With the advent of AI, data centers and energy storage systems are expanding quickly. However, the assembly methods used to build additional infrastructure are under increasing pressure. The challenge isn’t necessarily limited to throughput, as it is more driven by the physical complexity of the assemblies themselves. Dense packaging and limited access points create conditions that are difficult to manage with standard manual assembly methods.
Many data center assemblies are not designed with automation as the primary consideration. Tight clearances between components can restrict tool access. Raised features (such as connectors and busbars) create uneven surfaces that can complicate positioning. Fastening points are often located within a confined, fairly obstructed area, which requires a non-standard approach to reach the Drive location.
Variation across assemblies adds a layer of difficulty. Differences in component geometry and layout require adjustments at the process level. Instead of applying a repeatable method, manufacturers often adapt tooling and workflows to match the design, which can be limiting to consistency and can make scaling more difficult.
Manual assembly remains common in operations that require component placement and alignment. Leads (which connect electrical components through ring terminals) must be positioned correctly before fastening in place.
These steps rely on operator input rather than relying on automated processes. While effective at lower production volumes, this can introduce unwanted variability across shifts between operators. As the necessary output increases, it can become difficult to maintain consistency in joint quality due to operator variation.
Production environments reflect these constraints directly. Limited clearance areas require specialized guides to reach some joints. Deep or narrow recesses prevent standard tools from engaging with the component, which requires tools to be extended reach. In enclosed assemblies, electrostatic discharge requirements can further complicate the process.
High component density presents another challenge. Assemblies may require multiple installation steps to be completed in sequence or in parallel within a confined space. This type of component layout is commonly seen in battery backup and power distribution assemblies.
Automation becomes effective when it addresses these constraints directly. Robotic screwdriving systems help maintain constant positioning in confined areas, and fastener feeding systems can orient and deliver components such as nuts and set screws before installation.
Controlled assembly processes allow for repeatable seating of each fastener to help reduce any variation in joint quality and support a stable output from production. Rather than having to replace every manual step, automation is applied wherever variability has the greatest impact.
Adoption has remained inconsistent across the data center industry. Many manufacturers continue to rely on manual processes because their components were not designed for automation; there is also a gap in how automation is evaluated (particularly in relation to throughput and rework). At the same time, demand for data centers and energy storage infrastructure continues to grow. As the need for automation increases, the limitations of manual assembly will become more visible, and the ability to manage complexity in a controlled and repeatable way is becoming a requirement.