Ultra-High-Speed Cylindrical Battery Module Production Line

With the deep integration of new energy and smart manufacturing, cylindrical battery module assembly lines are entering a new era characterized by higher speed, precision, and flexibility. Leading manufacturers are now leveraging advanced process innovations and intelligent technologies to create highly efficient, fully integrated, and sustainable production lines.

1. Ultra-High Throughput: Over 20 PPM Per Line

The traditional bottleneck in module production efficiency has been broken. Next-generation lines can achieve a throughput of over 20 modules per minute (20 PPM), significantly enhancing output capacity.

For example, Lead Intelligent’s "All-Tab Cylindrical Assembly Line" optimizes process flow and equipment synergy to reduce footprint by 53% and cut energy consumption by 33%, setting a new industry standard for efficiency.

2. Full-Process Integration with Flexible Architecture

These advanced lines integrate the entire manufacturing process—from cell sorting and laser welding to module packaging and automated testing—and support multiple cylindrical cell formats including 18650, 21700, and 4680.

HuiyaoLaser’s advanced laser welding solutions are deeply embedded in this stage, ensuring precise, high-strength joints critical to modern cylindrical modules.

A modular design enables rapid line reconfiguration to adapt to different customer product needs, ensuring maximum flexibility and scalability.

3. AI-Driven Precision with 3D Vision Systems

Combining full-space 3D vision with AI-powered defect detection, the system conducts real-time analysis of weld quality, detects surface defects such as pores and cracks, and ensures module flatness.

HuiyaoLaser integrates intelligent visual inspection and adaptive control into its laser processing systems, enabling continuous self-optimization and enhancing production stability.

4. Digitalized, Intelligent Production Management

Equipped with an MES (Manufacturing Execution System), the line provides full traceability of production parameters. Digital twin technology is used to simulate and optimize production line design, dramatically reducing time-to-production and improving operational efficiency.

5. Core Advantages

High Efficiency & Cost Optimization

Ultra-fast cycle times reduce labor and unit manufacturing costs while maximizing equipment utilization.
Example: Huaguan Technology’s third-generation assembly line adopts a cam + turret mechanism, achieving high-speed and high-stability operation.

Precision & Consistency

• Laser positioning accuracy within ±0.05mm
  

• Weld strength increased by 30%
  

• AI algorithms dynamically adjust parameters in real time to prevent weak welds or burn-throughs

• HuiyaoLaser’s precision laser technology ensures consistent quality at high throughput levels

Safety & Reliability

• Multiple safety mechanisms such as air-electric separation and directional pressure relief ensure safe thermal management under extreme conditions

• Full-process quality inspection prevents defective modules from reaching the market

Green & Sustainable Manufacturing

• Energy-efficient systems like Lead’s high-speed coating solutions reduce power consumption

• Integration with solar and energy storage systems promotes low-carbon, green manufacturing

6. Application Scenarios

Case Highlight: EVE Energy’s large cylindrical cells demonstrate high-frequency output and strong safety in drones and robotic applications.

7. Industry Trends & Outlook

Accelerated Technological Evolution

• Advancements in all-tab cell technology and solid-state battery mass production are shaping the next generation of battery pack lines
  

• Lead Intelligent has introduced a complete solid-state battery production solution, covering critical processes such as solid electrode and electrolyte membrane fabrication

Global Expansion

• Chinese manufacturers are expanding globally through innovation and certification

• Huaguan Technology’s PACK lines now serve major European automotive OEMs and have obtained UL certification for the U.S. market

Intelligent Ecosystem Integration

• Deep integration with smart logistics and factory systems enables end-to-end digitalization

• Schneider Electric’s EcoStruxure™ platform empowers customers from design to deployment to operations, ensuring seamless smart factory management

About HuiyaoLaser

  HuiyaoLaser (Luoyang) Technology Co., Ltd. is a trusted partner in intelligent laser processing solutions, specializing in laser welding systems for battery module and PACK lines. With a strong focus on automation, precision control, and AI-driven visual inspection, HuiyaoLaser supports global manufacturers in achieving higher quality, lower cost, and safer production.

  Whether enabling ultra-high-speed lines or facilitating solid-state battery innovation, HuiyaoLaser is committed to empowering the future of energy through laser intelligence.