Demonstration/Exploitation event of H2020 CarE-Service Project about circular economy holistic approach for used batteries of electric and hybrid-electric vehicles

1. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851

2. Please mute your microphone and open it only to ask questions in
the dedicated discussion slots at the end of each presentaion and in
the closing session
Use the chat to ask questions and submit comments during the
entire workshop
Raise your virtual hand if you want to ask a question in the
dedicated discussion slots
Presentations will be available for dowload in the CarE-Service
project website (www.careserviceproject.eu)
Connection recommendations

3. CarE-Service Dissemination Events
July 2021
October 2021
13th May (Training)
“Polyamides today:
from polymerization to recycling”
25th May (Training)
“Reforming technologies for re-manufacturing
of sheet metal parts, metals disassembly and
testing in automotive”
May 2021
June 2021
4th June (Demonstration)
"Innovative community platform for the reuse,
remanufacturing and recycling of metals,
techno-polymers and batteries in automotive”
29th June (Demonstration)
“Automotive Polyamide Circularity?
Yes, it’s feasible”
5th July (Training)
"Mobile Solutions and Flexible lines for vehicles
battery dismantling”
21st July (Demonstration)
“New solutions for disassembly, remanufacturing
and testing automotive metal parts”
September 2021
20th September (Training)
“Battery Circular Economy approaches for
redesign, reuse and regulation”:
• Battery re-design: a sustainable
solution for the transition to Circular
Economy
• Second life battery applications:
challenges, solutions and case studies
• New Battery Regulation: implications
for the European battery value-chain”
18th October (Demonstration)
“Circular Economy holistic approach for
used batteries of electric and hybrid-electric
vehicles”
19th October (Demonstration)
“Circular economy-based mobility services”
October 2021
November 2021
25th November
(Final Exploitation Event)
The CarE-Service project will celebrate the
final event with a holistic discussion of
demonstrated results:
“Circular economy in the future automotive
market: new products and services generated
by the CarE- Service project"
(hosted by Fiat Chrysler Automobiles)

4. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851
Demonstration Event
Circular Economy holistic approach for
used batteries of electric and hybrid-
electric vehicles
18th October 2021

5. Demonstration Event – Agenda
- General introduction
- Smart Mobile Module for Dismantling
- Design of the Module
- Demonstrator: real setup and environment of the test
- Demonstrator: real cycle on battery pack dismantling
- Demonstrator outputs
- Second life: introduction
- Second life case study
- Second life real application of recovered batteries
- Conclusions
- Q&A session

6. Project figures
No Name Country
1 CONSIGLIO NAZIONALE DELLE RICERCHE* - Coordinator Italy
2 LINKOPINGS UNIVERSITET Sweden
3 ENVIROBAT ESPANA SL Spain
4 PRODIGENTIA - TECNOLOGIAS DE INFORMACAO SA Portugal
5 AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS Spain
6 CIRCULAR ECONOMY SOLUTIONS GMBH Germany
7 COBAT SERVIZI Italy
8 FIAT CHRYSLER AUTOMOBILES ITALY SPA Italy
9 RADICI NOVACIPS SPA Italy
10 IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK GMBH Germany
11 FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V Germany
12 AVICENNE DEVELOPPEMENT France
13 CIA AUTOMATION AND ROBOTICS SRL Italy
14 E-VAI SRL Italy
15 JRC -JOINT RESEARCH CENTREEUROPEAN COMMISSION Belgium

7. CarE-Service Concept

8. Smart Mobile Modules
Mobile units bringing advanced technology for on-site
disassembly and testing/certification where is the demand
Disassembly Module
• DSS suggesting which
components to disassemble
based on car sensors data,
manufacturer product data and
market
• Disassembly guidelines
• Robotics cooperative
disassembly
• Mechatronics tools
Testing Module
Functional, geometric, mechanical
and electric testing methods and
technologies for:
• Certification of re-usable parts
• Testing of components and parts
for remanufacturing
• estimation of the type and
content of high value-added
materials for recycling

9. CarE-Service ICT Platform
ICT Platform connecting demand and supply
of re-usable parts and allowing the coordination
and optimization of the re-use value chain

10. Partners presentation
Cia Automation And Robotics s.r.l. is an Italian
system integrator that provide customized
robotic solution to the customers.
Robotics is appliable in a wider range of fields and the goal of CIA is to find
easy solutions to complex problems with the application of advanced
technologies.
The strength of CIA is the production of full integrated systems that combine
mechanical desing, electronical develop and custom software realization.
The challenge inside CarE-Service project is to automatize processes that
nowadays are performed manually.

