»REVAMP: Automated remanufacturing of variant-rich vehicle batteries«

In order for the automotive industry to achieve a successful transition to mobility with clearly discernible environmental benefits, more holistic approaches are required for the future: Only through a sustainable closed-loop economy can e-mobility be put on the road in an environmentally friendly and efficient way, using limited resources and producing as little environmentally problematic waste as possible. New concepts for remanufacturing and the subsequent use of used batteries for other applications at the end of their first life cycle phase must be taken into account right from the production stage.

The "REVAMP" project offers a new approach to recycling used vehicle batteries after their so-called "First Life": The process starts with an automated assessment of the batteries condition. This assessment is used to make autonomous decisions about their use for a "Second Life". Only then do the used batteries undergo a highly flexible disassembly and reassembly process to efficiently prepare them for their second life. In this way, the implementation of sustainable closed loop concepts in the REVAMP project can help to further reduce the ecological footprint of electromobility.

High complexity of the various battery states after the First Life

Automated disassembly and reassembly is essential to keep battery remanufacturing costs low. The wide variety of used batteries, due to different initial variants, First Life applications and production periods, places high demands on the remanufacturing line. In addition, batteries and modules are delivered in different states. To manage this complexity and to process the individual components in an efficient manner, a flexibly networked assembly line is required. Modern algorithms for data processing and artificial intelligence enable autonomous planning and control of production.

The work plan is divided into eleven work packages:

1. Requirements & application examples

2. Battery health assessment and second-use planning

3. Planning disassembly and reassembly

4. Control of freely interlinked remanufacturing systems

5. remanufacturing of battery parts

6. Automated disassembly and reassembly

7. Application-oriented testing of second-use batteries

8. Construction, demonstration, and validation

9. KPI-based life cycle assessment

10. Development of a digital twin (incl. traceability) from raw material to second use

11. Integration of the developed digital twin into the remanufacturing process

The Fraunhofer FFB and its project partners are focusing on the development of a Digital Product and System Twin so that the linked production system for disassembly and reassembly can successfully make the right decisions. Data from battery cell production, usage data from the first life and process data from the ongoing remanufacturing process are collected and processed to create the digital twin. This ensures that all requirements of the Battery Passport according to the EU Battery Regulation, Article 65, are met and that a detailed digital image of the battery is created and maintained throughout all life cycle phases. A concrete example of an autonomous decision by the production system based on the created Digital Twins is the determination of the optimal application scenario for the second life of a battery. The collected data is also used to evaluate the life cycle assessment of the developed remanufacturing concept based on key performance indicators (KPI).

The project is being implemented and tested in cooperation with the eMobility Technical Center at MAN Truck & Bus SE. The goal is to create an autonomous remanufacturing line for batteries that is ready for industrial use.