The 5th GGII Energy Storage Industry Summit 2026 was held in Nantong, Jiangsu, on July 23–24, hosted by Gaogong Industry Institute (GGII). The new energy storage industry is currently undergoing rapid expansion. Demand for long-duration energy storage and large-scale standalone power stations has surged, and high-capacity cells have emerged as a core route for the industry to cut costs. Nevertheless, with dramatic upgrades in cell size and capacity, manufacturers are confronted with systematic manufacturing bottlenecks, including insufficient assembly precision, poor production line adaptability, low efficiency during model switching for multiple specifications, high labor and maintenance costs, and fluctuating mass production yields. Against this critical industry backdrop, Dr. Du Yixian, Director of Lyric R&D Institute, delivered a keynote speech titled Deconstructing New Manufacturing Barriers of Full Intelligent Production Lines for Ultra-Large Energy Storage Cells, presenting complete sets of intelligent equipment and underlying technical solutions covering the entire cell and module production workflow.

I. Three Core Energy Storage Equipment Series to Form a Closed-Loop Manufacturing System for Full-Capacity Battery Cells

To meet the iterative demands of prismatic energy storage cells ranging from 280Ah to 1175Ah, Lyric has deployed production lines covering all processes including front-end cell assembly, mass production of ultra-large cells and module integration. These three standardized production lines deliver comprehensive intelligent manufacturing capabilities.

1. Prismatic Energy Storage Cell Assembly Line

Compatible with mainstream energy storage prismatic cells of 280Ah to 314Ah, this line reaches a maximum output of 46 PPM, with equipment failure rate ≤ 2%, yield rate ≥ 99.5%, and overall equipment efficiency (OEE) ≥ 80%.

Equipped with high-precision maglev conveying and full-range AI vision online inspection systems, the line realizes fully unmanned automatic operation in post-stage processes. It supports 40% of mainstream energy storage cell specifications, balancing standardized mass production and customized flexible retrofitting.

2. Large-scale Energy Storage Cell Assembly Line

Designed for mass production of ultra-high-capacity cells ranging from 587Ah to 1175Ah, this line delivers a maximum throughput of 32 PPM. It maintains the same high standards as standard cell production lines in terms of failure rate, yield and OEE. Supported by our proprietary maglev conveying solution, the line addresses widespread industrial challenges including cell shifting during transportation, uneven stress distribution and casing deformation. It boasts outstanding mass production stability and product expandability to accommodate the iterative upgrade of next-generation ultra-large cells.

3. Large-scale Energy Storage Module PACK Line

Compatible with full-capacity cells from 314Ah to 1175Ah, this line adopts a modular architecture compatible with diverse module design routes.

Equipped with intelligent AGV logistics to enable flexible cross-process material transfer, the line features full-process inline inspection and remote real-time monitoring systems. It supports one-click rapid model changeover and meets production demands for diversified application scenarios including new energy bases, industrial & commercial energy storage, and supporting energy storage for data centers.

II. Four Core Technical Systems to Crack Key Bottlenecks in Ultra-Large Cell Mass Production

Dr. Du Yixian pointed out that the pain points in manufacturing ultra-large energy storage cells fall into four major dimensions: production capacity efficiency, labor costs, multi-specification compatibility and assembly precision. Lyric has rolled out four complete technical solutions to systematically eliminate pain points in intelligent manufacturing.

(1) OEE Performance Improvement

With an innovative dual-buffer collaborative architecture, we build a two-layer buffer pool consisting of in-process buffers and external logistics buffers. The buffer capacity is equivalent to no less than 5 minutes of production output, which balances tact time differences across all processes. Actual tests show the overall line throughput rises by over 5%, fully resolving the bottleneck of intermittent production on conventional production lines.

Complemented by an AMR automatic tape replacement system, the equipment eliminates manual tape changing operations. It cuts daily manual operation time by 136 minutes, with a short equipment payback period of merely 1.5 years. The system enables 24/7 unattended tape replacement, slashing equipment downtime losses at the source and stabilizing core OEE indicators.

(2) Production Line Manpower Reduction

With the LEIP intelligent management and control platform as the core, it integrates AMR autonomous mobile robots, automatic refilling silos, and precision vibrating feeder systems to build a fully automated hardware foundation. The platform collects full-dimensional real-time data covering equipment operation, throughput and fault alarms, and establishes remote maintenance access channels. It enables rapid online resolution of software malfunctions, automatically generates material replenishment orders based on production line consumption, and performs intelligent scheduling of production resources.

The implementation results are clearly quantifiable: the manual intervention rate of back-end production lines has dropped by 90%, greatly reducing reliance on highly skilled workers. Production efficiency is lifted by 30%, material loss is controlled within 0.5%, and product delivery cycle is shortened by 25%. The 24/7 continuous production capacity fully caters to the large-capacity capacity expansion demands of energy storage manufacturers.

(3) Rapid Model Changeover

A dual-flexible solution integrating modular electromechanical design and self-developed SmartDL intelligent vision system is adopted.

On the hardware side, complete machines are fully engineered to fit the maximum compatible cell dimensions. Robots are pre-equipped with adjustable mounting holes for compatibility. Operators can switch product specifications with one-click program control without replacing tooling parts.

On the software side, our self-developed intelligent labeling system leverages AI multi-point calibration to replace manual vision tuning, cutting commissioning time by 80%.

The complete solution cuts downtime losses caused by model changeovers by 80%. The new product introduction cycle is shortened from weeks to days. General operators can independently complete model switching after short-term training. It effectively reduces inventories of special tooling and boosts the production line’s market agility to handle multi-variety and small-batch orders.

 (4) Precision Enhancement

To address common mass-production defects of ultra-large cells including shell displacement, tab tearing and welding thermal deformation, we have developed four high-precision processes: vertical film wrapping, vertical cell casing loading, side-standing core assembly and top cover welding without pre-spot welding.

Vertical cell casing loading adopts a vertical mechanical structure, paired with vision guidance and servo closed-loop systems to achieve micron-level dynamic centering. This process boosts product yield by 0.3% and cuts the commissioning cycle by over 30%. The side-standing core assembly innovates the conventional inverted core assembly structure. Side stoppers support the cell to prevent downward sliding and pulling force that causes tab tearing.The pre-spot-free top cover welding process eliminates the two-step welding workflow. Its welding speed reaches 300–400 mm/s, eliminating thermal deformation risks induced by pre-spot welding. This technology streamlines equipment layout and cuts maintenance costs, comprehensively boosting cell consistency and safety yield from the fundamental process level.

High-capacity and long-duration energy storage represent the long-term development backbone of the new energy storage industry. Accelerated iteration of cell capacities is forcing upstream manufacturing equipment to undergo systematic upgrades. Adopting an integrated full-production-line mindset, Lyric delivers synchronous breakthroughs across four dimensions: equipment hardware, intelligent software, precision processes and smart logistics. We provide complete implementable solutions targeting all pain points throughout the mass production chain of ultra-large energy storage cells. Our highly flexible, high-efficiency and high-precision intelligent manufacturing system empowers the energy storage industry to achieve steady large-scale, low-cost and high-quality development, laying a solid manufacturing foundation for the sustained capacity expansion of new energy storage.