Battery packs for power tools and special-purpose machines

This product segment is one of the most representative examples of our engineering and manufacturing expertise, covering the entire value chain from product design (R&D) to the development of automated and robotic production lines.

• 12V, 18V, and 36V Li-ion battery types
• Product design and development concept - redesign: optimization of existing battery packs; structural reinforcement: functional strengthening of the plastic housing and designing new robust components for enhanced durability; 3D design, 2D drafting, simulations, testing of breadboard model sub-assemblies, prototyping, planning and conducting engineering tests in accredited laboratories (TÜV), validation tests, and comprehensive DfM, DFMEA, and PFMEA analysis
• Manufacturing technology and automation with robotic semi-automated lines - robotic cell handling: automatic cell loading, movement, cell balance measurement, and polarity check; precision joining: automated resistance welding, automated soldering, and silicone dispensing; sensor-controlled assembly: automated screwdriving and robotic assembly; EOL (End-of-Line) testing: comprehensive functional inspection, charging test, and laser marking on every unit; product traceability: laser or optional RFID-based tracking recording all built-in materials and test results throughout the entire lifecycle

Batteries for electric garden tools and robotic lawnmowers

The backbone of this project is provided by in-house developed, highly automated robotized production equipment and carefully planned automated quality control.

• Manufacturing of two main battery types on dedicated semi-automated and automated assembly lines, with a capacity of up to 900,000 units per line annually
• Product design proposals by Videoton - active engineering involvement in optimizing manufacturability (DfM), mechanical design, and design and management of plastic injection molds
• In-house developed automated assembly lines
• Robotized precision operations - automatic cell handling and polarity check, robotized resistance welding and soldering, silicone dispensing
• Advanced quality control - 3D camera inspection, optical cell label position checking
• Complex final inspection - electrical parameter measurement, automated EOL (End-of-Line) testing, labeling, and laser marking for full traceability

Wheelchair power assist battery packs

Our first customer-collaborative project, where the entire product development—including electronics and mechanical design—was performed in-house.

Development and engineering competencies

• Conceptualization - design based on a single specified dimension, resulting in a marketable technical solution
• Electronic and mechanical design - comprehensive development including cell selection based on required electrical parameters, as well as design of safety and control electronics
• Proactive design - DFMEA analysis performed during the design phase to detect potential failure modes early
• Prototyping - flexible consultation and rapid physical implementation to minimize development time
• Engineering and validation tests conducted by TÜV
• Design and implementation of the assembly lines for production volume
• Supply chain optimization - close cooperation with subcontractors to select components with the best price-performance ratio
• Intensive customer relationship - continuous engineering coordination and weekly technical consultations throughout all development phases

Manufacturing solutions

• Dedicated mass production process built based on developed prototypes
• Strict quality assurance protocols appropriate for medical and rehabilitation devices

Backup batteries for automatic emergency call systems (e-Call)

• Compliance with the strictest automotive standards, including tolerance for extreme temperature ranges (-40 °C to +80 °C).
• Active participation in the design of 2-cell battery packs, from concept and feasibility studies to the first sample production
• Implementation of precision laser welding technology to ensure vibration-free stable connections
• In-house designed 22-meter long complex assembly line in an ESD-protected environment
• 3–4 position turntables to optimize production cycle time
• Multi-stage testing protocol - cell testing, ICT (In-Circuit Test), and EOL (End-of-Line) functional testing on each unit
• Advanced quality control: QR code readers, camera inspection systems, and automated packaging phase
• Automotive-level traceability system and laser-engraved identifiers to document the lifecycle of the product

Li-ion batteries for other household devices (electric toothbrushes, shavers)

• Special-purpose machinery design and construction - complex automated equipment for cell inspection, thin-film greasing, and tray loading, developed under Videoton engineering authority
• Voltage level control for each Li-ion cell to ensure correct parameter units are installed
• Machine-applied thin grease layer for stable oxidation-free contact
• Automatic sorting - based on measured data, the system sorts cells into appropriate trays using robotic arms without human intervention
• High throughput - large series production with consistent quality (approx. 40 million units per year)
• Environmentally friendly rotating tray packaging