Case Overview

This case presents a full-process custom fabrication solution for industrial energy storage enclosures, developed and delivered by Dongguan Longwang Hardware Co., Ltd. for new energy storage system integrators and industrial power equipment manufacturers. Targeting commercial & industrial energy storage cabinets, outdoor battery clusters and power distribution enclosures, the solution centers on medium-thick plate precision forming, heavy-load frame welding and industrial-grade heavy anti-corrosion surface treatment, providing one-stop manufacturing services covering DFM (Design for Manufacturability) optimization, precision blanking, structural welding, automated spraying and pre-assembly verification.

Case Details

Project Background

The client is a leading domestic supplier of industrial and commercial energy storage systems, with products widely used in factory, photovoltaic energy storage stations, outdoor power stations and industrial park power distribution scenarios. Its former sheet metal suppliers had long been unable to match the product upgrading requirements:

• Large-format thick-plate enclosures suffered from severe springback and dimensional deviation, leading to difficulty in on-site battery module assembly and poor interchangeability of modular cabinets.
• Uncontrolled welding deformation caused sealing failure, with ingress protection failing to reach the rated IP55 standard, resulting in dust and moisture intrusion and battery operation safety risks.
• Simple manual spraying with incomplete pretreatment caused coating peeling and rust within 1–2 years in outdoor and high-humidity coastal areas, failing to meet the 8–10 year service life requirement.
• Unreasonable heat dissipation structure and low opening precision led to excessive internal temperature rise and poor matching with electrical components.
• Slow response to customized demands such as cabinet size adjustment, internal beam layout and special cable openings, with long delivery cycles for project-based orders.

After strict process audit, full-size prototype verification and on-site factory inspection, the client selected Longwang Hardware as its core strategic fabrication partner for energy storage enclosures, to achieve ·comprehensive improvement in product structural reliability, environmental adaptability and batch delivery stability.

Manufacturing Challenges

• Industrial energy storage enclosures usually have a height of 1.8–2.2m, with main body plate thickness of 2.5–6.0mm and load-bearing frame thickness up to 8.0mm. Large-size bending is prone to uneven springback and dimensional drift, making it difficult to guarantee the flatness, verticality and assembly interchangeability of the whole cabinet.
• A single cabinet bears a static load of 1–2 tons due to built-in battery modules. A large number of full-penetration welds on load-bearing columns and bottom frames easily generate residual stress, causing overall cabinet deformation, which directly affects the fitting accuracy of door frames and the realization of IP protection grades.
• Deployed outdoors, in coastal areas or chemical industrial parks, energy storage enclosures face long-term erosion by salt spray, ultraviolet rays, acid-base gas, high humidity and dust. Conventional surface treatment schemes cannot meet the requirements of long-term outdoor reliable operation.
• Energy storage enclosures need to achieve IP55/IP65 dust and water resistance on one hand, and efficient heat dissipation for high-power battery packs and BMS systems on the other. The contradiction between sealing and ventilation puts high requirements for structural design and manufacturing precision.
• Battery modules, busbars, BMS units and power distribution components have strict requirements on the position accuracy of mounting holes. Deviation will lead to assembly failure and even affect the electrical insulation and safety performance of the whole system.

Longwang Solution

• Equipped with high-power large-format fiber laser cutting machines Longwang has established a dedicated process parameter database for 2.5–8.0mm energy storage special steel plates. Through segmented bending process and springback compensation algorithm, the linear dimensional tolerance is stably controlled within ±0.3mm (within 1500mm length), and the bending angle accuracy reaches ±0.5°, ensuring the dimensional consistency of large cabinets and the interchangeability of modular parallel cabinets.
• The 8-meter automatic spraying production line implements a full pretreatment process including degreasing, rust removal, phosphating and passivation to thoroughly remove surface impurities and welding residues. Outdoor-grade TGIC polyester powder is applied by electrostatic spraying with coating thickness precisely controlled at 70–100μm. The salt spray resistance stably exceeds 800 hours, with excellent UV resistance and acid-base corrosion resistance, fully adapting to long-term outdoor and harsh industrial environment deployment.
• Internal mounting beams are processed by CNC punching with hole position accuracy of ±0.2mm, supporting front-back and up-down adjustment to match battery modules and electrical components of different specifications. Standard grounding copper bar positions, waterproof cable gland holes and wire routing slots are reserved in accordance with electrical safety standards, effectively reducing customers’ on-site assembly man-hours.

Results Achieved

After Longwang’s tailored fabrication solution was fully implemented, the client’s industrial energy storage enclosure line achieved major gains in quality, reliability, delivery speed, and total cost. Mass production yield reached 99.1%, on-site assembly qualification rose to 100%, welding defects dropped by 95%, and IP55/IP65 certification passed on the first attempt. At the same time, salt spray resistance exceeded 800 hours, after-sales failures fell by 98%, lead times shortened, delivery performance exceeded 99.5%, and overall management and maintenance costs were significantly reduced through a standardized modular platform.

Why This Project Matters

This industrial energy storage enclosure project goes beyond a single product supply case, showcasing Longwang’s core strengths in large-format sheet metal forming, heavy welding deformation control, and industrial anti-corrosion finishing. It solves key pain points such as cabinet deformation, weak protection, and poor weather resistance, while delivering a high-reliability solution for stable outdoor operation and rapid project delivery. The project also deepens strategic cooperation across battery racks, confluence cabinets, and PCS enclosures, creating a scalable model for future expansion in new energy and heavy industry markets.