As  the power battery industry strides into the TWh era, welding quality  directly determines the reliability and safety limits of battery cells.  Confronting persistent challenges like false welding and over-welding in  complex scenarios involving multi-layer foils and dissimilar materials,  Lyric tackles these issues head-on through profound technological  innovation by introducing its Ultrasonic Welding Quality Monitoring  System.

This  system represents not merely an upgrade of individual equipment, but a  comprehensive intelligent leap across the entire chain—from perception  and control to diagnosis and maintenance. At its core, it integrates a  full series of ultrasonic generators featuring automatic frequency  tracking and constant amplitude control, coupled with the IPC-2.0  welding quality monitoring system equipped with AI inference models.  This integrated solution aims to build an impregnable quality defense  for battery manufacturing.

The full series of ultrasonic generators equipped with automatic frequency tracking and constant amplitude control functions.

Building  upon its extensive experience in project delivery, Lyric has integrated  solutions for common welding challenges in battery production  automation lines into the R&D and design of these ultrasonic  generators. Through groundbreaking innovation, Lyric has consolidated  multiple functions—including sensor data acquisition, intelligent  control of welding equipment, coordination with upstream and downstream  processes at the welding station, as well as ultrasonic generation with  frequency tracking and stable amplitude control—into its self-developed  ultrasonic generators. This integration simplifies circuit configuration  and wiring in production environments, resulting in cleaner equipment  layouts and more stable operational performance.

4kW Ultrasonic Generator P402F20H-2C1-R1

Product Parameters

• Operating Voltage: 230Vac

• Input Power Frequency: 50/60Hz

• Maximum Output Power: 4000W

• Output Frequency: 20kHz

6kW Ultrasonic Generator P622F20H-3C1-R1

Product Parameters

• Operating Voltage: 380Vac

• Input Power Frequency: 50/60Hz

• Maximum Output Power: 6200W

• Output Frequency: 20kHz

8kW Ultrasonic Generator P802F20H-3C1-R1

Product Parameters

• Operating Voltage: 380Vac

• Input Power Frequency: 50/60Hz

• Maximum Output Power: 8000W

• Output Frequency: 20kHz

Equipped  with the Ultrasonic Welding Quality Monitoring System IPC-2.0, it  empowers the entire production process with data, making the welding  process visualized and intelligent.

1.  In-process Welding Inspection: High-density sampling of welding process  data, high-speed AI inference model, and immediate result determination  upon welding completion.

Welding Materials: 50-layer copper foil + TAB

Welding Parameters: Energy 30J, Amplitude 60%, Pressure 0.15MPa

This  experimental validation demonstrates that multi-curve boundary anomaly  detection can effectively identify false welding and over-welding  conditions.

On actual production lines, the  system leverages multimodal fusion, dynamically self-adjusting anomaly  thresholds, and low-latency inference to achieve real-time detection of  foil wrinkling issues.

2. SPC Predictive Defense Line: Utilizes I-MR charts to detect equipment  anomalies and trend charts to provide early warnings for horn aging.

Intelligent  Diagnosis: Based on Statistical Process Control (SPC), the system  automatically generates I-MR and CPK trend charts, autonomously  identifying defects such as false welding and over-welding.

Predictive  Maintenance: By analyzing horn fatigue using wavelet entropy combined  with AI models, it delivers early warnings for equipment degradation,  effectively reducing unplanned downtime.

3.  Multimodal Fusion Diagnostics: Accurately identifies over 10 types of  welding defects, including false welding, over-welding, and foil  wrinkling.

Multimodal Perception:  Simultaneously collects parameters such as voltage, current, frequency,  power, pressure, and welding depth, enabling real-time visual comparison  of hundreds of welding curves

4. Cloud-based Collaborative Management: Cloud-based Training, Local Inference, Three-Dimensional Defense

Safety  Assurance: Provides triple protection against empty welding, wrinkling,  and temperature drift, combined with AI real-time monitoring to  eliminate risks of false welding and over-welding.

5.Digital  Twin: 3D simulation technology reproduces welding thermal field  distribution, optimizes welding tooth shape design, and facilitates the  improvement of welding yield.

Ultimate  Service Life: Unique four-sided symmetric welding horn design, wear  resistance exceeding industry standards, and cumulative welding service  life exceeding 500,000 cycles.

The  launch of Lyric's Ultrasonic Quality Monitoring System marks the  evolution of ultrasonic welding from a reliable process equipment into  an intelligent entity capable of "perception, decision-making, and  execution." By integrating real-time in-process monitoring, SPC trend  prediction, multimodal fusion diagnostics, and cloud-edge collaboration,  it establishes a full-cycle quality defense system covering "real-time,  short-term, and long-term" horizons. This shifts quality control from  post-event inspection to in-process suppression and pre-event risk  warning. In the future, Lyric will continue to delve into the path of  "technology-driven development," leveraging more precise process control  and smarter data-driven capabilities to provide more reliable and  efficient solutions for global intelligent manufacturing, empowering  customers to forge ahead steadily on the path of high-quality  development.