From Manual to Robotic Disassembly: Adhesive Lid Removal in EV Battery Packs

Abstract

The increasing need for efficient and safe disassembly of electric vehicle (EV) batteries has made robot automation an important focus. This thesis explores solutions of a robotic end-effector for the removal of adhesive-bonded EV battery lids, with the aim of supporting future automated recycling systems. The work is based on interviews with industry professionals, literature, and patent reviews, as well as a structured design evaluation process. Key requirements identified for automation included robustness to battery design variation, safe operation near cells, and acceptable process speed. A possible concept was evaluated: a vertically mounted shoulder mill that uses a semi-destructive approach to cut along adhesive paths without risking cell damage. While no physical testing was performed, the concept was assessed using CAD models and process calculations. For the Tesla Model S lid geometry, an estimated process time of approximately 6 minutes was calculated, with a total cutting force around 560 N at a feed per tooth of 0.08 mm. These results suggest that the tool could offer similar or better performance compared to current manual methods, while also being safer and easier to automate. Future work should include experimental validation using a robotic system, focusing on cutting performance, vibration effects, and toolpath stability.