Danikor Wireless Tightening Solution: Solving the Assembly Challenges of New Energy Battery Packs

Danikor Wireless Tightening Solution

The assembly of new energy battery packs often involves hundreds of screws. In high-intensity assembly line operations demanding one screw every 3 seconds, any issue—be it missing screws, wrong screws, data loss, or signal interruption—can become a safety hazard in subsequent use. Danikor's TBE Wireless Pulse Sensor Tool, paired with a 3D Vision Positioning and Error-Proofing System, leverages stable and reliable tightening technology to create a comprehensive, end-to-end error-proofing solution for battery pack assembly.
I. Four Core Pain Points in New Energy Battery Pack Assembly

At battery pack tightening stations, traditional operating modes have long faced the following challenges:

1. Vast Number of Screws, High Difficulty in Preventing Misses and Errors
A single battery pack contains hundreds of screws, distributed in different locations and with various specifications. Manual operations are prone to missed screws, wrong screws, and incorrect tightening sequences. Traditional manual self-inspection is inefficient and has a high error rate, making it difficult to ensure that every screw is correctly tightened.

2. High-Intensity Continuous Operation, High Pressure on Production Line Takt Time
High-frequency tightening operations (one screw every 3 seconds) demand high stability, battery life, and response speed from the tools. Traditional wired tools are restricted by cables, making them inconvenient to move and limiting takt time. Conversely, ordinary wireless tools often suffer from insufficient battery life and performance degradation, failing to meet the demands of prolonged, high-intensity fastening operations.

3. Wireless Communication Susceptible to Interference in Complex Working Conditions
Battery pack production workshops are often primarily metal structures, which strongly shield wireless signals. Common wireless tightening tools are prone to signal disconnection and data transmission interruptions. This not only affects the real-time upload of tightening data but can also lead to data loss, impacting production traceability.

4. Poor Tightening Consistency, Prominent Safety Risks
The tightening torque of screws in a battery pack directly affects its sealing performance and structural stability. Insufficient torque can lead to seal failure, water ingress, and short circuits, while excessive torque can cause housing deformation and thread stripping. Traditional tools struggle to maintain consistent torque accuracy during high-frequency operations.

II. Core Advantages of the Danikor TBE Wireless Tightening Solution

Addressing the specific requirements of battery pack assembly, Danikor's TBE Wireless Pulse Sensor Tool, combined with the 3D Vision Positioning and Error-Proofing System, creates an end-to-end tightening solution that "prevents missed screws, prevents wrong screws, prevents disconnection, and prevents data loss":
1. Prevents Misses and Errors with 3D Vision System for Full-Process Control

Paired with the 3D Vision Positioning and Error-Proofing System, it can identify screw positions and tightening status in real-time. The tightening sequence, torque, and angle for each screw can be precisely recorded, completely eliminating issues like missed screws, wrong screws, and sequence confusion.

The tool has a built-in barcode scanning module, allowing each screw's tightening process to be scanned and bound. This data is linked one-to-one with the battery pack's serial number (SN), enabling full lifecycle traceability from production to after-sales service.

2. Wireless Freedom and Stable Performance During High-Intensity Operations

The stand-alone integrated design features a built-in control system and battery, with no cable restrictions. It can be easily operated with one hand, suitable for mobile assembly across different stations. Eliminating cable drag significantly improves operational flexibility at stations and production line takt time.

Equipped with industrial-grade batteries supporting prolonged continuous operation. The low reaction force design in pulse mode significantly reduces operator fatigue during long working hours, easily meeting the demands of high-frequency tightening (one screw every 3 seconds).

3. Strong Signal Transmission, Stable Online Even in Complex Conditions

Utilizes a high-penetration WiFi module, with a signal transmission distance of up to 40 meters in interference-free environments. It can easily penetrate the metal structures of workshops, maintaining a stable signal for assembly across different stations and areas.

Supports multiple devices online simultaneously. A single controller can connect to 6 tools, and a host computer can support up to 20 tools operating at the same time, meeting the collaborative production needs of multiple stations. Automatic protection activates upon instantaneous signal disconnection, with data temporarily stored locally and automatically resumed after signal recovery, completely solving the data loss problem.

4. High-Precision Tightening, Ensuring Battery Pack Assembly Consistency

Achieves torque accuracy of 6σ ±7.5% in pulse mode and 6σ ±5% in standard mode. Exclusive tightening strategies can be set for different screw specifications. Whether in soft or hard joint applications, it delivers stable and precise torque, avoiding seal failure or housing damage caused by improper tightening force.

Features a built-in control system, allowing stand-alone operation for tightening strategy settings, data storage, and MES integration. WiFi connects in seconds, enabling lag-free real-time data upload without the need for additional complex control equipment, thus reducing production line deployment costs.

III. The Ideal Choice for Upgrading Battery Pack Assembly

Danikor's TBE Wireless Pulse Sensor Tool, with its core advantages of "wireless freedom, stable online connectivity, and precise error-proofing," perfectly meets the tightening needs of new energy battery packs:

Prevents Misses and Errors: Paired with a 3D vision system, it ensures full control over the tightening process for every single screw, eliminating human errors.

Efficient Takt Time: The wireless, untethered design adapts to high-frequency operations across multiple stations, significantly improving production line efficiency.

Stable Transmission: High-penetration WiFi coupled with disconnection protection guarantees complete data upload even in complex working conditions.

Precise and Reliable: Industrial-grade torque accuracy ensures the stability and safety of every connection point within the battery pack.

Danikor's wireless tightening solution not only addresses the challenges during battery pack tightening but also builds an efficient, stable, and traceable intelligent assembly system for enterprises, helping new energy vehicle manufacturing advance towards higher standards.