Enhance efficiency with nexonar
Battery pack assembly
With an advanced Real-Time Location System all critical assembly actions like high voltage busbar tightening are done in the right position at the right time
Optimize your battery pack assembly
Imagine an electric vehicle as a human body, and its battery pack is like the heart that pumps life into every part. If the battery pack is assembled incorrectly, it poses life-threatening hazards not only for plant operators but also for vehicle drivers and passengers.
Typical customer challenges
Size variation of the battery pack
Battery pack sizes vary significantly across car models, making it challenging for a Real-Time Location System to maintain accuracy across the entire battery due to the large field of view required. Scalability is also crucial—production lines designed for smaller battery packs today must be easily upgradable to accommodate the manufacturing of larger ones.
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Large number of screws
When a worker must handle a large number of screws, maintaining precise control and the correct sequence becomes difficult. Missing screws or tightening them out of order poses serious risks to both the plant and the company’s customers.
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Moving by the AGV (automated guided vehicle
Battery packs are typically transported through the plant by Automated Guided Vehicles (AGVs). The positional tolerance of the AGVs can affect the precise location where screws are tightened, so the Real-Time Location System (RTLS) must compensate for these variations.
How can nexonar solve these challenges?
Size variation of the battery - Cluster camera management
With only one camera, Nexonar can cover an area of 2.83 × 2.83 meters at a distance of 2 meters. By clustering cameras, the field of view can be expanded, making battery size irrelevant and minimizing the risk of obstructing the line of sight when the operator is working around the battery.
Large number of screws - Intuitive operator guidance
Language-neutral operator guidance is provided by nexonar, either through an external display or with an augmented laser that projects directly onto the battery pack to boost assembly efficiency.
Moving by the AGV - dynamic tracking options
The nexonar system employs various methods to measure the exact position of the AGV—such as reference trackers or real-time laser distance measurements. With either approach, screw positions adjust dynamically with the battery pack to maintain optimal accuracy
nexonar in DRÄXLMAIER
Complexity shouldn’t lead to errors. nexonar offers the flexibility to handle the wide variety of data center builds, guiding operators to ensure every rack and server is assembled accurately the first time.
Muhammad Yunus Mazlan
Sales Leader
Advantages of the nexonar solution at a glance
Rework cost saving
Focus on specific operations instead of larger groups with missing detailled (position) information. Remove risk of recall because of faulty screws. NOK screws at the rework station are correctly managed and documented.
Productivity improvement
Improved efficiency with using a maintenance free measurement technology based on light.
Operator support
Improved operator support because there are no missing operations possible and the operator is assisted by state of the art visualization methods.
Your questions about nexonar in battery pack assembly answered
What makes battery pack assembly different from other automotive assembly processes?
Battery pack assembly involves large systems, many fasteners, and strict safety demands due to high voltage and positional precision requirements.
What are the biggest challenges in battery pack assembly?
Common challenges include variations in battery pack size, screws positioned very close together, high risk of missing or incorrect tightenings, operator ergonomics due to heavy or large modules, maintaining traceability across many steps, ensuring correct rework on NOK screws only. These issues can lead to safety hazards such as electrical faults or thermal events.
How does nexonar help ensure every screw is tightened correctly?
nexonar uses real‑time infrared tracking to guide the operator to each exact screw location. Tools only enable when positioned correctly, ensuring no missed screws, correct sequence, and millimetre‑level precision.
Can nexonar help prevent missing or incorrectly tightened screws in battery pack assembly?
Yes - with intuitive operator guidance and dynamic screw sequence management, nexonar reduces risk of misses or errors.
How does nexonar handle battery packs moved by AGVs?
The system dynamically tracks AGV position using reference trackers or laser measurement, keeping position accuracy consistent during assembly.
How does nexonar improve operator safety during battery pack assembly?
By ensuring all fastening steps are executed correctly, nexonar prevents conditions that may lead to short circuits, loose module connections, or thermal risks. Improved ergonomics from wireless RTLS also reduces strain.
Does nexonar integrate with MES, AGVs, and wireless tools?
Absolutely. nexonar integrates seamlessly with MES/ERP systems, wireless nutrunners, and even AGVs using reference trackers to compensate for movement.
How does nexonar improve productivity in battery assembly?
By reducing manual errors, improving operator guidance, and offering real-time positional feedback, nexonar increases workflow efficiency. Manufacturers report up to 8% productivity gain compared to using positioning arms, thanks to real‑time guidance, faster setup, and no repeated calibration.
Can nexonar support both initial assembly and rework?
Yes. The system automatically identifies NOK screws from the line or MES and ensures operators rework only the affected ones, guaranteeing 100% rework completion and full traceability.
