuity, signal acquisition, or downstream testing results.
For this reason, joint reliability, positioning accuracy, electrical testing, and inspection capability are important considerations when designing a CCS production line.
Pulse Hot Riveting vs. Laser Welding: What Is the Difference?
Pulse hot riveting and laser welding are complementary processes rather than interchangeable technologies.
Pulse hot riveting is primarily a mechanical fixation process. Heated riveting tools soften and form plastic posts to secure the FPC, busbars, and carrier components in their designed positions, where the CCS structure uses this type of fixation.
Laser welding is a joining process used to create electrical connections between compatible metal components. Depending on the CCS design, it may be used to join nickel sheets and busbar components.
In simple terms, hot riveting helps secure the CCS components in position, while laser welding creates the required electrical joints.
Because the two processes perform different functions, they should be evaluated separately when specifying a CCS automated production line.
The required process configuration depends on the CCS architecture, materials, connection design, and product specifications.
Why Does Hot Riveting Typically Come Before Laser Welding?
Hot riveting can establish the mechanical position of CCS components before the welding process.
Once the FPC, busbars, carrier, and related components are secured, downstream welding and inspection stations can work from a more stable reference.
If components must be re-fixtured or transferred between separate process areas, additional handling and positioning steps may introduce cumulative positioning errors.
For this reason, an integrated CCS production line may combine hot riveting, laser welding, electrical testing, and Automated Optical Inspection (AOI) into a coordinated production flow using consistent carrier positioning and process references.
However, the actual process sequence should be determined by the CCS structure, joining requirements, and customer specifications. Not every CCS design requires the same process route.
How Is a Pulse Hot Riveting Station Configured?
A pulse hot riveting station can use a multi-head structure to process multiple riveting points within a production cycle.
A reference configuration may include:
- 12 riveting heads, depending on the equipment design.
- A reference processing time of approximately 10 seconds, subject to the specified cycle-time definition and product configuration.
- Positioning repeatability of approximately ±0.05 mm for a specified configuration.
- Independent temperature control for individual hot-melt nozzles.
- Real-time temperature monitoring.
Independent temperature control helps maintain consistent riveting conditions across different points of the assembly.
Because riveting positions may differ in material thickness, structure, and thermal characteristics, individual temperature settings can be adjusted according to the actual joint requirements.
The number of riveting heads is not fixed. It can be configured according to the customer’s product structure, riveting-point count, and production-capacity target.
Important: These figures are reference parameters for a specific configuration, not universal performance guarantees. The final riveting-head count, cycle time, positioning performance, and temperature-control requirements should be confirmed in the project technical proposal.
How Is Laser Welding Configured in CCS Production?
Laser welding is used to create electrical connections within the CCS assembly.
Because CCS welding often involves thin metal components, weld quality depends not only on laser power but also on part positioning, clamping, focus control, and welding-path accuracy.
A laser welding station may incorporate the following functions.
1. Clamping and Position Control
The welding fixture may use a brass clamping structure combined with a spring mechanism.
The spring provides controlled compression during clamping, helping maintain contact between the components while reducing the risk of excessive mechanical pressure.
The final fixture design should be selected according to the component geometry, material properties, and welding requirements.
2. Focus Distance Detection
Focus distance detection helps maintain the required laser focal position during welding.
In one reference configuration, focus-distance detection accuracy is approximately ±0.1 mm, with automatic focus adjustment.
The actual specification should be determined according to the material, thickness, joint structure, and laser process used in the project.
3. Vision-Based Alignment
A vision system can identify the actual position of the nickel sheet or other designated welding features and correct the welding position before the laser process begins.
This approach can help compensate for positioning deviations and improve welding-path consistency.
For a specific reference configuration, a laser welding pass-rate target may be approximately 98% or higher.
However, actual welding yield depends on the material, joint structure, laser parameters, fixture accuracy, production conditions, and acceptance criteria. The final performance target should be agreed upon during technical evaluation and equipment acceptance.
How Are CCS Joints Verified?
CCS quality verification commonly combines electrical performance testing and AOI inspection because these systems identify different types of potential defects.
1. Electrical Performance Testing
Electrical testing verifies whether the CCS circuit meets the specified electrical requirements.
A reference configuration may support up to 512 measurement points, with test conditions including AC 1000 V and DC 1500 V, depending on the product and test requirements.
The test scope may include:
- Voltage measurement
- Insulation performance
- Internal resistance
- Circuit continuity
- NTC performance
- Resistance measurement
Not every CCS project requires all these tests or voltage levels. The test program, test voltage, measurement channels, and acceptance limits must be defined according to the product design and applicable safety requirements.
The number of measurement points should match the actual CCS architecture. Products with higher sampling density may require additional test channels.
2. Automated Optical Inspection (AOI)
AOI provides automated visual inspection of the CCS assembly.
A reference configuration may use a line-scan camera with approximately 20 μm or finer resolution, covering a detection area of approximately 2000 mm × 800 mm.
Depending on the inspection system and product requirements, typical inspection items may include:
- Laser welding: Missing welds, weld-position deviations, and nickel-sheet misalignment.
- Hot riveting: Missing rivet points, rivet-position deviations, and damaged rivet posts.
- FPC/FFC: Creases, missing components, and positioning defects.
- Connectors: Pin deviations, damaged or missing pins, and foreign objects.
It is important to distinguish between full-inspection items and inspection items governed by a specified detection rate.
For example, missing components or clearly defined positioning defects may be specified as full-inspection items. Some appearance-related conditions may require separate detection criteria because their identification can be affected by lighting, material batches, and product variation.
