Robotic Battery Disassembly for High-Voltage Pack Variability
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Solution Overview
Problem
Manual disassembly of secondary batteries is challenging due to the need for specialized knowledge, potential dangers from high voltages and currents, time-consuming safety protocols, and variations in battery types, making it inefficient and risky for human technicians.
Innovation Solution
An automated battery disassembly system (ABDS) using robotic agents with sensors and tools, following disassembly instructions to perform tasks on batteries, including tool selection, motion trajectories, and disassembly operations, with adaptive capabilities to handle different battery types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual disassembly is performed by trained technicians, then disassembly can be completed with human dexterity and judgment, but technicians are exposed to high voltages and currents creating safety hazards
Solution Approach 1:
The patent replaces manual mechanical disassembly operations with an automated robotic system equipped with specialized tools. The robotic agent performs all disassembly tasks without human technicians needing to physically handle the battery, thereby eliminating exposure to electrical hazards while maintaining disassembly capability through automated control systems
Solution Approach 2:
The robotic agent serves as an intermediary between the operator and the hazardous battery. The system allows remote or automated operation where the robotic agent physically interacts with the battery while humans remain isolated from harmful electrical fields, using the robot as a mediator that handles all direct contact with dangerous components
2Reliability
If batteries are discharged before disassembly to ensure safety, then technician safety is improved, but state of health analysis requires charged batteries and this process becomes time-consuming
Solution Approach 1:
The system performs preliminary safety preparations by implementing automated safety protocols and protective measures before disassembly begins. The robotic system can work with charged batteries using automated safety interventions rather than requiring time-consuming charge/discharge cycles, as the robot can safely handle charged components through programmed safety procedures
Solution Approach 2:
The automated robotic system replaces manual safety procedures with automated safety management. The robot can operate on charged batteries under controlled conditions with automated monitoring and protection systems, eliminating the need for time-consuming discharge cycles that were necessary when human technicians performed manual disassembly
3Productivity
If destructive disassembly methods are used to access glued or welded battery portions, then disassembly completeness is improved, but the task becomes more dangerous to human technicians
Solution Approach 1:
The patent employs automated robotic tools equipped with specialized end-effectors for destructive disassembly operations. The robotic system can apply controlled force, heat, or other energy forms to break adhesive bonds or welds without human technicians being present during these hazardous operations, maintaining disassembly completeness while eliminating human exposure to risks
Solution Approach 2:
The robotic agent acts as an intermediary that performs destructive operations on behalf of the operator. The robot handles all potentially dangerous destructive disassembly tasks involving adhesives, welds, or structural bonds, allowing complete disassembly while keeping human technicians isolated from harmful effects through automated execution
4Reliability
If human technicians wear protective gear for safety, then protection from hazards is improved, but dexterity and performance of delicate tasks become more challenging
Solution Approach 1:
The patent replaces human manual operations with automated robotic manipulation. The robotic system inherently provides protection while maintaining full dexterity through precision actuators and specialized end-effectors, eliminating the need for protective gear that would compromise human dexterity. The robot performs delicate tasks with precision without any protective equipment interfering with operation
Data Source
AI summary
Batteries can be disassembled using robotics. One or more robotic agents can use the output of a suite of sensors to identify a battery type, and follow a set of disassembly instructions to disassemble a battery. The set of disassembly battery instructions can include a series of tasks primitives, where each task primitive is a selection of a tool, a motion trajectory for the tool and a disassembly task performable on a battery feature. In some embodiments, the disassembly instructions and/or the task primitives can be constructed from observing the output of sensors attached to the tools operated by a human technician and/or the human technician body. During the disassembly, the prestored task primitives can be modified to better fit the conditions of the battery.