As the demand for long-range, fast-charging electric vehicles surges, the 46-series large cylindrical battery has emerged as a pivotal innovation in global power battery technology. With superior energy density, high capacity, and rapid-charging capabilities, this format is driving a wave of strategic investments by leading battery manufacturers and OEMs worldwide.

At the forefront of this evolution, LEAD, a global leader in intelligent manufacturing for the new energy sector, introduces its high-efficiency 46-series large cylindrical battery integrated production line solution. Developed in close collaboration with top-tier clients and powered by advanced concurrent engineering, this cutting-edge solution redefines industry standards—delivering breakthrough processes, exceptional yield rates exceeding 99%, and unmatched production efficiency.

End-to-End Process Integration: Building the Industry’s Premier High-Efficiency Solution

LEAD’s solution delivers comprehensive end-to-end coverage across the entire production chain—from slurry preparation, winding/core manufacturing, and cell assembly to formation/grading and Cell-to-Pack (CTP) integration. This seamless integration combines proven sub-processes with multiple industry-first innovations:

• Innovative Welding Process:

An innovative laser welding process with proprietary structural design eliminates auxiliary time, boosting laser utilization by over 600%. Supported by multi-stage inspection—pre-weld detection, in-process monitoring, and post-weld review—it delivers 99.5% system availability and a welding yield rate exceeding 99.8%.

• Multi-Step Electrolyte Filling

Precision multi-stage control reduces single-cell filling time by 80%, significantly accelerating production cycles and enhancing operational efficiency.

• RFID Full-Process Traceability

Lifetime data tracking for each cell ensures exceptional accuracy with 500 ppm read efficiency, a defect rate under 0.005%, and cost savings of over 90%.

• High-Speed Rotary Turret

An ultra-efficient multi-station design achieves a single-machine capacity of 200 ppm. Mold changeovers are streamlined, requiring only 10 minutes for disassembly and 20 minutes for installation, maximizing uptime and flexibility.

Through these advanced technologies, LEAD’s fully integrated production solution sets new industry benchmarks for efficiency, precision, and scalability in 46-series large cylindrical battery manufacturing.

Disruptive Formation & Grading Redefines Energy Efficiency

As manufacturers push to meet the growing demands for faster, more efficient battery production, LEAD is raising the bar with its next-generation formation and grading solution designed for 4680 cylindrical cells. The company’s latest advancements deliver over 75% energy utilization efficiency while simultaneously reducing equipment footprint and optimizing system architecture for leaner, more cost-effective manufacturing.

‌Key Highlights:

• Highly Integrated Formation Design

By combining PCS technology, series-parallel module configurations, and multifunctional units, LEAD’s solution achieves a remarkable balance of performance and cost. The result: 20% lower CAPEX, 10% energy savings, 18% reduced floor space, and 40% faster commissioning—allowing manufacturers to scale production with speed and efficiency.

• Precision Grading for Enhanced Consistency

Tight control of temperature uniformity within ±1℃ ensures consistent cell performance, addressing one of the critical challenges in large cylindrical battery production: capacity variation and reliability.

• Flexible, High-Speed Sorting

Intelligent sorting technology offers fast, accurate classification capabilities that support complex, multi-client, and multi-batch production scenarios, delivering flexibility without compromising throughput. Together, these innovations reflect LEAD’s commitment to redefining battery formation and grading.

By merging advanced process design with smart manufacturing principles, the company’s solution is engineered to meet — and exceed — the evolving needs of global battery manufacturers navigating the 4680 era.

Ultra-High Automation & Quality Control: Setting New Industry Standards

In Cell-to-Pack (CTP) integration, LEAD’s advanced solution delivers exceptional flexibility and performance, accommodating a wide range of cell and pack variants. Key performance indicators reflect this robust capability, including 80%+ line automation, a 99.9%+ station yield rate, 99.5%+ station availability, and a production capacity of 33 JPH.

• Automatic Glue Dispensing

An integrated process combining mold assembly, filling, curing, and inspection delivers a 99.9%+ first-pass yield in foam application, ensuring reliable and repeatable results.

• High-Precision Encapsulation & Riveting

Designed for versatility, this solution supports multiple CTP designs. It completes flipping and tray switching in just 95 seconds and maintains ±0.1 mm riveting accuracy, achieving a 99.98%+ yield rate.

• Smart End-of-Line (EOL) Testing

A proprietary floating structure accommodates ±5 mm positional deviations, delivering a 99.5%+ docking yield while fully eliminating manual operations and reducing labor costs.

Complementing its advanced automation capabilities, LEAD employs a synchronized engineering development system that spans process design, product development, and equipment manufacturing, creating a closed-loop correction and optimization mechanism. Coupled with comprehensive digitalization — including single-station analysis, full-line simulation, and plant-level virtual planning — this approach significantly reduces manufacturing risks. Leveraging virtual reality, virtual debugging, and big data analytics, LEAD enables customers to accelerate commissioning, achieve faster production ramp-up, and reach full-scale output with confidence and efficiency.