Hidden Code Reading and Product Traceability on Battery Assembly Line

Project Overview

On the battery assembly line of one of the leading automotive manufacturers, we developed a specialized code reading solution to automatically read invisible CDOT codes laser-etched onto vehicle chassis and seamlessly transfer them to the manufacturing execution system (MES).

The primary goal of the project was to ensure fast and reliable reading of the chassis code during production, transmit the captured data to the production system, and provide end-to-end traceability for every unit throughout its lifecycle.

Challenges & Operational Demands

Because the codes on the chassis are microscopic laser-etched CDOT marks invisible to the naked human eye, conventional barcode scanners failed and manual inspection was impossible. Additionally, the line required untethered mobility with encrypted wireless transmission reaching up to 50 meters in open space with server response times strictly under 2 seconds.

The ANAVIS Solution

High-performance Direct Part Marking (DPM) code readers equipped with specialized optical illumination were implemented to capture high-contrast images of the microscopic laser etchings.

Once decoded, data is transmitted instantly via wireless handheld reading terminals directly to the central server. This eliminated the physical tethering of operators to fixed terminals and enabled seamless wireless data ingestion across the entire assembly bay.

Thanks to our proprietary communication architecture, code data is transmitted to the central server in under 2 seconds from distances up to 50 meters in open plant environments.

How the System Works

01 Hidden Code Identification: Microscopic laser-marked CDOT code is located on the vehicle chassis.
02 DPM Optical Acquisition: The DPM reader captures a high-resolution image under tuned lighting.
03 Algorithm Decoding: Specialized vision decoding algorithms extract the encrypted payload.
04 Wireless Transmission: The payload is securely relayed via industrial wireless handheld hardware.
05 Sub-2s Server Sync: Data is ingested by the central server within 2 seconds.
06 Full Traceability Match: The part identifier is paired with the production record (MES/ERP) for full lifecycle traceability.

Key Results and Business Impact

With this engineered solution, invisible codes that previously required complex manual handling are now verified instantaneously and reliably.

Flawless Identification: Zero-error decoding of microscopic DPM codes on bare chassis metal.

Sub-2s Real-Time Sync: Industrial wireless range exceeding 50 meters open-air.

Zero Manual Error: Complete elimination of human data-entry inaccuracies.

Enhanced Line Velocity: Maximized operational speed and assembly flow on the EV battery line.

The ANAVIS Engineering Difference

This project demonstrates how industrial code reading, robust wireless networking, and enterprise traceability integrate under demanding shop-floor conditions. At ANAVIS, we do not merely scan codes; we develop comprehensive end-to-end architectures that ensure critical production data arrives at the right destination, at the right instant, with total reliability.