An experimental robotic cell for the disassembly of electric vehicle battery modules

Abstract

The increasing shift towards electrification in the automotive industry has highlighted the critical need for a large-scale and efficient processing of end-of-life (EoL) lithium-ion batteries (LiBs) from electric vehicles (EVs). Linear EoL strategies, such as landfilling, pose significant environmental hazards, while recycling, repurposing, and remanufacturing offer more sustainable alternatives; however, these alternatives require scalable, safe, and cost-efficient disassembly processes. To support circular EoL practices, a prototype of a robotic cell was proposed, presenting a novel automated disassembly process for EV-LiB modules, addressing challenges in the areas of safety and cost-effectiveness. Safety was addressed by encapsulating the work area with protective windows and implementing a safety system that suspends operation if safety conditions are not met. Cost-effectiveness was achieved by implementing a cell layout and robot program that can easily be reconfigured to be compatible with a range of Battery module designs available in the market, and utilising low-cost tools. This paper also presents a methodology for assessing the economic impact of the robotic cell. Initial assessments conducted on a mock-up Samsung model 12S1P Battery module demonstrate that the robotic cell can match the productivity of 5.50 workers within a workweek, saving over £15,000 per month in operational expenses, leading to a potential payback period of 1.33 years. This research marks a step towards realising scalable and financially feasible robotic disassembly systems for EoL EV-LiBs, promoting a circular economy in the automotive sector.