New battery pack dismantling system from Bosch Rexroth

Battery packs on recycling line (Photo: Bosch Rexroth)

Bosch Rexroth has unveiled its new TS 5 transfer system for battery recycling at Hannover Messe 2023.

The fully-automated system can analyse, transport and dismantle battery packs in preparation for recycling and reclamation of critical minerals and elements, including lithium. Importantly, the system can also ensure that battery packs are fully discharged – and that they do not regain any charge generated by the chemical elements.

“The chemical elements within the battery cells can spontaneously generate small levels of power,” said Sebastian Krieger, senior manager, Assembly Technology, at Bosch Rexroth, who spoke with Diesel Progress International at this year’s Hannover Messe. “The system takes away this possibility, helping to improve the full recycling process.”

A primary issue with battery packs is the sheer number of variations. Packs come from different companies with different exterior and interior designs, a series of fixing types and interior components. Krieger said that the Bosch Rexroth system can identify and log the various pack types before they advance through the dismantling/discharge process. 

Sebastian Krieger (right), senior manager, Assembly Technology (Photo: Bosch Rexroth)

The ctrlX Core and ctrlX Drive from the Bosch Rexroth modular toolkit are used to discharge the battery packs at a dedicated station. CrtlX Core controls the energy transfer and deep discharging, while ctrlX Drive takes that energy via an AC/DC converter and feeds it into either an intermediate circuit or back to the grid. The deep discharging process is followed by a chemical process which ensures full deactivation.

Compared to the previous manual discharge process, which takes about 24 hours, the automated process can be completed in less than 15 minutes. The deactivation further reduces any chance of a battery fire.

The TS5 transfer system is said to meet all requirements for recycling lines and roller conveyor systems. Instead of a chain drive, the system features a low-wear king shaft drive, helping to reduce related roller maintenance. Options from the i4.0 range of tools includes the capability to view the dismantling process in real time.

The battery dismantling system from Bosch Rexroth is intended to help address an increasing mountain of end-of-life battery packs coming from passenger cars and electrified machines.

Automated battery pack recycling process takes human element out of the equation (Photo: Bosch Rexroth)

“The system will speed up delivery of recycled raw materials for production of new packs,” said Krieger. “Having raw materials and reclaimed parts from used packs should also help pack manufacturers achieve the reused content targets put in place by the European government.”