Highlights 2025 Electromobility 50 – 51 Dismantling battery packs Modern batteries are not only the powerhouses of electromobility, they also are as a source of raw materials for producing new energy storage systems. At the end of their first life, they can be dismantled, reprocessed, and given a second life. Italian company Comau, supported by Festo technology, has now developed the Flexible Dismantling (Flex-BD) robot cell precisely for this purpose. With the robot-assisted battery disassembly cell, different types of batteries with a low state of charge can be flexibly managed, and safety for operators and equipment in the recycling process is also increased. Excellent processing flexibility The Flex-BD from Comau uses a flexible, repeatable and standardized process to automate all the steps for dismantling used batteries from electric cars. The robot cell was designed with the simplest possible processes in mind. Flex-BD feeds battery packs one by one into the disassembly room, where a heavy-duty industrial robot adapts the handling and machining process to the requirements of the different battery types. In a typical recycling application, for example, the robot unscrews the battery cover, changes the grippers to remove the cover, attaches a suitable screwdriver to loosen the modules and then transports the parts to the storage area using grippers. From there, the separated components can be sent for reprocessing. Easier conversion A key advantage of Flex-BD is its amazing flexibility to process different types of battery packs from different manufacturers. In addition, simple yet innovative solutions reduce implementation and setup costs, as well as cycle times. Festo components are instrumental in ensuring the excellent performance and reliability. They range from electromechanical components to soft start/quick exhaust valves of type MS6-SV, which de-energize critical parts in the event of an emergency stop. Festo solutions also make it easier to modify the system and help to automatically adjust the positioning of the battery packs. The Festo remote I/O system CPX-AP-I ensures a high degree of flexibility and self-learning capability. Precise positioning of different modules The technologies and solutions used by Festo also include the compact and lightweight valve terminal VTUG with fast switching times, low power consumption and high flow rates – ideal for use in robotic applications. Toothed belt axis ELGG and spindle axis EGC have also been integrated, making sure the different-sized modules are precisely positioned and processed. Festo electric motors enable the module grippers to be reconfigured so that parts which have different dimensions as a result of mechanical or thermal deformation, can also be processed during battery disassembly. > www.comau.com > www.festo.com/cpx-ap-i > www.festo.com/ms6-sv The Flex-BD robot cell from Comau dismantles battery packs quickly, safely, and flexibly. Equipped with Festo solutions, it ensures the battery packs are optimally handled and increases the efficiency of the entire process. (Photo: Comau)
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