Partial Automation of Traction Battery Cell Module Handling: Feasibility and Ergonomic Improvements

Abstract

Associated with the high level of market placement of electric vehicles comes the challenge of the disposal of end-of-life (EoL) lithium-ion traction batteries (LITB). Recycling LITB is a multi-step process including the disassembly into cell modules (CM) and subsequent handling for further processing. Disassembly, currently conducted manually, poses an ergonomic strain and hazard potential for workers but is crucial to enhancing the ecology of downstream recycling processes by enabling selectivity. Based on requirements for the use-case handling during disassembly (process-related) and 13 design features of CM (product-related), a suitable lifting and handling system (LHS) was selected from six gripping options. An analysis of 50 CM models representing 90% of the Austrian market yielded an applicability of 75% for a pivot arm featuring lifting pins and electrically powered lifting capability. Both scenarios, manual handling and handling supported by the LHS were simulated in ema Work Designer and evaluated using the Ergonomic Assessment Worksheet (EAWS) method. The ergonomic assessment yielded an improvement from red to green in the EAWS scale for the simulated use-case featuring three different CM weights. The considerable ergonomic improvements call for further efforts to enhance partial or full automation to foster LITB disassembly for selective recycling.