全球储能产业正加速迈向TWh规模化新阶段，电芯大容量化、尺寸大型化成为行业主流演进方向。从314Ah标准方壳电芯到千安时级超大储能电芯，产品规格的跨越式升级，对制造装备的工艺适配性、运行稳定性与整线效能提出了前所未有的要求。作为储能电池制造的核心链路，电芯装配技术能力直接决定产品品质一致性、生产综合成本与规模化交付能力，是打通大容量储能量产落地的核心关卡。
01
重负载装配的品质管控难题
老式卧式入壳极易挤压电芯，造成壳体变形、隔离膜划伤；合芯工艺存在天然矛盾，带连接片旋转合芯易扯断极耳损伤电芯，无连接片堆叠模式又无法满足大容量多层极片需求。
02
核心工序的效能与成本失衡
传统全腔注氦检测氦气损耗量大，还存在胶塞密封漏检隐患；顶盖焊接需增设预点焊工序，调试门槛高、兼容电芯规格有限，拖累产线节拍与柔性生产能力。
03
整线稼动的效率与人力损耗
人工首件校验、定点抽检导致产线频繁停机；物料补给、软件异常处置高度依赖现场人员，人力成本高且响应滞后；产能缓冲不足易引发上下游工序产能错配，拉低整线综合效率。
02
全场景覆盖的柔性适配不足
储能电芯容量区间跨度极大，并存多条技术路线；传统设备换型配件繁多、改造成本高昂，无法兼容多规格同步生产，阻碍企业多元化产品布局。
针对行业共性痛点，利元亨依托锂电智造全栈自研积淀，推出大储电芯装配线解决方案，聚焦千安时级电芯装配场景，以重载工艺突破、智能化运营与高柔性设计，系统性破解大容量量产难题。
该产线全面适配 587Ah~1175Ah 超大容量电芯，最高产能达 32PPM，核心指标处于行业第一梯队。针对大重量电芯的负载稳定性挑战，产线升级立式入壳与合芯工艺，通过多段式挤压与微米级精准定位控制，全程保障电芯结构完整性与膜层防护，从源头规避形变、划伤等品质风险。产线搭载高速磁悬浮传输系统，以非接触式传输大幅提升运行平稳性，降低机械磨损，为高节拍、长周期稳定生产筑牢硬件底座。
针对大容量电芯多层极耳焊接难点，设备搭载高规格裁切与大功率超声焊接单元：极耳裁切上限达 200 层，超声焊采用双支撑全波长焊头，可一次性完成 120 层铜箔焊接，62×12mm 大焊印搭配 8150W 峰值功率，振幅均匀、焊接一致性优异。设备良率≥99.5%，故障率≤2%，OEE 稳定超 80%，形成成熟千安时电芯装配解决方案。
整套产线搭载完整智能化智造体系：缓存扩容、自动校验、不停机抽检多重机制提升稼动，10 分钟缓存增量产 9.4%，全自动校验每日缩短停机 180 分钟；LEIP 远程运维、AMR 自动补料实现工段少人化，适配黑灯工厂；系统化优化将换型成本降低 30%，快速切换多规格电芯。设备出厂前经过 6 大类 28 项严苛验证，充分保障量产工况长效稳定。
新型储能规模化发展离不开高端制造装备的底层支撑。利元亨大储电芯装配线以工艺创新破解品质难题，以智能运营提升生产效能，以柔性设计适配全场景需求，为不同容量、不同技术路线的储能电芯量产提供核心装配支撑，也为我国储能产业降本增效、高质量发展注入装备端的核心动力。
Anchoring New Energy Storage Goals 丨Lyric Establishes New Smart Manufacturing Standards for High-Capacity Energy Storage Cell Production
The global energy storage industry is rapidly advancing into a new phase of terawatt-hour (TWh) large-scale development. Upscaling cell capacity and enlarging cell dimensions have become the mainstream evolutionary trends across the sector. From 314Ah standard prismatic cells to ultra-large energy storage cells with a capacity of kiloampere-hour level, the leapfrog upgrade in product specifications has placed unprecedented demands on manufacturing equipment in terms of process adaptability, operational stability and overall line efficiency. As the core link in energy storage battery manufacturing, the technical competence of cell assembly directly determines the consistency of product quality, comprehensive production costs and large-scale delivery capacity. It serves as the core bottleneck to realize mass production and commercial application of high-capacity energy storage batteries.
