Automation solution from Bosch Rexroth industrializes deep discharging for battery recycling

• Patented process for the reliable deep discharging of electric vehicle batteries
• Core process now 100 times faster
• Modular structure allows quick scaling to higher volumes

Sales of electric vehicles are increasing sharply throughout the world. The recycling of high-performance batteries to recover the valuable chemical components as part of a sustainable circular economy is thus a key issue. At HANNOVER MESSE 2023, Bosch Rexroth will present the first industrial automation solution for the success-critical step of deep discharging. Thanks to the new system, a process that used to take 24 hours now takes less than 15 minutes.

Electrified mobility is gaining ground, with sales of electric vehicles increasing throughout the world. According to market observers such as EV Volumes from Sweden, more than ten million electric vehicles were registered worldwide in 2022 alone. Governments and companies are already planning a sustainable circular economy in order to recover the scarce raw materials for batteries such as lithium or nickel. By recycling the batteries, up to 95 percent of the chemical elements can be fed back into the battery production process. With a complete automation solution for the deep discharging of batteries, Bosch Rexroth offers an introduction to industrial recycling with potential for rapid scaling.

Process now 100 times faster

As part of a process patented by Bosch Rexroth, the automation solution takes over the innovative deep discharging of the high-performance battery cells prior to subsequent process steps. Only fully discharged batteries can be safely shredded and then broken down into their chemical components.

The TS 5 transfer system from Bosch Rexroth transports battery cells of different sizes and types from various manufacturers between the diagnostic discharging and dismantling stations. After contacting, a modular solution from the automation toolkit ctrlX AUTOMATION toolkit with the control platform ctrlX CORE and the drive system ctrlX DRIVE discharges the battery cells in the discharging station. The discharging equipment automates the initial inspection, the patented deep discharging process with chemical inactivation and the final check. Compared to the previous manual discharging process which took 24 hours, the automated process takes less than 15 minutes and is thus 100 times faster than before. At the same time, it offers optimum protection for workers and significantly reduces the fire risk later on.

Flexible and largely maintenance-free: The TS 5 transfer system

The TS 5 transfer system for heavy loads meets all the requirements of recycling lines as a roller conveyor system. A variety of different modules opens up a high degree of freedom for the targeted transfer of battery cells in any layout. Compared to systems with a normal chain drive, the TS 5’s king shaft drive and conveyor rollers allow a virtually maintenance-free production process with low wear. The transfer system fits seamlessly into the ctrlX AUTOMATION control architecture and offers a full range of options for connecting to i4.0 tools, for example to visualize production processes in real time.

Complete solution made up of modular hardware and software

The compact ctrlX CORE, which is based on modern app technology, controls the transfer and the deep discharging process. For the discharging process, the developers at Bosch Rexroth have integrated all functions such as switchover management. Bosch Rexroth also uses apps that are already being used in the final tests at various battery manufacturers. Users can collect all process data via the ctrlX CORE’s ctrlX Data Layer and save these data for quality assurance purposes.

The ctrlX DRIVE takes the energy from the discharging process. Via an integrated AC and DC converter, the energy is fed either into an intermediate circuit, which supplies other loads in the line in an energy-saving manner, or back into the public electricity grid. The discharging station thus reduces the external power requirements of the entire recycling facility and reduces CO2 emissions.

Easily scalable

The combination of TS 5 and ctrlX AUTOMATION offers great flexibility for users. The modular structure of the automation solution allows very economical scaling to higher volumes in the future as well as adaptation to new battery cell types with higher power ratings. Bosch Rexroth relies on open standards for communication and programming throughout. As a result, the solution fits very easily into users’ IT structures.