Battery pack recycling challenges for the year 2030: Recommended solutions based on intelligent robotics for safe and efficient disassembly, residual energy detection, and secondary utilization

Abstract

With the increasing use of batteries, battery recycling would become a considerable problem in the next decade. However, the current recycling technologies are still on the stage of research and development. A significant challenge in the traditional recycling method is that the recovery procedure relies heavily on manual work. Therefore, it is necessary to develop an intelligent, automatic or semi-automatic framework for rapid disassembly and efficient recovery of retired batteries. In this study, the key research problems during the battery recycling process were identified first. The main recycling process was divided into three parts: automatic disassemble process, residual energy detection, and second utilization as well as chemical recycling. Based on the above research gaps, a qualitative framework of UR5 robots for safe and fast battery recycling, residual energy detection, and secondary utilization of retired batteries was proposed. The framework includes a battery position and shape measurement system based on machine vision, an automatic battery removal system based on UR5 industrial robot, a battery residual energy detection, and classification system. Furthermore, a real case study of battery pack recycling was carried out based on manual work and automatic robot work. The results show that the proposed recycling framework can work efficiently compared with the traditional recycling method. Moreover, the future perspectives of battery recycling are summarized. K E Y W O R D S conservation of materials, disassembly, efficient recycling, environmental benefits, intelligent robotics, recovery 1 | INTRODUCTION At present, China ranks among the world's largest producers and consumers of lithium batteries. The annual battery consumption reaches 8 billion. 1 If the waste lithium batteries are not processed and recycled systematically, it will seriously waste resources, pollute the environment, and endanger human health. It can be seen that the recycling and reuse of waste batteries has a broad market. Due to the accelerated replacement of consumer

Assessment of recycling methods and processes for lithium-ion batteries

“…This brings about difficulties in regulating the automated process and optimizing it to accommodate different batteries with different structures and dimensions. Similarly, it is challenging for batteries to be properly classified for large-scale automated disassembly ( Zhou et al., 2021 ). Battery designs differ from manufacturer to manufacturer.…”

Reconfigurable battery systems: Challenges and safety solutions using intelligent system framework based on digital twins

“…The digital twin built for real-time determination of residual energy or health status of each cell in the pack during its operation can be used as an important input in digital twin of recycling for intelligent sorting of cells for echelon utilisation (reusability or recovery applications). This whole process is so far manual and needs thorough further research by further incorporating non-destructive testing and advanced human to machine systems for making it semi-automatic [71,72].…”

Recent Advancements in Battery Management System for Li‐Ion Batteries of Electric Vehicles: Future Role of Digital Twin, Cyber‐Physical Systems, Battery Swapping Technology, and Nondestructive Testing

“…At present, recycling of the batteries involves mechanical and chemical processes. Various researches are going on battery waste management, for instance, Zho et al [ 82 ] presented three major aspects in battery recycling‐disassembling, estimation of residual energy, and the process of chemical recycling. [ 82 ] However, there are certain challenges associated with the recycling process of the batteries and which classified into three categories: dismantling process, estimation of SOH or reminiscent life of the battery, and reutilization of the retired battery.…”

“…Various researches are going on battery waste management, for instance, Zho et al [ 82 ] presented three major aspects in battery recycling‐disassembling, estimation of residual energy, and the process of chemical recycling. [ 82 ] However, there are certain challenges associated with the recycling process of the batteries and which classified into three categories: dismantling process, estimation of SOH or reminiscent life of the battery, and reutilization of the retired battery. The internal structure of the battery consists of inflammable material, so any external application of pressure to disassemble it may cause severe fire hazard or explosion.…”