In context
As Europe accelerates electric vehicle production, the challenge of managing end-of-life batteries became increasingly pressing. By mid-2023, the EU's Flex-BD project, part of the EIT Manufacturing initiative, was addressing this with robotic automation, and Comau was renewing its commitment for a second year, expanding its scope to include second-life repurposing.
What was reported
Comau validated the proof-of-concept for Flex-BD, a robotized system that fully automates the dismantling of worn-out electric batteries. The system uses a high-payload Comau NJ industrial robot that executes paths and changes end-effectors automatically—unscrewing covers, removing them, and transferring modules to storage—all defined through CAD and using LowCode programming for easy cycle redefinition.
In the second year, Comau expanded the project to include second-life repurposing, where batteries are handled while maintaining a low active charge, unlike recycling which fully discharges and destroys them. This automation reduces risks to operators and equipment, and improves efficiency and sustainability compared to manual handling.
Comau estimates that by 2030, Europe could have over 1 million discarded batteries to reuse, driven by predicted production volumes. The company aims to meet growing demand for recycling and repurposing solutions, enabling businesses to reduce waste and optimize raw material reuse.
Why it mattered
Flex-BD represented a significant step toward a circular economy in eMobility, combining automation expertise with sustainability goals. By automating both recycling and second-life repurposing, it addressed worker safety, operational efficiency, and the scalable handling of battery waste—key for the mass adoption of electric vehicles and the development of a robust battery value chain in Europe.
“By expanding our smart automation solution to include second life repurposing of high-power batteries, many of which have a residual capacity of up to 80%, Comau is making a concrete contribution to the realization of truly sustainable mobility.”
Source: Robotics & Automation News (roboticsandautomationnews.com) · Published 2023-07-08 · “Comau developing fully automated system for battery recycling”