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

customer challenge during battery assembly

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.
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.
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?

Upgrade your manufacturing process with advanced technology that prioritizes safety, ergonomics, and efficiency. By reducing recall risks and optimizing workflows, you can ensure a more reliable and productive operation.

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

Do you want to learn more how the Real-Time Location System from nexonar works?

nexonar in DRÄXLMAIER

We were very positively surprised that even with the test system, everything worked flawlessly right from the start! Now we are able to ensure that all screws are fitted according to specification.

Christian Grötzinger

Product Manager

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.