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Recirculate Discharge System Gives Old Electric Vehicle Batteries a New Lease on Life

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  • Using artificial intelligence, machine learning, and a KUKA KR10 industrial robot, the EU-funded Recirculate project has developed a new system that sorts electric vehicle batteries for recycling.

    Recirculate, an EU-funded project, has been working for the past 18 months to recycle electric vehicle (EV) batteries using smarter methods. The most challenging step is the physical disassembly process to separate the battery into its modules and then into individual cells. To accelerate this process and reduce costs, the Recirculate team utilized a KUKA KR10 industrial robot along with advanced machine learning (ML) and artificial intelligence algorithms.

    The project aims to create a sustainable and circular economy by more efficiently disassembling EV batteries. The robotic system can quickly and safely separate battery modules.

    With the widespread adoption of electric vehicles, the question of what to do with aging batteries is becoming a pressing issue. The best solution is recycling rather than landfilling. However, battery materials are expensive and can raise ethical concerns. Furthermore, if not disposed of properly, they can release toxic chemicals into the environment.

    Recycling EV batteries is difficult; disassembly can be time-consuming and costly. For this reason, in many cases, old batteries are sent to landfills.

    Recirculate's robotic cell can safely disassemble EV battery packs with specially designed tools and accelerate material separation. This innovative solution contributes to sustainable and environmentally friendly battery recycling.

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    EV Battery Disassembly Made Easier with KUKA KR10 Robots

    Recirculate uses a KUKA KR10 industrial robot specifically designed to disassemble EV battery packs. The robot is equipped with specialized tools such as screwdrivers and vacuum grippers.

    Battery disassembly is one of the most time-consuming and labor-intensive stages. Each battery pack contains hundreds of screws, cable connections, and components. These parts must be carefully removed. Batteries are first opened, then separated into modules, and finally into individual cells.

    To facilitate this process, Recirculate developed a robotic cell. This system uses a KUKA KR10 robot with screwdrivers and vacuum grippers. Each of the robot's tools has a depth camera to determine dimensions and position. This allows the robot to perform precise tasks in x, y, and z coordinates.

    Recirculate Robotic Cell

    With machine learning models, Recirculate maps battery parts for robotic disassembly.

    With the use of machine learning and artificial intelligence, the battery disassembly process becomes faster and more reliable. Traditional methods were time-consuming due to complex screw arrangements and different battery manufacturers. Recirculate aims to facilitate battery recycling using this technology.

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    Environmentally Friendly Automation with the Recirculate System

    Recirculate's system, integrated into the robot's tool using artificial intelligence and a depth camera, detects various screw and battery configurations and directs the tools to the correct locations. ML algorithms program the robot by comparing photos with known battery libraries. For new or damaged batteries, the algorithm helps create new libraries. This system was brought to life through 18 months of research and effort.

    Circular Battery Economy

    Electric vehicles promise to reduce pollution and offer other environmental benefits. However, with the growing use of batteries, the disposal of large and potentially toxic batteries will become a problem. Projects like Recirculate are the first steps in preventing this waste. They provide sustainable battery recycling solutions against this increasing danger in the coming years.
     
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