It takes an electrician with additional high-voltage certification several hours to completely remove an electric car battery. “Time that a recycling company simply doesn’t have, given the shortage of skilled workers and the millions of used batteries expected in the coming years,” emphasizes Viktor Bayrhof, product manager at Liebherr-Verzahntechnik in Kempten.
That is why Liebherr has developed a robotic disassembly system that can even handle the often chaotic mix of screws, whether Torx or hex. The "LHDismantle" automated screw-removal system is equipped with an automated tool changer and removes the screws using a pick-and-place gripper or a vacuum system.
“Plant operators don’t even need to have any knowledge of robotics or automation, because operating the system requires no programming or teaching skills,” explains Daniel Reischmann from the Technical Sales team for Automation and E-Mobility at Liebherr. The company can integrate the robotic cell into a system designed to completely disassemble the components of a battery pack.
The CMAD servo-pneumatic position controller enables robot grippers to apply a given force with an accuracy of 0.2 mm in both horizontal and vertical orientations. Thanks to its built-in spatial position detection, the CMAD position controller can maintain a constant force even when the position in space changes. Liebherr also takes advantage of this feature in the LHDismantle, as the bolts on a vehicle battery are mounted not only vertically but also horizontally. Looking ahead, this solution will also enable the automation of other bolting processes, such as those involved in the complete disassembly of a vehicle.
Pneumatic drives are particularly popular for use in robots and front-end applications. Thanks to their light weight combined with high power density, they are ideally suited for these end-of-arm applications. What has limited the use of pneumatic drives up to now is the fact that they could only be operated in open-loop mode. The CMAD, with its piezo valves, is now capable of controlling even small pneumatic cylinders.
This gives it the same control characteristics as an electrical system – but with a much lighter weight. The piezo valves can be operated in both position control and force control modes. The CMAD flow controller is complemented by the VEAB proportional pressure control valve, which offers precise control at low flow rates, the flexible VTUX valve manifold, and a wide range of pneumatic cylinders.
“The development of the CMAD position controller came at just the right time, allowing us to do away with the vision system we had been using – which wasn’t always reliable – as we continued to develop the system,” explained Jan Pollmann, Head of Development at Liebherr. “The experts at the Festo Experience Center (FEC) in Esslingen were a great help to us in this regard; they enabled us to thoroughly test the planned solution.”
Seamless automation
By combining pneumatic and electrical automation, we offer the broadest portfolio of hardware, software, and AI to meet any industrial motion requirement. Our open system architecture guarantees that individual components will interact in systems from Festo and third-party providers. Our Digital Experience provides support from design and operation to maintenance, throughout the entire length of the project. We complement our technology with a comprehensive learning offering that supports you every step of the way.
That’s the best fit in automation. That’s Seamless Automation from Festo.
With the use of Liebherr’s LHDismantle automated system, battery recycling companies are well prepared for the future, as the need for action is urgent: By 2030 the volume of used batteries from electric vehicles in the EU is expected to increase more than tenfold. This makes it possible to recover valuable raw materials such as lithium, cobalt, and nickel, and thanks to automation, electric vehicle manufacturers are able to meet the recycling targets set by the EU at an acceptable cost.