Circular Economy for E-Car Batteries Robot Automatically Dismantles Old Battery Cells

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Used batteries often end up directly in the shredder. The Rob@t2cell research project is changing this: in future, robots will discharge and dismantle the cells in a targeted manner. In this way, the researchers are saving intact components for a second life or for recycling.

In order to prevent fires or short circuits, disposal companies usually discharge the batteries completely. However, this rigorous deep discharge process destroys the cells. Even intact components are then no longer suitable for reuse in other devices or vehicles. This is precisely where the Rob@t2cell research project launched in spring 2026 under the leadership of Umicore comes in. The partners involved from industry and science want to discharge battery cells and entire modules automatically and, above all, as required in future.

Depending on what is to happen to the components, the newly developed system adapts the unloading process individually. If a module is about to be finally recycled, the system continues to discharge it completely in order to guarantee safety in the shredder systems. However, if the sensors detect that a cell is suitable for further use, the system only gently reduces the voltage to a defined value. The cells thus remain undamaged and can be processed later for reuse.

Robots Decide on Further Use in Real Time

For this sorting to work on an industrial scale, the system needs early information about the condition of the batteries. The project team is developing a system that automatically contacts the cells, evaluates the performance data and decides on the battery's further path in real time. The mechanical part of this dangerous work is carried out by a specially designed robot cell. The partners are building on the results of the previous Demobat project. The robot safely dismantles the modules until the cell poles are exposed. The system meets high requirements in terms of high-voltage and software technology. Following the current development phase, the materials technology company Umicore is testing the system in an industrial pilot operation.

Modern, firmly bonded battery systems pose a further technical problem for the researchers. The consortium is developing specific mechanical concepts to safely separate these complex assemblies and make the individual cells usable. If the components do end up being recycled, a water-based process is used. This process safely processes even cells that are not deeply discharged and recovers critical raw materials. In this way, the project partners are helping the industry to meet the requirements of the new EU Battery Regulation and make recycling processes suitable for mass production.

Consortium Combines Research And Industry

The Fraunhofer Institute for Manufacturing Engineering and Automation (Fraunhofer IPA) is contributing its experience from the Center for Digitized Battery Cell Production to the project. The Stuttgart-based (Germany) researchers are simulating processes, testing the material and evaluating the remaining service life of the batteries. The Fraunhofer Research Institution for Materials Recycling and Resource Strategies (Fraunhofer IWKS), the Institute for Industrial Production and Factory Operation at the University of Stuttgart and plant manufacturer ACP Systems are also involved. The Borgwarner and Siemens groups are supporting the project as associated partners. The Federal Ministry of Research, Technology and Space is funding Rob@t2cell until the end of 2028. (mc)

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