ActiveAssist assistance system - modular, connected, interactive


The digital assistant for multi-variant assembly tasks.

The ActiveAssist assistance system is revolutionizing the manual workstation and moving the focus of Industry 4.0 towards people. At the heart of ActiveAssist is freely configurable software that supports employees with targeted information and help functions and intelligently guides them through the assembly process. This means that there is nothing standing in the way of multi-variant assembly tasks down to batch size 1. Intuitive to use and completely connected, the assistance system increases process reliability and quality.

ActiveAssist assistance system: modular, connected, interactive.


Discover more advantages of ActiveAssist!


Product information

  • Advantages at a glance


    • Modular design in both software and hardware and freely configurable, the appropriate scope is available for every application case.
    • Incorporation of sensors from various manufacturers possible.


    • ActiveAssist is a flexible and open system thanks to its web-based software and standardized interfaces.
    • Seamless connection of many systems and assembly stations is possible.


    • Many different assistance functions can be realized by connecting touchscreens, 3D cameras and projectors.
    • Virtual buttons directly above the workstation ensure optimal ergonomic operability of the software by the employee.
  • Key technical data
    • Web-based configurator
    • Data management: user management, order management
    • Communication with MES-/ERP systems via standardized interfaces (XML file folder or REST API)
    • Context-based provision of information
    • Hardware solutions: e.g. depth-sensing camera, projector, pick-to-light
  • Special components

    ActiveAssist basic set

    Basic set
    • Forms the basis of ActiveAssist
    • Creation of individual workflows
    • Shows step-by-step work instructions on a touchscreen
    • Web-based configuration: intuitive integration of assembly processes, online and offline
    • Data management: user and order management

    ActiveAssist projection module

    Projection module
    • Expands the ActiveAssist basic set
    • Projects the work steps onto the assembly area
    • Marks grab containers or points of interest (e.g. screw positions) in the workspace
    • Increases efficiency through the provision of information in an ergonomic viewing field

    ActiveAssist hand-tracking module

    Hand-tracking module
    • Expands the ActiveAssist projection module
    • Reliably tracks employees' hand movements without a distracting sensor on the wrist
    • Improves process reliability by recognizing gripping movements

    Baton screwdriver control

    Baton screwdriver control
    • Defines the precise torque for all functions of the baton screwdriver
    • Improves process reliability by releasing baton screwdrivers at the desired process step

    Product identification

    Product identification
    • Defines the precise torque for all functions of the baton screwdriver
    • Improves process reliability by releasing baton screwdrivers at the desired process step

    Incorporation of conventional pick-to-light systems

    Pick-to-light system
    • ActiveAssist can be expanded with classic pick-to-light components e.g. to connect side/end shelving or to detect large-scale material supply at the workstation

    Screwdriver integration

    Screwdriver integration
    • to integrate open protocol-compatible tightening systems into the ActiveAssist system
    • Transmission of screw parameters to be executed during the correct process step via Wi-Fi or Ethernet

    Screwdriver localization

    Screwdriver localization
    • to localize screwdrivers and other tools in a production operation with the help of ultrasound technology
    • Activation of the screwdriver on the appropriate screw position with the help of an ultrasonic transmitter

    External communications interface

    External communications interface
    • interface to connect higher-level systems (MES-/ERP system)
    • The software offers two standardized interfaces for connection purposes:
      - XML file folder
      - REST API

Industries and customer applications

  • Production with:
    • High proportion of manual work processes
    • High variance
    • High degree of process reliability
  • Automotive industry
  • Electronics industry
  • ESD environments
ActiveAssist application Magnifier
ActiveAssist application Magnifier
ActiveAssist application Magnifier

ActiveAssist - the digital assistant for multi-variant assembly tasks

ActiveAssist - the digital assistant for multi-variant assembly tasks Magnifier

More information


Find out more about Manual Production Systems

Read more about Rexroth's products and solutions for Industry 4.0