As the core assembly of a power battery, the PACK's assembly and tightening process directly determines the overall safety performance of the vehicle. The internal workstations of the PACK are complex, with numerous screw points and stringent safety requirements. Traditional tightening tools are increasingly unable to meet the production demands of high cycle rates, high reliability, and full data traceability. Many new energy vehicle manufacturers encounter practical challenges such as space constraints, difficulty in mixed-line control, high error-proofing pressure, and lack of data traceability when implementing PACK production lines.

I. Five Core Industry Pain Points in Power Battery PACK Assembly

A power battery PACK includes a large number of components such as the BMS, high and low voltage wiring harnesses, modules, and housings, with a significant number of A/B class safety-critical connection points. The traditional tightening mode reveals multiple process shortcomings, restricting production line yield improvement and quality control.

1. Limited Workspace, Poor Tool Accessibility, and Frequent Assembly Anomalies: PACKs have many deep-cavity, lateral, and obstructed narrow workstations. Traditional straight screwdrivers are prone to interference, making it impossible for the bit to align vertically with the screw, leading to assembly defects such as tilted screws, floating screws, and stripped threads. The restricted posture in tight spaces makes manual operation difficult and increases rework costs.

2. Multi-Model Mixed-Line Production, Complex Process Changeovers, and Difficulty in Ensuring Tightening Consistency: OEM PACK production lines generally support multi-model mixed-line production, with frequent changes in screw specifications and torque parameters. Traditional tools rely on manual parameter modification, which is prone to setting errors. Operational differences among workstations and operators make it difficult to guarantee the tightening consistency of every screw during mass production, affecting the residual torque of connections and threatening the operational safety of the battery pack.

3. Frequent Missed, Incorrect, and Repeated Tightening, Creating High Error-Proofing Pressure: Screws on a single PACK are distributed across different areas, with critical connections classified as A/B class safety level. Traditional modes lack mandatory error-proofing mechanisms, making them susceptible to missed, incorrect, or repeated tightening. Process failures at critical points can lead to poor contact and heat generation, and in extreme cases, trigger thermal runaway risks. Relying solely on manual re-inspection is inefficient and has a high miss-rate.

4. Stringent Safety Level Requirements and Difficulty in Controlling Residual Torque: Critical connections like high and low voltage wiring harnesses, busbars, and BMS fixation demand extremely high standards for residual torque and connection reliability. Ordinary tools lack sufficient torque control accuracy; over-tightening damages components, while under-tightening leads to torque decay and loosening, making it difficult to meet the high-safety assembly specifications for power batteries.

5. Fragmented Torque Data and Insufficient Full-Chain Traceability Capability: New energy manufacturing demands increasing traceability of process data. Traditional tools cannot fully collect data such as torque, angle, tightening curve, and workstation information. This data is difficult to interface with the MES system. Consequently, when faults occur, it is impossible to quickly review and pinpoint the root cause, and process optimization lacks data support.

II. Danikor Angle Sensor Tools: A Targeted Solution for Complex PACK Tightening Conditions

To address the pain points mentioned above in PACK assembly, Danikor has developed a complete intelligent tightening solution comprising Angle Sensor Tools and a Web Server platform. The hardware overcomes spatial constraints, while the software constructs a full-chain quality closed loop, adapted for mass production scenarios in power battery PACKs.

1. Angle Head Structure Design, Overcoming Operational Challenges in Narrow, Deep-Cavity Workstations: Danikor's wired angle sensor tool features an angle head that cleverly avoids interference with the PACK's internal structure. It can adapt to complex workstations involving deep cavities, lateral approaches, and obstructed areas where straight tools cannot operate. This enables flexible multi-angle and multi-posture tightening, significantly improving tool accessibility and physically reducing problems like tilted screws, floating screws, and misalignment, adapting to assembly scenarios with densely packed screw points inside the PACK.

2. Built-in High-Precision Sensor and Self-Developed Algorithms, Ensuring Tightening Accuracy for A/B Class Points: The tool incorporates a high-precision torque sensor paired with self-developed tightening control algorithms to precisely manage both torque and angle—the two core parameters—suitable for A/B class high-safety connections like BMS and high/low voltage wiring harnesses. It maintains stable output during high-cycle continuous production, guaranteeing tightening accuracy and effectively managing residual torque. This prevents over-tightening from damaging components and under-tightening from causing loosening and failure, ensuring the reliability of battery pack connections.

3. Job Task and Pset Program Calls, Meeting Error-Proofing Needs in Mixed-Line Production: The tool supports Job task management and Pset program calls, enabling one-key switching of process parameters in scenarios with multiple screw specifications, suitable for multi-model mixed-line production. It features screw counting management, with the system automatically identifying the operation sequence to effectively prevent subjective human errors like missed or repeated tightening. It monitors torque, angle, time, and the tightening curve in real-time, immediately alerting upon detecting anomalies like stripped threads or floating screws. This achieves real-time error-proofing during assembly, shifting quality control forward to the production stage.

III. Web Server Platform: Building a Digital Traceability Closed Loop for the Entire PACK Assembly Process

High-performance tightening tools alone are insufficient for complete quality control. Danikor complements the hardware with a Web Server platform that consolidates hardware data, completes line-wide quality management, and fills the digital gap in PACK production lines.

1. Comprehensive Real-Time Data Acquisition, Seamless Integration with MES Systems: The platform collects comprehensive tightening data in real-time, including torque, angle, tightening curve, timestamp, tool status, and workstation information. It supports seamless connection with the production line's MES (Manufacturing Execution System), achieving data interconnectivity and solving the data silo problem of traditional models.

2. Multiple Data Assurance Mechanisms, Ensuring Complete and Secure Data Integrity: Features like breakpoint resumption, smart backup, and hierarchical permission management ensure that tightening data storage is complete and reliable, preventing the loss of critical process records due to on-site operational fluctuations. Engineers can perform equipment operation monitoring, process execution analysis, and tightening curve overlay comparison, enabling rapid identification of assembly anomalies, shortening fault review time, and improving line problem-solving efficiency.

3. Automated Push of Customizable Reports, Empowering Process Iteration and Optimization: The Web Server platform supports role-based customization of data analysis reports and can automatically email anomaly reports to responsible personnel. Quality issues are communicated to relevant parties as soon as they occur. This truly achieves a complete digital closed loop from tightening execution and quality monitoring to process iteration, supporting the smart manufacturing upgrade of power battery factories.

Danikor's complete intelligent tightening solution helps new energy manufacturing enterprises enhance PACK assembly production efficiency, strengthen full-process quality control, and accelerate the digital transformation of their production lines.