The mass production of high-capacity energy storage batteries across the industry is currently confronted with four major core bottlenecks:
First, difficulties in quality control during heavy-load assembly. Conventional horizontal casing insertion tends to squeeze cells, resulting in shell deformation and separator scratching. There is an inherent contradiction in core stacking processes: rotary core stacking with connecting tabs may tear tabs and damage cells, while the tab-free stacking method fails to meet the requirements of multi-layer electrodes for high-capacity batteries.
Second, an imbalance between efficiency and cost in core processes. The traditional full-chamber helium injection and leak detection process consumes excessive helium and carries hidden risks of missed inspection on rubber plug sealing. Top cover welding requires an additional pre-spot welding procedure, which comes with high commissioning difficulty and limited compatibility with various cell formats, dragging down line tact time and flexible production capacity.
Third, insufficient overall line uptime efficiency and excessive labor consumption. Frequent line shutdowns are caused by manual first-article inspection and fixed-point sampling tests. Material replenishment and software fault troubleshooting rely heavily on on-site operators, leading to high labor costs and delayed responses. Insufficient production buffer easily causes capacity mismatch between upstream and downstream processes, reducing the overall efficiency of the entire production line.
Fourth, inadequate flexible adaptability to full-scenario production. Energy storage cells cover an extremely wide capacity range with multiple coexisting technical routes. Conventional equipment requires numerous replacement parts for model changeover and incurs high modification costs, making it incompatible with simultaneous production of multiple specifications and hindering enterprises from diversifying their product portfolios.
Heavy-Duty Precision Intelligent Manufacturing | Restructuring the Technical System for High-Capacity Cell Assembly
To address the universal pain points plaguing the industry, Lyric draws on its accumulated experience in full-stack independent R&D of lithium battery intelligent manufacturing and launches a dedicated assembly line solution for large-scale energy storage cells. Centered on the assembly scenarios of kiloampere-hour (kAh)-grade cells, it systematically resolves bottlenecks in high-capacity mass production through breakthroughs in heavy-duty processes, intelligent operation and highly flexible design.
This production line is fully compatible with ultra-high-capacity cells ranging from 587Ah to 1175Ah, with a maximum throughput of 32 PPM, placing its core performance indicators among the industry’s top tier. To tackle load stability challenges posed by heavyweight cells, the line adopts upgraded vertical casing loading and core stacking processes. With multi-stage compression and micron-level precision positioning control, it safeguards cell structural integrity and separator protection throughout the entire process, eliminating quality risks such as shell deformation and separator scratches at the source. Equipped with a high-speed maglev conveying system, the line delivers drastically improved operational stability via non-contact material transport and reduced mechanical wear, laying a solid hardware foundation for high-takt and long-term stable mass production.
To address the welding challenges of multi-layer tabs in large-capacity battery cells, the equipment is equipped with high-specification cutting and high-power ultrasonic welding units. The maximum trimming capacity for electrode tabs reaches 200 layers. The ultrasonic welder adopts a fully wavelength welding head with dual supports, enabling one-pass welding of 120 layers of copper foil. With a large welding mark of 62×12 mm and a peak power of 8150 W, it delivers even amplitude and outstanding welding consistency. The equipment achieves a production yield of 99.5% with a failure rate ≤ 2% and a stable OEE above 80%, forming a mature assembly solution for kAh-level energy storage cells.
The entire production line is equipped with a comprehensive intelligent manufacturing system. Multiple mechanisms including expanded buffering capacity, automatic inspection and non-stop sampling inspection are deployed to boost line utilization. The expanded buffer function increases production output by 9.4% within a 10-minute cycle, while fully automatic inspection cuts daily downtime by 180 minutes. LEIP remote operation & maintenance and AMR automatic material feeding enable low-manpower operation for each workshop section, well suited to dark factory deployment. Systematic optimization slashes model changeover costs by 30% and supports rapid switching between multiple cell specifications. Prior to factory delivery, the equipment undergoes rigorous verification covering 6 major categories and 28 individual items to guarantee long-term stable performance under mass production conditions.
The large-scale development of new energy storage is inseparable from the underlying support of high-end manufacturing equipment. Lyric’s energy storage cell assembly line tackles quality challenges via process innovation, improves production efficiency through intelligent operation, and accommodates full-scenario demands with flexible design. It delivers core assembly support for mass production of energy storage cells with diverse capacities and technical routes, and injects core driving force from the equipment side to advance cost reduction, efficiency improvement and high-quality development of China’s energy storage industry.