As electric vehicle adoption continues to grow, the demand for safe, efficient and standardized EV battery repair is increasing rapidly. Manufacturers and remanufacturers must repair complex high-voltage battery systems while maintaining the highest standards of quality, safety and traceability.
To meet these challenges, Autocraft Solutions Group implemented the Ansomat Operator Guidance Platform as the digital backbone of its advanced EV battery repair centre.
By combining augmented reality, digital work instructions, battery diagnostics and real-time process validation, technicians are guided through every repair step while the system automatically records process data and ensures consistent execution.
The result is a connected repair environment that supports repeatable, high-quality battery remanufacturing while reducing unnecessary battery replacements.
Read more about repair & rework digital workflows
Repairing modern EV battery packs is significantly more complex than replacing conventional automotive components. High-voltage safety, multiple battery variants and detailed repair procedures require technicians to follow precise workflows every time.
Autocraft needed a solution capable of:
Digital operator guidance enables technicians to perform every repair consistently while ensuring every critical step is validated before the repair continues.
See how Autocraft transformed EV battery repair by replacing manual repair procedures with an intelligent digital operator guidance platform.
| Traditional EV Battery Repair | Ansomat Operator Guidance |
| Paper-based repair manuals | Interactive digital work instructions |
| Manual repair procedures | Step-by-step guided workflows |
| Technician-dependent quality | Standardized repair processes |
| Manual battery diagnostics | Guided diagnostic procedures |
| Limited repair traceability | Complete digital traceability |
| Manual quality documentation | Automatic digital process recording |
| Long technician onboarding | Guided workflows that reduce training time |
| Reactive quality inspections | Real-time process validation |
| Generic repair instructions | Battery-specific repair workflows |
| Manual reporting | Automatic digital repair records |
Autocraft integrates the Ansomat Operator Guidance System across several use cases:
Dynamic work instructions guide technicians through every repair procedure while ensuring the latest approved process is always followed.
In-house EV battery remanufacturing lines, built on AR technology projects visual guidance directly onto battery assemblies, helping technicians identify repair locations quickly while reducing the risk of assembly errors.
Autocraft's OptEVizer EV-health test & diagnostics stations, advanced battery analytics provide detailed insight into battery condition, allowing technicians to identify repair opportunities before unnecessary battery replacement occurs.
The REVIVE® platform standardizes battery repair procedures while ensuring technicians follow validated repair sequences from start to finish. tHIS to ensure OEM-level quality and a true no-fault-forward process.
The system delivers digital, step-by-step work instructions, providing full quality assurance and traceability throughout every repair and remanufacturing operation.
Machine connectivity enables real-time communication between equipment, diagnostics and the operator guidance platform, ensuring every repair step is automatically synchronized.
Every technician action, diagnostic result and repair operation is automatically captured, creating a complete digital history for every repaired battery pack.
Unresolved or misdiagnosed EV battery faults lead to high warranty costs, repeat repairs, and reduced customer confidence. Many garages lack the specialist tools and safe procedures required to detect false battery failures, resulting in unnecessary full pack replacements or unresolved issues.
Autocraft’s EV-health testing and guided repair workflow begins by scanning each battery into the Autocraft Cloud platform. Technicians then select the correct test sequence, including initial diagnostics, functional testing, post-repair validation, cell balancing, or tap testing. Advanced, cell-level diagnostics are performed instead of relying solely on the vehicle’s BMS.
Throughout the process, Ansomat digital work instructions guide technicians step-by-step and communicate with Autocraft infrastructure via MQTT, ensuring safe, standardized execution. Each job concludes with a comprehensive battery health report, reducing unnecessary pack replacements and improving first-time-fix success.
A revolutionary EV battery service concept
Autocraft is redefining EV battery servicing with its REVIVE® mobile service van, a containerized, on-site solution capable of testing, repairing, and remanufacturing EV battery packs using the Ansomat Digital Guidance Platform.
These semi-permanent or fully mobile containerized units can be rapidly deployed at super-dealerships or vehicle recycling centres, allowing packs to be safely tested and discharged prior to dismantling or recycling. Modular by design, they are ideal for customers managing high volumes of failed EV batteries across multiple vehicle brands.
Ansomat Operator Guidance – precision with human flexibility
Ansomat enables the flexibility of a skilled human operator with the repeatability and accuracy of a machine. It integrates machine vision, DC tooling, and dynamic function processes to error-proof every operation for any variant product.
The system supports batch-of-one production, automatically loading the correct workflow for each battery type with zero changeover time.
Electric vehicle battery repair requires precision, safety and complete process control. Discover how Ansomat Operator Guidance helps Autocraft overcome the challenges of modern battery remanufacturing.
| EV Battery Repair Challenge | Ansomat Solution |
| High-voltage repair procedures | Guided digital workflows |
| Multiple battery variants | Configurable digital work instructions |
| Complex battery diagnostics | Integrated diagnostic guidance |
| Technician variability | Standardized operator guidance |
| Incorrect repair sequence | Real-time process validation |
| OEM quality requirements | Complete digital traceability |
| Manual repair documentation | Automatic digital reporting |
| Scaling battery repair operations | Flexible connected workflows |
Autocraft has created a connected digital repair environment that supports safe, repeatable and scalable EV battery repair.
✔ Standardized EV battery repair workflows
✔ Complete repair traceability
✔ Digital work instructions
✔ Augmented reality guidance
✔ Guided battery diagnostics
✔ Improved repair consistency
✔ Reduced unnecessary battery replacements
✔ Faster technician onboarding
✔ OEM-quality repair processes
✔ Continuous process improvement
By combining digital work instructions, augmented reality and intelligent diagnostics, Autocraft has established a modern battery repair process that supports both operational efficiency and long-term sustainability.
The Ansomat Operator Guidance Platform helps manufacturers and remanufacturers improve every stage of EV battery repair by delivering:
Discover how Ansomat Operator Guidance helps EV manufacturers and battery remanufacturers improve repair quality, technician performance and complete process traceability with digital workflows and augmented reality.
