Fraunhofer Institute for Production Technology IPTResearch project "REVAMP"
In order for the automotive industry to achieve a successful transition to mobility with clearly discernible environmental benefits, more holistic approaches are required for the future: Only through a sustainable closed-loop economy can e-mobility be put on the road in an environmentally friendly and efficient way, using limited resources and producing as little environmentally problematic waste as possible. New concepts for remanufacturing and the subsequent use of used batteries for other applications at the end of their first life cycle phase must be taken into account right from the production stage.
The "REVAMP" project offers a new approach to recycling used vehicle batteries after their so-called "First Life": The process starts with an automated assessment of the batteries condition. This assessment is used to make autonomous decisions about their use for a "Second Life". Only then do the used batteries undergo a highly flexible disassembly and reassembly process to efficiently prepare them for their second life. In this way, the implementation of sustainable closed loop concepts in the REVAMP project can help to further reduce the ecological footprint of electromobility.
High complexity of the various battery states after the First Life
Automated disassembly and reassembly is essential to keep battery remanufacturing costs low. The wide variety of used batteries, due to different initial variants, First Life applications and production periods, places high demands on the remanufacturing line. In addition, batteries and modules are delivered in different states. To manage this complexity and to process the individual components in an efficient manner, a flexibly networked assembly line is required. Modern algorithms for data processing and artificial intelligence enable autonomous planning and control of production.
Digital Twin for mastering production and decision-making complexity
The Fraunhofer IPT and its project partners are focusing on the development of a Digital Product and System Twin so that the linked production system for disassembly and reassembly can successfully make the right decisions. Data from battery cell production, usage data from the first life and process data from the ongoing remanufacturing process are collected and processed to create the digital twin. This ensures that all requirements of the Battery Passport according to the EU Battery Regulation, Article 65, are met and that a detailed digital image of the battery is created and maintained throughout all life cycle phases. A concrete example of an autonomous decision by the production system based on the created Digital Twins is the determination of the optimal application scenario for the second life of a battery. The collected data is also used to evaluate the life cycle assessment of the developed remanufacturing concept based on key performance indicators (KPI).
The project is being implemented and tested in cooperation with the eMobility Technical Center at MAN Truck & Bus SE. The goal is to create an autonomous remanufacturing line for batteries that is ready for industrial use.
Consortium
Project Coordinator:
MAN Truck & Bus SE, Munich
Project partners:
- Bertrandt Technikum GmbH, Ehningen near Stuttgart
- Software AG, Darmstadt
- IBG Automation GmbH, Neuenrade
- BE-Power GmbH, Fernwald
- Wacker Neuson Produktion GmbH & Co. KG, Reichertshofen
- Weidemann GmbH, Korbach
- MAN Truck & Bus SE, Munich
- Machine Tool Laboratory WZL of RWTH Aachen University
- Institute for Power Electronics and Electrical Drives ISEA of RWTH Aachen University
- Fraunhofer Institute for Production Technology IPT, Aachen
- Fraunhofer Research Fabrication Facility Battery Cell FFB, Münster
Funding source
The project is funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK).
Funding code: 16BZF311A