When comparing CCS production-line proposals, manufacturers should request an itemized AOI inspection list rather than relying on a single headline resolution or accuracy figure.
3. Process Data and Traceability
For manufacturers that need production traceability, the CCS line can be evaluated for its ability to associate process parameters and inspection results with a unique board or product ID.
Depending on the system configuration, traceability may cover riveting parameters, welding records, electrical test results, and AOI inspection data.
Before ordering the equipment, confirm which data will be collected, how records will be stored, and whether the system can exchange data with the customer’s MES or other manufacturing systems.
What Should You Confirm Before Selecting a CCS Production Line?
Beyond equipment price, several technical points should be clarified before selecting a CCS automated production line.
1. Measurement Points and Expansion Capacity
Confirm the required electrical measurement-point count and whether additional test channels can be added if future products require denser sampling.
2. Consistent Positioning References
Ask whether the riveting and welding stations use a consistent carrier and positioning reference.
Maintaining a stable positioning datum between processes can help reduce cumulative positioning errors and improve process consistency.
3. AOI Inspection Scope
Request an itemized inspection list.
Clarify which defects require full inspection, which are evaluated against a specified detection rate, and how inspection performance will be verified during acceptance testing.
4. Data Traceability
Confirm whether process parameters and inspection results can be associated with a unique board or product ID.
If MES integration is required, clarify the communication interface, data fields, storage requirements, and integration responsibilities before the equipment design is finalized.
5. Production Capacity and Cycle Time
Define the required output, operating schedule, and target cycle time.
The actual line capacity depends on the number of processing stations, product structure, riveting-point count, welding time, inspection scope, and material-handling arrangement.
Ask the supplier to explain the assumptions behind the proposed capacity and identify any potential bottlenecks.
6. Product Compatibility and Changeover
Confirm which CCS designs the line needs to process and whether different product variants require fixture changes, tooling adjustments, or software parameter changes.
If multiple products are planned, provide their drawings and technical specifications early so that the supplier can evaluate the required flexibility.
The testing and inspection sections can significantly influence equipment cost and quality-control capability. Any reduction in inspection functions should be evaluated against the customer’s quality requirements and downstream risks.
Frequently Asked Questions
What Is the Difference Between a CCS Production Line and a Standard PACK Line?
A battery PACK line assembles battery cells into modules and, depending on the project scope, modules into complete battery packs.
A CCS production line focuses specifically on manufacturing and testing the Cell Contact System used within a battery module.
In simple terms, the PACK line handles the broader battery assembly process, while the CCS line focuses on the electrical interconnection and sensing assembly inside the module.
Can Laser Welding Replace Pulse Hot Riveting?
Not necessarily. The two processes serve different functions.
Pulse hot riveting provides mechanical fixation where the CCS design requires it, while laser welding creates electrical connections between compatible metal components.
Depending on the CCS architecture, both processes may be required. The final process route should be determined by the product design and joining requirements.
Can the Riveting-Head Count and Measurement Points Be Expanded?
Potentially, depending on the equipment architecture and the scope of the original design.
The riveting-head arrangement and electrical sampling capacity should be evaluated against the required product variants, cycle time, and future expansion plans.
The final configuration should be confirmed in the technical proposal.
Is On-Site Installation and Commissioning Available?
Jialuo Intelligent provides on-site installation and commissioning through engineers and technicians.
For overseas projects, interpretation support is also available to facilitate communication between the Jialuo engineering team and the customer’s local team.
Equipment is pre-commissioned at our Shenzhen facility before shipment.
Project timelines depend on equipment configuration, project scope, customer readiness, and site conditions. Installation and commissioning arrangements should be confirmed in the project schedule.
How Should Reference Technical Parameters Be Interpreted?
Technical parameters presented in product materials should be understood as reference values for a specific equipment configuration.
Actual cycle time, positioning accuracy, production capacity, testing capability, and automation level should be evaluated according to the customer’s:
- CCS structure and component specifications
- Required process route
- Production-capacity target
- Quality and acceptance requirements
- Electrical testing requirements
- Traceability and data-integration needs
The final specifications should be confirmed in the project technical proposal and equipment acceptance criteria.
About Jialuo Intelligent
Shenzhen Jialuo Intelligent Technology Co., Ltd. develops intelligent equipment and production-line solutions for lithium battery manufacturing.
Our product portfolio includes:
- Battery Module PACK Production Lines
- Battery Module Steel Strap Forming Lines
- CCS Automated Production Lines
- Prismatic Cell Cover Plate Assembly and Welding Equipment
- Battery Module Testing Solutions
- Customized Lithium Battery Automation Equipment
Founded in 2008, Jialuo Intelligent has focused on intelligent equipment for the new energy and lithium battery industry since 2019.
Our engineering capabilities cover mechanical design, automation control, equipment integration, line commissioning, and customized manufacturing solutions.
Planning a CCS Production Line?
Every CCS project starts with a different product design.
Busbar dimensions, riveting-point count, sampling density, FPC structure, welding requirements, inspection scope, and traceability requirements can all affect the final production-line configuration.
If you are planning a new CCS production line or upgrading an existing CCS manufacturing process, [contact our engineering team] to discuss your product drawings and process requirements.
We can evaluate the required process route and develop a CCS automated production solution based on your product structure, production capacity, and quality requirements.
Shenzhen Jialuo Intelligent Technology Co., Ltd.
Room 101, Building 2, No. 8, Chengguang Industrial Park, Kukeng, Dafu Community, Guanlan Street, Longhua District, Shenzhen, China
Email: jch@cnjialuo.com
WhatsApp: +86 181 2473 5015
Jialuo Intelligent | Battery Automation Solutions