After more than 2,000 charge and discharge cycles – equivalent to around 300,000 kilometres driven and approximately eight to ten years – the batteries in electric cars are hardly cost-effective any longer. The reason: compared with a new system, the reduced charging capacity of the batteries significantly shortens the range. However, a residual capacity of around 80 per cent grants the batteries a second life, for example as part of a battery farm. As the dismantling process becomes increasingly automated, the recycling process becomes more flexible and dynamic, meaning that materials for reuse are also made available more quickly. Festo is driving this development forward with a view to its vision of a sustainable circular economy.

Automated recycling

However, before used vehicle batteries are sent for recycling, they are utilised – once removed from the vehicle – in so-called ‘battery farms’ or stationary storage systems, for example. At the end of a battery’s life, however, proper recycling is ultimately required. The first step is to mechanically dismantle the packs into modules, battery cells and other components – a task that has, until now, been manual, labour-intensive and time-consuming. Festo already offers modular automation concepts that accelerate and simplify this process.

The next step involves separating materials such as metal, plastics and others. However, the focus here is not exclusively on the automation solution. Festo offers suitable process automation products, particularly for hydrometallurgical recycling processes. Various process valves are used for gaseous, solid or liquid substances.

Disassembly systems for modules and packs

Specialised factory facilities are already being planned for these tasks. In this context, Festo has already developed and presented an initial mechanical modular disassembly system for battery modules and packs. This system utilises both handling and gripping systems as well as tried-and-tested components from Festo’s pneumatic and electrical automation portfolio.

Festo also has its sights set on the long-term future of electromobility and is participating in research into manufacturing concepts for innovative solid-state batteries. Experts predict that these even more powerful storage solutions will replace the currently prevalent lithium-ion batteries in the coming years.

Requirements of the new gigafactories for production sites

Large sites, good transport links, low infrastructure costs and a secure and sustainable energy supply are key prerequisites, which are usually found far away from urban centres. A key aspect is having sufficient skilled personnel. The transition to electric mobility is not only creating new factories, but also new tasks, fields of work and job profiles. Employees must be trained and educated for these roles.

Training is essential

Targeted further training programmes are provided by Festo Didactic. Here, employees gain the expertise required for highly automated production. The offering includes, amongst other things, practical ‘hands-on’ training at the plants and the establishment of in-house training facilities, right through to digital learning content that can be accessed via the Festo Learning Experience (Festo LX) at any time and from any location.

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