Development of a semi-automated remanufacturing line to produce rechargeable block batteries from end-of-life bike batteries

Repurposing end-of-life e-mobility batteries for second-life applications is challenging. This paper focuses on the development of a semi-automated remanufacturing line to produce rechargeable block batteries from end-of-life bike batteries. The residual power in these bicycle batteries suits the low power needs of such lamps. The production process should be designed for a sheltered workshop, ensuring clarity, safety, and precision. The complex production process is divided into subassemblies, supported by custom tools to operate in a collaborative production line. For the disassembly process, three stations are developed: a screw-loosening setup, a setup to break open snap-fits, and a setup that pushes the battery module out of the housing. The assembly steps are facilitated by custom-developed molds, tools, and an automated spot-welding process. Notable achievements include the automation of the spot-welding process, a method for adding rivets and electrical safety components, optimized test software, and a user-friendly human-machine interface. The process flow is simulated, analyzed and optimized using FlexSim. The result is a clear, unambiguous, and safe production line that can handle 86% of 50 randomly selected bicycle batteries, saving 48.3% in production time compared to using off the shelf tools. Additionally, the processes run simultaneously, and the installation reduces labour intensity.