11. Partners presentation
ENVIROBAT ESPAÑA, S.L. is an SME company
specialized in the recycling of all type of batteries
declassified by the manufacturers.
✓ Strengths:
- Through knowledge of environmental standards and legislations.
- Different types of battery recycling, logistical support and advice on
environmental issues.
✓ Challenges within CarE-Service Project:
- Battery dismantling, testing and classification.
- Demonstration of batteries remanufacturing and 2nd life applications.
- Demonstration of batteries recycling and recovered compounds.

12. CHALLENGE:
EoL
PROCESSES
FOR EV/HEV
ECONOMIC
ASSESMENT
QUICK
INCREASE
OF EV/HEV
VEHICLES
Smart Movable Module for Dismantling: why?
ESTIMATED:
30 million electric cars
by 2030 in the EU
ACHIEVING CIRCULAR ECONOMY FOR EV/HEV VEHICLES
BATTERY PACK:
most valuable component
in EV/HEV vehicles
KEY POINTS:
- Safety
- Technologies
- Equipment

13. Why disassembly EV batteries (PACK to MODULE)?
Main reasons for diassembly
• Safety
• Logistics
• Second life
• Recycling
1st LIFE
Remanufacturing Recycling
2nd LIFE
Disassembly
process
Requirements
• Product analysis
• Disassembly planning

14. Pack To Module example of manual dismantling

15. Why Manual?
Since the volume of EoL batteries is still low and nowadays the manual
disassembly is the most used approach, in the near future it would be fundamental
to have an automated approach able to face capacity issues and overcome
battery variety.
Nowadays, the manual disassembly is the most used solution to separate the
different constituent components of a battery.
In case of automotive applications, this represents a critical step due to the related
safety issues and the need of highly-skilled operators.

16. Processes

17. Solution for battery pack dismantling
Battery dismantling is a complex process but automation can help.
The solution designed during this project can overcome technical problems
but can also be sustainable in this transition period.
Smart Movable Module
(SMM)

18. Smart Movable Module for Dismantling: how?
What is an SMM?
Is a special container fully equipped with all the technologies required
for dismantle a battery pack.
With the SMM is guaranteed the presence of a skilled operator.
Scope of the SMM is bring the missing technologies to all the
dismantler that require the service.

19. Smart Movable Module for dismantling
What is inside an SMM?
The key elements are:
- 6 axis robot
- Turing Table
- 6 different tools
- 3D vision system
- Safety equipment (3D safety scanners, lasers, safety switch)
- Linear axis for battery pack loading
- Side opening to increase volume of work.
- Automatic Toolchange

