Scenario-based development of disassembly systems for automotive lithium ion battery systems

The rising number of lithium ion batteries from electric vehicles makes an economically advantageous and technically mature disassembly system for the end-of-life batteries inevitable. The disassembly system needs to cope with the size, the design and the remaining state of charge of the respective battery system. The complex design resulting from the number and type of connection elements challenges an automated disassembly. The realisation of an automated disassembly presupposes the consideration of elements from Design for Disassembly throughout the battery system development. In this paper a scenario-based development of disassembly systems is presented with varying possible design aspects as well as different amounts of end of life battery systems. These scenarios point out the resulting implications on battery disassembly systems in short, medium and long term. Using a morphological box the best option for each disassembly scenario is identified and framed in a disassembly system design. The disassembly systems are explained and the core elements are introduced. Newly developed and innovative disassembly tools, such as a robot that allows a hybrid human-robot-working-space and an advanced battery cell gripper are introduced. The gripper system for the battery cells enables with an integrated sensor an instant monitoring of the battery cell condition. The proposed disassembly element is verified in an experimental test series with automotive pouch cell batteries.