Assembling Battery Packs


Battery pack assembly errors can add delays and increase rework when tolerances are tight. Vision-enabled automation guides module placement, locates bolt holes for busbar installation, and verifies each step without slowing the line. Smart cameras apply pattern matching, measurement, edge finding, and blob analysis to confirm correct alignment, connections, and coolant routing of assembled battery packs mounted on autonomous mobile robots (AMRs). Issues surface in real time, enabling correction before the next station.

Automated manufacturing warehouse using Iris GTX smart camera for battery inspection

Guide placement and verify assembly with machine vision to speed battery pack build and improve quality

Automated manufacturing warehouse with a close up view of a Iris GTX camera inspecting an electric vehicle battery

Guide battery module placement with vision

Iris GTX smart cameras capture high-speed images to guide precise module placement, while 2D code-reading and measurement tools locate cases, detect bolt holes, and verify seating before torque. Iris GTX smart cameras provide the resolution and frame rates needed for moving targets, automatically confirming position and fit to reduce manual scans and bottlenecks. Operators receive visual feedback and pass/fail cues, enabling alignment corrections without stopping the line.

Screenshot of the Aurora Design Assistant software interface, showcasing a detailed flowchart and an analyzed image with multiple detected objects, demonstrating its advanced object recognition and workflow automation capabilities for assembling battery packs.

Inspect and verify assemblies in real time

Zebra’s Aurora Design Assistant software provides a flowchart-based environment that enables teams to configure assembly inspection workflows without writing code. It uses a common toolset, including pattern matching, measurement, edge and blob analysis, OCR/OCV, and code reading, to inspect structural integrity, cable clips, electrical connections, coolant fittings, and busbar placement. Results are published in real time to logs and production systems for traceability. Configurable error-handling features, such as retries, alternative checks, and automatic routing to rework, ensure robust inspections under varying conditions.

Robotic arm with CV60 Machine Vision Camera attached provides guided assistance during assembly of an automotive battery pack, allowing for precise alignment while detecting defects

Improve robot guidance and component inspection

Zebra CV60 cameras play a dual role in robot guidance and quality verification. During assembly, the system ensures precise alignment and adapts to new designs via an intuitive interface. Additionally, the CV60 performs fastener verification by inspecting for the correct type, presence, and proper placement of fasteners, while detecting defects such as damaged threads or improper torque. For cover-to-lid assembly, the CV60 provides advanced guidance and alignment, ensuring proper sealing and environmental protection, while performing pre- and post-assembly inspections for defects. 

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