Automation for Electric Vehicle Battery Pack Disassembly

Islam, Abu; DeHaven, Matthew; Neipert, Marshall; Nenadic, Nenad

doi:10.1002/amp2.70025

Automation for Electric Vehicle Battery Pack Disassembly

Journal Article · Thu Jun 26 00:00:00 EDT 2025 · Journal of Advanced Manufacturing and Processing

DOI:https://doi.org/10.1002/amp2.70025· OSTI ID:3025753

Islam, Abu ^[1]; DeHaven, Matthew ^[1]; Neipert, Marshall ^[2]; ^[1]

Rochester Inst. of Technology, Rochester, NY (United States)
BigBattery, Chatsworth, CA (United States)

Battery‐electric vehicles (EVs) are growing exponentially. The demand for these batteries is expected to increase sevenfold by 2035. The EV batteries reach their end of life when the capacity fades to 70%–80% of new, with some being removed from the primary applications with even lower levels of degradation. These batteries can be used in less demanding applications. The disassembly process is currently manual, slow, unsafe, and expensive. Automation is needed to increase the throughput. EV battery packs feature various continually changing designs and form factors, which limit the usefulness of deterministically programmed robotic solutions. The conceptual robotic disassembly of EV batteries has attracted the attention of researchers. However, while many approaches have been proposed, practical implementations are lacking. Here, we review proposed concepts for EV battery disassembly and describe the selected approach, with elements of partial solutions validated in a laboratory setting, including the selection of commercial solutions, the development of custom end effectors, and methodologies for detection, localization, and classification of fasteners. The computer vision tasks employed an overhead 2D camera to detect the type of battery pack and approximate localization of fasteners, and a 3D camera mounted on the robotic arm for precise localization (position and tilt) and classification.

View Accepted Manuscript (DOE)

Research Organization:: Rochester Inst. of Technology, Rochester, NY (United States); Sustainable Manufacturing Innovation Alliance Corp., West Henrietta, NY (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0007897

OSTI ID:: 3025753

Journal Information:: Journal of Advanced Manufacturing and Processing, Journal Name: Journal of Advanced Manufacturing and Processing Journal Issue: 3 Vol. 7; ISSN 2637-403X

Publisher:: American Institute of Chemical Engineers (AIChE), WileyCopyright Statement

Country of Publication:: United States

Language:: English

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