20. Demonstration Event – SMM Design

21. Demonstrator: Design of module and tools

22. Demonstrator: Design of module and tools

23. Demonstrator: building the SMM

24. Demonstrator: building the SMM

25. Demonstrator: building the SMM

26. Demonstrator: building the SMM

27. Demonstrator: building the SMM

28. Demonstrator: robot

29. Demonstrator: building the SMM

30. Demonstrator: building the SMM

31. Demonstrator: test on 500e Batteries

32. Demonstrator: test on 500e Batteries
Test on Linear axis and turning
Table for loading

33. Demonstrator: test on 500e Batteries
Test on cutting the external cover
on both sides

34. Demonstrator: test on 500e Batteries
3D scanning Test

35. Demonstrator: test on 500e Batteries
Test on cutting the external cover

36. Demonstrator: test on 500e Batteries
Test on cutting the external cover

37. Demonstrator: test on 500e Batteries
Test on uscrewing and unlocking
moduels

38. Demonstrator: test on 500e Batteries
Test on uscrewing and unlocking
moduels

39. Demonstrator: dismantling cycle on 500e Batteries
Removal of modules and
handling

40. Demonstrator: dismantling cycle on 500e Batteries

41. Demonstrator: dismantling cycle on 500e Batteries

42. Demonstrator: dismantling cycle on 500e Batteries

43. Demonstrator: dismantling cycle on 500e Batteries

44. Demonstrator: real dismantling cycles

45. Output and Results of Demonstrator
• Demonstrate that automation is appliable to battery pack dismantling.
• Demonstrate that automation can increase the level of safety
• Demonstrate that module can be extracted from packs even in case of not optimized
processes for assembly
• Increase the number of the battery packs dismantled per day
• Physical output of the SMM are modules that can be re-used for second life
application or recycled if performances are not enough for other applications.

46. Introduction
ENVIROBAT ESPAÑA, S.L. is an SME company
specialized in the recycling of all type of batteries
declassified by the manufacturers.
Role in CarE-Service Project:
- Battery dismantling, testing and
classification.
- Systematization and
automatization of these processes.
- Study and development of
applications using 2nd life batteries.
CarE-service battery value-chain

47. End of Life Battery: POSSIBLE PATHS
EV
BATTERY
Re-use
Repair
Recycling 2nd Life
(Repurpose)
End of first life
(application for which it was
originally manufactured)
Start of 2nd life
(application for which it was not
originally manufactured)
European regulation to address difference:

48. Second life battery – KEY POINTS
2nd LIFE
BATTERY
Dismantling
2nd LIFE
APPLICATION
Application
Requirements
Testing
Remanufacturing
2nd Life

49. Real applications for 2nd Life batteries are classified into 2 main groups
depending on different size, complexity and requirements:
Requirements for Real Applications
FEATURES SMALL SCALE LARGE SCALE
Electrical
properties
Voltage 12, 24, 48 V >48 V
Power 1500W >1500W
Physical
characteristics
Size Relevant Less relevant
Weight Relevant Not relevant
Mobility Possible Not recommended
Safety & Control
BMS Simple Complex
Thermal control Not needed Required
Power Electronics None/Minimum Required
External protection Casing Polymeric, PETG Container, small building

50. Real applications of 2nd Life batteries classification:
1. Small scale batteries:
• Vacuum pump to liquid extraction
• Electric cool box
• Rotor engine for laboratory experiment
• Fishing eco-sonar device
• Ventilator
2. Large scale batteries
• Street lighting, stationary storage system
Examples of Real Applications

51. SMALL SCALE: Vacuum pump for liquid extraction
DEVICE POWERED:
Vacuum extractor pump
ELECTRICAL REQUIREMENTS:
12 V DC, 60 W, 5 A
CELL CHARACTERISTICS:
NMC, prismatic, 49 Ah
BMS: Charge control, Over current (10 A)
BATTERY DESIGN: 3s
APPLICATION:
Refrigerant extraction from discarded EV & HEV batteries before
their dismantling process in ENVIROBAT facilities.

52. SMALL SCALE: Vacuum pump to liquid extraction

53. SMALL SCALE: Electric Cool Box
DEVICE POWERED:
Electric Cool Box E 30 B Trolley
ELECTRICAL REQUIREMENTS:
12 V DC, 48 W, 20 h
CELL CHARACTERISTICS:
NMC, prismatic, 49 Ah
BMS: Charge control, Over current (10A)
ADDITIONAL COMPONENTS:
Universal lighter, 12 V
BATTERY DESIGN: 3s
APPLICATION:
Keep drinks cool in camping, beach, etc.

54. SMALL SCALE: Electric Cool Box
Video recorded after 8 h running….
(the remaining beers were still cool)

55. SMALL SCALE: Rotatory engine for laboratory
experimentation
DEVICE POWERED:
Rotatory engine Walfront 50 rpm
ELECTRICAL REQUIREMENTS:
24V DC, 35 W
24h x 7 days function
CELL CHARACTERISTICS: NMC, prismatic, 49 Ah
BMS: Charge control, Over current (20 A)
BATTERY DESIGN:
7s, speed controller 30 A DC
APPLICATION:
Laboratory experiments in Envirobat.

