Circular economy and battery recycling

Next generation automation

Automated dismantling of high-voltage batteries

Circular economy in electromobility

In pursuit of climate-neutral mobility, the automotive sector is undergoing a significant transformation. The growing demand for battery-electric vehicles raises questions about the environmental impact of vehicle batteries, the security and availability of raw materials, and the competitiveness of the German and European industry.

Whether battery parts are to be reused or recycled, dismantling the battery systems is the first necessary step in all standard processes.

Automated dismantling of high-voltage batteries for safe battery recycling

Life cycle, second life applications, remanufacturing, and recycling of high-voltage battery systems

Liebherr is setting new standards in this regard: Building on the results of the ZIRKEL project, an innovative dismantling cell was developed, which carries out the decisive steps of non-destructive dismantling in a fully automated process.

The research project demonstrated the technical feasibility of automated dismantling of high-voltage batteries, for example of the Volkswagen MEB. The focus there was on non-destructive dismantling, especially the automated unscrewing of the numerous screw connections. This process is time-intensive and critical for safety, but is crucial for risk-free further dismantling and safe discharging of the battery module.

The result represents significant technological progress: The dismantling cell developed by Liebherr enables reliable, efficient and future-proof automated reconditioning of high-voltage batteries. It forms a central technical basis for the development of closed-loop recycling in electromobility.

Pilot system for dismantling of battery packs

First pilot system for high-voltage battery dismantling

As part of the joint project subsidised by the Federal Ministry of Education and Research, Circular Production for Highly Integrated Electromobility Components – “ZIRKEL”, Liebherr-Verzahntechnik GmbH, as an industry pioneer, supplied a system for automated dismantling of high-voltage battery systems to the Open Hybrid LabFactory (OHLF) research campus in Wolfsburg.

After separating the joints, the system employs handling technologies to remove and transfer the dismantled components, sorted by type, into the containers provided.

Automated screw-removal process for industry: LHDismantle as a solution for series production

Based on the findings from the pilot system, the screw-removal process was further developed specifically for industry production. LHDismantle provides a market-ready industrial solution that implements this process in an automated, robust, and efficient way. The solution overcomes key challenges such as a wide variety of parts, dirty or damaged components and very high safety requirements – thanks to intelligent sensors, flexible software and an intuitive user interface.

Highlights:

Tactile precision entirely without camera system

Also reliable with dirt, corrosion and changing light conditions

Smart sensor system for maximum flexibility

Automatic position correction for stable processes

Efficient screw removal

By tilt unit or suction module, depending on the requirements

App-based user interface

With intuitive, graphic live status for the whole screw-removal process

No-code programming

Easily select battery packs and screw-removal programs from the integrated database

Automatic tool changer

Tool storage for different screw types and variants

Digital twin

Simulation, validation and optimization of new battery variants and screw-removal programmes prior to real commissioning

LHDismantle: Non-destructive dismantling of high-voltage batteries

Future-proof solutions

Liebherr offers a comprehensive portfolio of products for the safe handling, transport and storage of high-voltage batteries and is expanding this in a targeted manner along the entire process chain for dismantling and recycling of high-voltage batteries.

In addition to non-destructive dismantling separating processes for opening the battery cover and a subsequent discharge can also be incorporated. These steps enable safe preparation of batteries for further processing in manual workstations that can be flexibly integrated into the automatic workflow.

The modular and scalable automation systems and Liebherr Automation Production Control for recording process data, traceability and intelligent control of processing steps create solutions that will grow with increasing quantities, new variants and future battery designs.

Liebherr is therefore offering a future-proof overall concept that combines automated and manual processes and is leading the way towards an efficient circular economy in electromobility.