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Dongguan Juneng New Energy Technology Co., Ltd.
137 5142 6524（Miss Gao）
susiegao@power-ing.com
Xinghuiyuan High tech Industrial Park, Dalang Town, Dongguan City, Guangdong Province
From 1GWh to 10 GWh: A Leap in Production Capacity for Jueneng New Energy’s Intelligent Manufacturing
time：2026-07-29
In 2024, the annual capacity of the new energy PACK plant remained at 1GWh. Two years later, the number doubled tenfold. Behind the capacity transition, it is not a simple plant expansion and equipment stacking, but a deep reform from "manufacturing" to "intelligent manufacturing. When digital twin maps virtual factories, AI algorithms replace human eye quality inspection, and flexible production lines are compatible with multi-variety switching, energy gathering new energy is redefining the manufacturing paradigm of power battery PACK.
I. Digital twins: rehearse everything in the virtual world
create a new PACK production line. The traditional mode requires a 6-8 month debugging cycle. The digital twin platform that gathers new energy resources will compress this cycle to 8 weeks.
"We engraved the entire production line in the virtual environment 1:1. "The intelligent manufacturing director opens the three-dimensional visualization interface, and the motion track of the mechanical arm, the scheduling path of the AGV, and the beat time of the station are all beating on the screen in real time. The introduction of new products no longer requires physical prototype trial and error-after completing process simulation, collision detection and capacity bottleneck analysis in the virtual space, it is directly sent to the physical production line for execution.
The more profound impact is predictive maintenance. The vibration, temperature, current and other operating parameters of production line equipment continue to be imported into the digital twin model. AI algorithm predicts fault trends such as bearing wear and motor aging, and proposesA maintenance warning is issued 72 hours ago. "In the past, it was" broken and repaired again ", but now it is" Prevent before getting sick '. "Equipment engineers showed maintenance records, and unplanned downtime decreased by 65%.
II. AI quality inspection: from eye scan to algorithm see-through"
the quality inspection of power battery PACK was once one of the bottlenecks in the production line. AI visual system, which gathers new energy sources, is rewriting this situation.
In the welding station, the high-speed industrial camera captures the shape of the molten pool at a speed of 5,000 frames per second, and the deep learning model judges the penetration, porosity and splash in real time, with a detection rate of more than 99.9%. In the gluing station, the width, height and continuity of the 3D line laser scanning strip, and the broken glue point of 0.1mm has nowhere to hide. At the assembly station, the six-side visual system synchronously detects cell polarity, module positioning and wiring harness insertion, and the misjudgment rate of missing installation approaches zero.
"AI is not a substitute for people, but for people to do more valuable things. "The quality supervisor explained," in the past, 80% of the efforts of quality inspectors were spent on repeated scans. Now they focus on abnormal root cause analysis and process optimization. "While the quality inspection efficiency has increased three times, the staffing has decreased by 40%.
3. Flexible production line: one line is compatible with hundreds of packages"
the technical routes of power batteries are diversified, lithium iron phosphate and ternary lithium coexist, CTP and CTC racing, and the battery pack sizes, voltage platforms and thermal management schemes of different car companies vary greatly. The traditional special production mode of leased line has been changed and debugged for several weeks, and the capacity utilization rate is low.
The flexible production line of energy gathering new energy has realized "one-click transformation" through modular design and intelligent scheduling ".
The quick-change device at the end of the mechanical arm can switch different fixtures such as welding, handling and detection within 30 seconds; The AGV scheduling system dynamically plans the material path according to real-time orders, supporting multi-Variety mixed line production; MES system is deeply connected with ERP and PLM, and process parameters are automatically issued with the product model, and manual intervention is minimized.
"Our production line can produce battery pack of 8 different specifications at the same time, and the change time has been shortened from the past 4 hours to 15 minutes. "The director of production and operation showed real-time Kanban, and the overall production line efficiency (OEE) increased from 72% to 89%.
4. Data closed loop: from "experience-driven" to "data-driven"
the ultimate support of capacity transition is data..
Energy gathering new energy has built a global data lake covering "equipment-process-quality-energy consumption. The running logs of each device, process parameters of each process, test data of battery pack per piece, and energy consumption distribution of each electric power are collected, cleaned, and modeled in real time.
Process optimization changes from "master experience" to "algorithm recommendation". By analyzing the correlation between the capacity attenuation curve of tens of thousands of pieces of battery pack and process parameters, AI model identifies the nonlinear relationship between Welding power and cycle life, and reversely optimizes the welding parameter window, the cycle life of the whole package is increased by 8%.
Energy consumption management also benefits from data insight. The operation strategy of high energy consumption equipment such as air compressor and water chiller is dynamically adjusted according to the order load and the peak valley of electricity price, and the energy consumption per unit capacity is reduced by 18%.
V. From 10GWh to the future: intelligent manufacturing has no final result
standing on the node of 10GWh, the intelligent manufacturing blueprint for gathering energy and new energy is still extending.
"Capacity transition is not the end, but the starting point. "The vice president of new energy manufacturing concluded at the annual strategy meeting," only when the ability of intelligent manufacturing is accumulated into organizational genes can we continue to lead the next generation of technology. "
from 1GWh to 10GWh, energy gathering new energy it took two years to complete a qualitative change in manufacturing capability. Digital twinning shortens the innovation cycle, AI quality inspection reshapes the quality paradigm, flexible production lines release capacity elasticity, and closed-loop data drives continuous evolution. In this capacity transition, energy gathering new energy proves a truth: Intelligent manufacturing is not a cost center, but a Competitiveness Center. When manufacturing becomes a technical barrier, production capacity is no longer a simple number, but the confidence of enterprises to cross the cycle.
Contact us
Dongguan Juneng New Energy Technology Co., Ltd.
137 5142 6524（Miss Gao）
susiegao@power-ing.com
Xinghuiyuan High tech Industrial Park, Dalang Town, Dongguan City, Guangdong Province
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