Reimagining EV Battery Assembly with Augmented Reality and Smart Tools

As electric mobility accelerates, the production of electric vehicles (EVs) is evolving — placing the battery at the center of the manufacturing process. The battery not only determines the vehicle’s range and charging time but is also a highly safety-critical component. Even minor assembly errors can lead to severe consequences, including fires that are difficult to extinguish. To meet these challenges, manufacturers are adopting advanced technologies such as augmented reality (AR) projection, smart tools, and real-time tool tracking. These innovations aim to enhance safety, improve quality assurance, and increase production efficiency.

To address these challenges, a holistic solution is proposed that integrates dynamic laser and video projection, smart tools, and digital tool tracking. These technologies work together to guide workers through complex tasks, ensure precision, and provide real-time feedback. Also, rework processes can dynamically be adapted to component-specific findings of image recognition systems, such as identifying defects in welding and foam applications. Data from all processes is collected and stored in the cloud, enabling long-term documentation as well as AI-driven analysis and continuous improvement. This integrated approach supports not only operational efficiency but also compliance with environmental and safety standards.

The system begins with digital worker guidance using augmented reality (AR) projection, which displays precise instructions directly onto the workpiece. This allows workers to perform tasks accurately without needing printed manuals or VR headsets. Smart tools receive torque specifications from the software and adjust automatically, ensuring each screw is tightened correctly. Tool tracking systems use cameras and infrared markers to monitor tool location and actions in real time.

In welding processes, smart tools analyze current and flame characteristics to assess weld quality. Image recognition software inspects the battery and flags any defects, which are then corrected at rework stations using projection guidance. For fire protection, thermally conductive foam is applied, and any voids are detected and highlighted for manual correction.

Welding robots are tested using dummy batteries equipped with test cells. Each cell is tracked via QR codes, and the entire process — from placement to welding — is documented. The results are analyzed in the lab, and robot settings are optimized based on the findings. All data is fed back into the digital model, creating a continuous feedback loop between the physical and digital environments.