Post-mortem analysis-based framework for automated disassembly processes of retired electric vehicle lithium-ion batteries

The recycling of retired lithium-ion batteries (LIBs) involves typically pretreatments such as discharging, disassembly, shredding, separation, followed by pyrometallurgical or hydrometallurgical processes to recover active materials. These processes face substantial challenges in efficiently separating materials and achieving high purity levels. This research focuses on conceptualizing a framework for developing automated battery disassembly process chains. Utilizing computed tomography (CT) scans, internal cell structures and joints are identified, contributing to the development of disassembly procedures. Through post-mortem analysis, cells are manually disassembled and the processes are evaluated, facilitating the establishment of the framework for automated disassembly. Key parameters are outlined and potential tools along with methods for further studies are summarized. A disassembly station derived from the framework is established, demonstrating automated disassembly processes with a 13.88 % increase in efficiency compared to the manual approach. This study contributes to advancing automated disassembly processes, enhancing an efficient recycling of LIBs through improved materials separation in pretreatments. • Different commercial cells are dismantled after CT scan for post-mortem analysis. • Various cell structures pose major challenges for automated disassembly. • A framework with potential approaches for process automation is developed. • A prototype disassembly station to explore automated cell disassembly is proposed. • Automated disassembly improves efficiency by 13.88 % compared to the manual process.