Dismantling Traction Batteries to a Cellular Level: Pilot Plant by Fraunhofer
In the heart of Germany, a pioneering project is taking shape at the Chemnitz site. The Fraunhofer Institute for Mechanics of Materials in Iron and Steel Technology (IWU) and EDAG Production Solutions are collaborating on an innovative automated disassembly plant for active traction batteries.
Led by Rico Schmerler and his team, this groundbreaking initiative aims to revolutionise the way we handle end-of-life traction batteries. The plant, once completed, will facilitate a largely damage-free disassembly of all components, down to the cell level.
The new infrastructure is designed to be variant-flexible and AI-supported, capable of handling various high-voltage storage systems. It is expected to serve as a data platform for standardising reuse and recycling processes, paving the way for a more efficient circular economy.
After years of use, traction batteries retain a residual capacity between 70 and 80 percent. By repairing and "remanufacturing" these batteries, valuable resources can be conserved, and the lifespan of components extended. Completely intact units could even be used for new traction batteries.
The plant includes an integrated system for analysing the health status of modules and cells. Only reusable components are released for reuse due to this health status analysis system. This approach could reduce the demand for energy-intensive new production, making the process more sustainable.
The automation of the disassembly process ensures economical and safe handling of traction batteries. Repaired and refurbished cells, deemed fit for long-term use in new applications, can provide good service in large storage systems.
By 2030, the amount of end-of-life batteries in the EU is expected to increase more than tenfold. Procedures beyond recycling and shredding batteries will be indispensable by then due to the growing demand for efficient circular economy solutions.
The data collected from the disassembly process will serve as the basis for the further development of qualification profiles for skilled workers in Saxony. Interdisciplinary knowledge from mechanics, electrical engineering, and computer science will continue to gain importance in many job profiles around the automotive industry.
The new plant is expected to contribute to the further development of circular economy solutions in the automotive industry. Moreover, it will facilitate the pure recycling of valuable raw materials such as lithium and cobalt from non-reprocessable cells.
The company working with Fraunhofer IWU on this innovative automated dismantling system for functional traction batteries in Chemnitz is EDAG Production Solutions. The automated pilot plant is currently under development, with a planned completion date yet to be announced. This project underscores the commitment of both organisations to a more sustainable and efficient future for the automotive industry.
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