Manual and Automated Battery Pack Dismantling

Understand safety protocols for handling high-voltage (HV) battery packs during dismantling

HV isolation procedures (lockout/tagout, insulated tools). • PPE requirements (arc-flash suits, face shields, HV gloves). • Thermal runaway mitigation (fire blankets, Class D extinguishers).

Perform manual disassembly of battery packs, including module extraction and cell separation.

Step-by-step disassembly of pack casing, wiring harnesses, and modules. • Cell removal techniques (adhesive release, laser debonding). • Coolant drainage (glycol-based vs. dielectric fluids).

Operate automated dismantling equipment (robotic systems, conveyor lines, sorting machines).

Robotic disassembly lines (e.g., CNC-guided cutters, robotic grippers). • Machine vision systems for component identification. • Sorting algorithms (NMC vs. LFP cells, copper/aluminium separation).

Identify and sort battery components (cells, busbars, cooling systems, BMS) for recycling/repair.

Cell grading (SoH testing, voltage checks). • BMS (Battery Management System) handling (data wiping, reuse evaluation). • Material segregation (black mass, plastics, metals).

Troubleshoot common dismantling challenges (welded joints, coolant leaks, damaged cells).

Welded joint challenges (ultrasonic vs. laser welds). • Coolant contamination (sealed vs. open-loop systems). • Cell damage prevention (crush hazards, short-circuit risks).

Follow environmental and regulatory guidelines for battery waste handling.

EU Battery Regulation (2023) – recycling efficiency targets. • EPA/DOT guidelines (hazardous waste transport, UN38.3 certification). • ISO 14001 (environmental management in recycling facilities).