56. SMALL SCALE: Rotor engine for laboratory experiment

57. SMALL SCALE: Fishing sonar device
DEVICE POWERED:
Lowrance Hook Reveal 7
ELECTRICAL REQUIREMENTS:
12 V DC, 7 A
At least 12 h function
CELL CHARACTERISTICS: NMC, prismatic, 49 Ah
BMS: Charge control, Over current (20 A)
BATTERY DESIGN: 3s
APPLICATION:
Powering fish finder sonar device.
Replacement of Lead-acid battery.

58. SMALL SCALE: Fishing sonar device

59. SMALL SCALE: Ventilator
DEVICE POWERED:
RESPIREM: Simple and low cost
ventilator for COVID-19 and other
diseases
ELECTRICAL REQUIREMENTS:
12 V DC, 5 A
CELL CHARACTERISTICS:
NMC, prismatic, 5 Ah
BMS:
Charge control, Over current (10 A)
APPLICATION:
Electric back-up in case of power supply cut.
Portable power supply in emergencies and field hospitals.

60. SMALL SCALE: Ventilator
Battery charge:
Battery discharge:

61. LARGE SCALE: Street lighting, stationary storage system
DEVICE POWERED:
23x LED street lights
ELECTRICAL REQUIREMENTS:
400 V AC, at least 12h/day during 3 days, 20 A máx.
MODULE CHARACTERISTICS:
NMC, 12s, 9 kg, 33 Ah, prismatic cells
BATTERY DESIGN:
36 modules required (4p108s)
BMS:
1 master, 3 slaves

62. LARGE SCALE: Street lighting, stationary storage system
REFRIGERATION SYSTEM:
Multiple fans controlled by BMS
INVERTER:
SMA battery storage and inverter (6 kW)
PHOTOVOLTAIC PANELS:
21x Amerisolar (330 W)
ADDITIONAL COMPONENTS:
Contactors, fuses, temperature sensors,
module interface and current sensors
APPLICATION:
Street lighting bike line with renewable power source (solar panels)

63. LARGE SCALE: Street lighting, stationary storage system
Cycle path illumination in Los Navalucillos (Toledo) -SPAIN

64. LARGE SCALE: Street lighting, stationary storage system
Cycle path illumination in Los Navalucillos (Toledo) -SPAIN
CONSTRUCTION PLAN

65. LARGE SCALE: Street lighting, stationary storage system
IN-SITU WORK PROGRESS:
Ground prepared
Small building in construction
BEFORE
AFTER
BEFORE AFTER
Small building
design

66. INTERFACE REPLACEMENT
LARGE SCALE: Street lighting, stationary storage
system
BEFORE
AFTER
LABORATORY WORK PROGRESS:

67. BMS Voltage Testing
LARGE SCALE: Street lighting, stationary storage
system

68. Temperature and contactor control testing
LARGE SCALE: Street lighting, stationary storage
system
HEATING
Initial Tª: 21 ºC
Cut-off Tª: 30 ºC

69. Start up current peak testing
LARGE SCALE: Street lighting, stationary storage
system
ON OFF

70. Conclusions
• Market of second life batteries is growing very fast as the market of the
Electric Vehicles. Automation technology applied to the dismantling is
mandatory for increase the volumes and to equalize the quality of the
products.
• Second life applications of batteries have a key role on the circular economy
approach on Hybrid and Electric vehicles since increase the number of
opportunities for re-use the modules or the cells in case of direct re-use is
not possible
• Output for the redesign of packs and modules are provided. Problems found
in the dismantling process can be easily solved with a different architecture
of the pack without a cost increase on the production side.
• Safety is increased without the direct exposition of operators to EoL
batteries.

71. Thanks for your attention!

72. Q&A

73. This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 776851