Smart Manufacturing Upgrade for Better Customer Value
Recently, Power Long Battery has successfully completed the full-process automation upgrade and implementation from electrode slurry mixing to cell assembly. For this comprehensive production line transformation, our sales team stationed themselves in the workshop for on-site study, while the technical team worked on the frontline for equipment commissioning. We strive relentlessly for product quality through continuous process improvement.
Below, we would like to share what this upgrade has truly changed.
I. Production Line Comparison: From Labor-Intensive to Fully Automated
Previously, due to equipment limitations, some key stations relied heavily on operators’ experience and proficiency. After the upgrade, such uncertainties have been completely eliminated. Taking the assembly section as a clear example:
| Process | Before Upgrade | After Upgrade |
|---|---|---|
| Electrode Manufacturing | Manual inspection: Visual check of electrode appearance; defective electrodes identified and labeled after line stop | Automatic inspection: CCD full inspection of electrode appearance; NG electrodes identified and processed per roll |
| Winding | Overhang inspection: First-article inspection / sampling inspection | Overhang inspection: Full CCD automatic inspection |
| Can Insertion | Manual: Manual placement of upper/lower gaskets + can insertion | Fully automatic: Automatic placement of upper/lower gaskets + can insertion |
| Bottom Welding | a) Semi-automatic: Manual pin insertion + weldingb) Multi-pin recycling | a) Fully automatic: Automatic pin insertion + weldingb) Fixed welding pins |
| Tab Welding | Manual: Manual bending and alignment of tabs + manual welding | Fully automatic: Automatic tab alignment + welding |
| Material Flow | Manual material transfer between stations | Automatic line conveyance |
II. Key Technical Breakthroughs: Dual Leap in Precision and Efficiency
On the surface, machines have replaced manual labor; fundamentally, this represents a tremendous upgrade in core processes.
Previously, manual inspection during electrode making, winding and can insertion often led to missed defects and cell scratching. After this production line upgrade, the entire line is now fully equipped with a CCD visual inspection system, coupled with automatic feeding, automatic can insertion and integrated fully automatic welding equipment, achieving zero scratching and zero missed detection.
Based on the application of double-sided density gauges and laser thickness gauges in the coating and calendering sections, we have also added SPC process control. The CPK value of the coating and calendering sections now exceeds 1.67, reaching an industry-leading level.
Multi-stage screens and high-intensity magnetic deironing devices have been added to core processes, eliminating the risk of self-discharge and short circuits caused by metal impurities from the source. In addition, full-tab production equipment has been installed in the assembly section, enabling truly compatible production of multi-specification cells, with simultaneous improvements in production capacity and consistency.
III. Technology Upgrade as a Means, Customer Service as the Core
Following the production line iteration, our sales team took the initiative to immerse themselves in the production line. They observed equipment operation on site, analyzed process logic, and engaged in in-depth communication with process leaders. Through this immersive learning, our sales team fully understood the quality and efficiency improvements brought by the new automated production line.
For Power Long Battery, technological upgrading is a means, while customer service is at the core.
The upgraded intelligent fully automated production line strengthens control across the entire chain from slurry mixing, coating to assembly and inspection, further ensuring that cells feature excellent performance in high consistency, long cycle life and high safety. Whether for energy storage or power tool applications, Power Long Battery can provide 26650 cells with greater stability and reliability, while improving delivery speed.
From intelligent manufacturing innovation in the workshop to in-depth customer service by sales, we return to our original aspiration of serving customers and creating value. With sophisticated manufacturing capabilities and professional service standards, we deliver high-quality lithium battery solutions to every customer.