Use case: Intelligent disassembly in the research project ZirkulEA
Together with renowned partners, we are shaping the “ Recyclability of the electric powertrain through intelligent disassembly and tracking” in the ZirkulEA research project. The aim is to recover valuable raw materials, components or entire assemblies from electric vehicle batteries and powertrains and reuse them in high-quality products.
To this end, we are developing modular dismantling systems in exemplary use cases and establishing a cross-company exchange of information that addresses technical and economic challenges along the entire value chain.
The challenges of disassembly
The disassembly of high-voltage batteries and powertrains involves several complex requirements:
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Diverse screw connections: different screw types, materials and conditions require flexible tools and adapters.
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Safety requirements: High-voltage protection, insulation and safe handling are essential to minimize electrical as well as mechanical risks.
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Cycle time optimization: Disassembly processes required in series production must be as fast as assembly processes in order to be economical.
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Data quality and traceability: High-resolution monitoring of torque, angle and other process data is essential for evaluating reusability.
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Automation complexity: The integration of gripper systems, vacuum suction and changing devices in a robot cell places special demands on software and control
Our solution: superior automation of the unscrewing process
For the use case in the ZirkulEA project, we developed a tailor-made process module for intelligent and cycle time-optimized disassembly. The robot-controlled disassembly unit combines our many years of expertise in special machine construction and screwdriving technology.
1. High-voltage-capable screwdriving function module (e-SFM)
The modular screwdriving system has been specially adapted for high-voltage applications. Among other things, the following were used
- Non-conductive insulators and resilient ceramic parts
- Light guides for process monitoring
2. Intelligent process data acquisition
The module collects high-resolution process data such as torque, angle of rotation, position of the E-axis and vacuum values of the suction. This data allows conclusions to be drawn about the condition of the screw connection - a decisive factor for evaluating the reusability of individual components.
3.Automatic tool change
Four different socket wrenches are required to disassemble the five connecting elements. These are changed automatically - quickly, precisely and without manual intervention. This saves time, increases system availability and allows for a wide range of parts.
4. Vacuum suction and conveying technology
After loosening the screws, the fasteners are automatically sucked in, safely picked up and discharged in a controlled manner via a closed discharge device. This protects against loss, ensures cleanliness and supports sorted collection - an important contribution to the circular economy.
5. Seamless integration into traceability systems
All process steps can be fully documented and traced. Structured data acquisition enables a well-founded assessment of the condition and reusability of components and creates the basis for a cross-company exchange of information.
Overview of DEPRAG components used
Our disassembly solution in the ZirkulEA research project impressively demonstrates how versatile and efficient our technologies can also be used outside of classic assembly tasks. Based on proven DEPRAG components, we have developed a highly flexible robot cell for intelligent unscrewing. A whole range of screwdriving and automation modules were used - some of which were specially modified to meet the requirements of the high-voltage sector.
The result: an automated, safe and traceable disassembly solution - with maximum quality, flexibility and data transparency. The interaction of mechanics, sensors and software enables safe and cycle time-optimized unscrewing - with high relevance for the industrial circular economy.
| Component | Function & special features |
|---|---|
| E-axis | Moves the screwdriver precisely in the screwdriving function module and generates the necessary contact pressure. Force-controlled sequence for controlled unscrewing. |
| E-SFM | The heart of the system - has been specially adapted to screwdriving processes in the high-voltage range using special insulators and ceramic components. Fiber optics are used for process monitoring. |
| Tool Changer | The tool station - automatic changeover between four different socket wrenches. The exchange is fully automatic, precise and without loss of cycle time - ideal for complex and varied disassembly tasks. |
| Vacuum suction | Secure pick-up of loosened fasteners directly after unscrewing. Enables the fasteners to be removed even from the tightest screw positions. |
| Conveyor module | A special mouthpiece for the controlled and fast removal of the loosened screws via a discharge device. Enables sorted collection and return to the material cycle. |
| Traceability Interface | Sensor technology for process data acquisition - real-time acquisition of high-resolution data such as torque curves, rotation angle, E-axis position and vacuum values. Basis for traceability, condition assessment and reuse. |
| Sequence controller AST12 | Controls and monitors all screwdriving parameters including drive control. |
What we have learned with ZirkulEA
Our automation expertise in screw fastening also proves its worth when unscrewing the most demanding assemblies - regardless of whether they are high-voltage batteries or complex drivetrains. Thanks to modular interfaces and automatic tool changes, the system adapts flexibly to different fasteners and grows effortlessly with your requirements. Real-time monitoring and traceability ensure consistently high process reliability: deviations are detected and evaluated immediately so that we always have the quality and traceability of the components under control.
By drastically reducing manual intervention and optimizing cycle times, the system pays for itself quickly, while operating costs are noticeably reduced. At the same time, we actively promote the circular economy with intelligently controlled dismantling - for sustainable resource management and a strong green energy profile.
A strong partner: screwing and unscrewing from a single source
With our special machine solution for automated unscrewing in the ZirkulEA project, we impressively demonstrate that DEPRAG can do far more than just screw fastening: we solve complex automation tasks along the entire value chain and pave the way for Industry 5.0 and a sustainable circular economy.
Contact us if you would like to fully exploit your recycling and reuse potential - we can also make your dismantling processes efficient, safe and future-oriented.
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