Disassembly of Traction Batteries Down to the Cell Level at the Pilot Plant, According to Fraunhofer
In the heart of Saxony, a pioneering project is underway. The Fraunhofer Institute for Manufacturing Technology and Advanced Materials Federation (IWU) and EDAG Production Solutions are collaborating to construct an automated disassembly plant for active traction batteries in Chemnitz. This plant, set to revolutionize the reuse and recycling of electric vehicle batteries, will serve as a data platform standardizing these processes.
The plant will be variant-flexible and AI-supported, ensuring economical and safe handling of various high-voltage storage systems. At its core, the plant will rely on AI to support the disassembly process and ensure safe handling of traction batteries.
The data collected from the plant will be instrumental in the further development of qualification profiles for skilled workers in Saxony. Researchers expect interdisciplinary knowledge from mechanics, electrical engineering, and computer science to gain importance in many job profiles around the automotive industry.
One might wonder why simply shredding used traction batteries would not suffice. The truth is that such a method would destroy their value. Instead, the lifespan of traction battery components can be extended through repair and "remanufacturing". Used traction batteries can provide good service in large storage systems, and the residual capacity of many used traction batteries ranges between 70 and 80 percent.
By 2030, the amount of end-of-life batteries in the EU is expected to increase more than tenfold. This new plant will contribute significantly to addressing this growing challenge by using only reusable components from traction batteries, even fully intact units could be used for new traction batteries.
The plant will also feature an integrated system for analyzing the health status of modules and cells, to ensure only reusable components are released for reuse. This system will be crucial in achieving a largely damage-free disassembly of all components down to the cell level, a prerequisite for a new battery life.
Another company, Hydrovolt, is working on the development of an automated disassembly plant for active traction batteries in collaboration with Fraunhofer IWU. This plant, planned to be located in Chemnitz, will make it possible to reduce the demand for energy-intensive new production and easier for recycling companies to recover valuable raw materials.
Through repair and "remanufacturing" of these batteries, valuable resources can be conserved. The future pilot plant in Chemnitz is aimed at addressing the rapidly growing demand for efficient circular economy solutions. The new infrastructure will serve as a beacon, setting the standard for sustainable battery management and paving the way for a greener future.
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