As the energy storage industry enters a TWh-level large-scale construction cycle, large-capacity energy storage cells impose stringent requirements on production yield, structural safety, process stability, and environmental control. As a leading supplier in the field of energy storage cell assembly equipment, Haosen Intelligent leverages over two decades of expertise in smart equipment R&D and manufacturing, a full set of proprietary intellectual property technology systems, and extensive experience in project delivery. The company has developed a high-yield integrated assembly production line for energy storage batteries. By utilizing self-developed processes across all stages, intelligent inspection, precision execution, and digital closed-loop control, it addresses various quality issues in large-cell production at the process level. This provides energy storage enterprises with a complete solution for stable mass production, quality control, and cost optimization.

I. Full-process coverage to build a high-quality standard smart production line for energy storage cells

Haosen Intelligent's high-yield energy storage cell assembly line covers all stages of cell assembly and inspection, forming a complete closed-loop process chain. It sequentially implements all core processes including bare cell preheating and hot-press forming, X-ray tab alignment inspection, internal foreign object screening on the large surface of the cell, intelligent cell pairing, ultrasonic welding of tabs, high-precision laser sealing welding of the top cover, real-time online weld defect detection, and multi-stage segmented airtightness testing — with no process gaps or inspection blind spots.

II. Five core self-developed process technologies precisely address mass production pain points and steadily boost overall yield

Addressing the industry challenges of large energy storage cells — large dimensions, thick and wide tabs, high assembly precision requirements, and strict sealing reliability demands — Haosen has developed targeted dedicated technical solutions for weak spots of each process. These precision control technologies have been implemented across the entire production line：

1. Full-Domain AI Vision Closed-Loop Inspection System

Each critical station along the production line is equipped with distributed AI vision inspection modules. Leveraging deep learning-based image algorithms, the system performs multi-dimensional assessments covering appearance, dimensions, alignment, and weld appearance. Throughout the entire process, abnormal cells are captured in real time and automatically diverted and intercepted. A pre-isolation mechanism for defective products is established, ensuring zero outflow of defective cells and fundamentally reducing the proportion of downstream failures at the source.

2. Multi-Parameter Closed-Loop Controlled Ultrasonic Welding System

The system synchronously collects and regulates five core parameters in real time — welding energy, welding stroke, output power, vibration frequency, and welding pressure — forming a dynamic closed-loop adjustment mechanism. Simultaneously, it performs welding head condition verification, welding base cleanliness monitoring, and tab bonding state identification, precisely identify latent defects including cold welds, false welds, and weld separation, thereby firmly safeguarding the quality gateway of tab conductive connections.

3. Full-Scenario Laser Welding Protection System

Equipped with a closed-loop high-efficiency fume extraction system paired with a customized welding protective cover structure, the system instantly captures metal spatter generated during high-temperature welding. This prevents residual splatter from adhering to the cell surface or falling inside the tray, effectively avoiding issues such as local short circuits and electrochemical performance degradation. The system significantly improves finished product yield and the long-term operational stability of the cells.

4. Precision Cell Casing Process

By utilizing customized high-precision gripping tooling, combined with a segmented real-time pressure monitoring module throughout the entire cell casing process, the process effectively mitigates the risks of bumping and scratching during casing. The centering accuracy of cell and case is controlled within ±0.1 mm, and the yield rate of the cell casing process consistently exceeds 99.5%. This resolves industry pain points such as misalignment during large-cell casing, case scratches, and cell damage caused by compression.

5. Top Cover Laser Welding Special Optimization System

Leveraging rigid precision positioning fixtures combined with an integrated negative-pressure dust removal module, the laser equipment achieves a repeat positioning accuracy of ±0.02 mm. Welding trajectory consistency and weld uniformity are significantly enhanced. The single-pass yield rate at the top cover welding station reaches ≥99.5%, substantially reducing sealing-related defects such as weld leaks, seal failures, and weld cracks.

6. Integrated Line-Wide Control, Building a High-Yield Production System Across the Entire Process

All core processes are connected through unified equipment interfaces, enabling real-time information exchange of inspection data, process parameters, and equipment operating data for real-time anomaly monitoring. The entire line is equipped with Haosen’s self-developed MES (Manufacturing Execution System), integrating digital twin and AI-driven predictive maintenance modules to achieve self-learning of process parameters, self-diagnosis of equipment conditions, and self-warning of quality trends. It supports flexible production requirements for large-capacity cells ranging from 300Ah to 1000Ah, and its modular structure enables rapid product changeover and commissioning. Even during new product iterations, the system maintains a stable yield rate. The comprehensive yield of the entire line has been verified through mass production by leading customers, reaching an industry-leading level.

The technological roadmap of the energy storage industry is rapidly diversifying, and product specifications are iterating at an ever-faster pace. For equipment manufacturers, this means we must move one step ahead of the industry.

Haosen Intelligent has positioned energy storage equipment as a strategic core track, with continuously increasing R&D investment. Currently, our product portfolio covers the entire spectrum of integrated and industrialized energy storage solutions — from cell assembly, cell testing, module and PACK, to rack and container integration and testing, as well as intelligent logistics and manufacturing data management systems. We are also persistently advancing research breakthroughs in multiple cutting-edge technology directions.

Equipment is the foundation of manufacturing, and data is the fuel for evolution. In the future, Haosen will leverage its trinity technology platform of “equipment + process + data” as the cornerstone, closely follow the pace of technological evolution in the energy storage industry, and respond swiftly to customers’ product upgrade needs. Together with partners across the industrial chain, we are committed to providing solid equipment support for the high-quality, large-scale development of the global energy storage industry.