Search Results (29)

The remanufacturing of end-of-life products is an effective approach to alleviating resource shortages, environmental pollution, and global warming. As the initial step in the remanufacturing process, the quality and efficiency of disassembly have a decisive impact on the entire workflow. However, the complexity of product structures poses numerous challenges to practical disassembly operations. These challenges include not only conventional precedence constraints among disassembly tasks but also sequential dependencies, where interference between tasks due to their execution order can prolong operation times and complicate the formulation of disassembly plans. Additionally, the inherent uncertainties in the disassembly process further affect the practical applicability of disassembly plans. Therefore, developing reliable disassembly plans must fully consider both sequential dependencies and uncertainties. To this end, this paper employs a chance-constrained programming model to characterise uncertain information and constructs a multi-objective sequence-dependent disassembly line balancing (MO-SDDLB) problem model under uncertain environments. The model aims to minimise the hazard index, workstation time variance, and energy consumption, achieving a multi-dimensional optimisation of the disassembly process. To efficiently solve this problem, this paper designs an innovative multi-objective adaptive large neighbourhood search (MO-ALNS) algorithm. The algorithm integrates three destruction and repair operators, combined with simulated annealing, roulette wheel selection, and local search strategies, significantly enhancing solution efficiency and quality. Practical disassembly experiments on a lithium-ion battery validate the effectiveness of the proposed model and algorithm. Moreover, the proposed MO-ALNS demonstrated a superior performance compared to other state-of-the-art methods. On average, against the best competitor results, MO-ALNS improved the number of Pareto solutions (NPS) by approximately 21%, reduced the inverted generational distance (IGD) by about 21%, and increased the hypervolume (HV) by nearly 8%. Furthermore, MO-ALNS exhibited a superior stability, providing a practical and feasible solution for disassembly optimisation. Full article

Problem: Remanufacturers want to increase consumer interest in refurbished products, which motivates the need to understand which product features are important to buyers of refurbished products such as mobile phones. Research Questions: This study addresses two questions. First, which product features are most important for buyers of refurbished iPhones? Second, how do those preferences differ from the preferences of buyers of new iPhones? Methods: Online reviews of iPhones are obtained and converted into a document–term matrix. Using this text model, three subsets of features are identified using statistical analysis of frequency of mention: most frequent, average, and least frequent. A logistic regression (LR) model is then used to identify which features are most predictive of whether a review is for a new or refurbished phone. Results: Buyers of refurbished phones mention battery health, screen/display, shell condition, and brand significantly more often than other features. Directly contrasting reviews of refurbished versus new phones shows that shell condition, brand, speaker, and charger are found to be the most predictive product features indicated in reviews for refurbished phones. Of those, the shell condition is significantly more predictive than the others. Implications: The results identify product features that remanufacturers of iPhones can emphasize to increase customer demand. Full article

The predicted rapid accumulation of end-of-life lithium-ion batteries (LIBs) from electric vehicles (EVs) has raised environmental concerns due to the toxic nature of LIB materials. Consequently, researchers have developed reusing and recycling plans for end-of-life LIBs to extend their life spans, mitigate residual capacity loss, and reduce their environmental impact. As a result, many studies have recommended establishing a lifecycle framework for LIBs to identify and manage the potential options for reusing, recycling, remanufacturing, or disposal of second life LIBs. In response, the state of health (SOH) and state of safety (SOS) methods were introduced as key performance indicators (KPIs) to determine the batteries’ health and usability based on their capacity levels. Thus, both SOH and SOS methods are crucial for battery cell selection frameworks employed to designate batteries’ second-life applications. Various papers have analyzed and compared SOH methods, yet none have clearly quantified their differences, to determine the most effective method. Therefore, this study aims to create a framework for selecting the most effective SOH method for use in LIB frameworks by identifying and quantifying their main KPIs. The proposed framework will utilize scientometric analysis to identify the KPIs necessary for a gray relation analysis (GRA)-based multi-criteria decision matrix (MCDM) to select the appropriate SOH method. Full article

Lithium-ion batteries are major drivers to decarbonize road traffic and electric power systems. With the rising number of electric vehicles comes an increasing number of lithium-ion batteries reaching their end of use. After their usage, several strategies, e.g., reuse, repurposing, remanufacturing, or material recycling can be applied. In this context, remanufacturing is the favored end-of-use strategy to enable a new use cycle of lithium-ion batteries and their components. The process of remanufacturing itself is the restoration of a used product to at least its original performance by disassembling, cleaning, sorting, reconditioning, and reassembling. Thereby, disassembly as the first step is a decisive process step, as it creates the foundation for all further steps in the process chain and significantly determines the economic feasibility of the remanufacturing process. The aim of the disassembly depth is the replacement of individual cells to replace the smallest possible deficient unit and not, as is currently the case, the entire battery module or even the entire battery system. Consequently, disassembly sequences are derived from a priority matrix, a disassembly graph is generated, and the obstacles to non-destructive cell replacement are analyzed for two lithium-ion traction battery systems, to analyze the distinctions between battery electric vehicle (BEV) and plug-in hybrid electric vehicle (PHEV) battery systems and identify the necessary tools and fundamental procedures required for the effective management of battery systems within the circular economy. Full article

Remanufacturing, which benefits the environment and saves resources, is attracting increasing attention. Disassembly is arguably the most critical step in the remanufacturing of end-of-life (EoL) products. Human–robot collaborative disassembly as a flexible semi-automated approach can increase productivity and relieve people of tedious, laborious, and sometimes hazardous jobs. Task allocation in human–robot collaborative disassembly involves methodically assigning disassembly tasks to human operators or robots. However, the schemes for task allocation in recent studies have not been sufficiently refined and the issue of component placement after disassembly has not been fully addressed in recent studies. This paper presents a method of task allocation and sequence planning for human–robot collaborative disassembly of EoL products. The adopted criteria for human–robot disassembly task allocation are introduced. The disassembly of each component includes dismantling and placing. The performance of a disassembly plan is evaluated according to the time, cost, and utility value. A discrete Bees Algorithm using genetic operators is employed to optimise the generated human–robot collaborative disassembly solutions. The proposed task allocation and sequence planning method is validated in two case studies involving an electric motor and a power battery from an EoL vehicle. The results demonstrate the feasibility of the proposed method for planning and optimising human–robot collaborative disassembly solutions. Full article

Disassembly is a key step in remanufacturing, especially for end-of-life (EoL) products such as electric vehicle (EV) batteries, which are challenging to dismantle due to uncertainties in their condition and potential risks of fire, fumes, explosions, and electrical shock. To address these challenges, this paper presents a robotic teleoperation system that leverages augmented reality (AR) and digital twin (DT) technologies to enable a human operator to work away from the danger zone. By integrating AR and DTs, the system not only provides a real-time visual representation of the robot’s status but also enables remote control via gesture recognition. A bidirectional communication framework established within the system synchronises the virtual robot with its physical counterpart in an AR environment, which enhances the operator’s understanding of both the robot and task statuses. In the event of anomalies, the operator can interact with the virtual robot through intuitive gestures based on information displayed on the AR interface, thereby improving decision-making efficiency and operational safety. The application of this system is demonstrated through a case study involving the disassembly of a busbar from an EoL EV battery. Furthermore, the performance of the system in terms of task completion time and operator workload was evaluated and compared with that of AR-based control methods without informational cues and ‘smartpad’ controls. The findings indicate that the proposed system reduces operation time and enhances user experience, delivering its broad application potential in complex industrial settings. Full article

In this age of global advancement in technology, environmental sustainability has become increasingly important. Electric vehicles (EVs) have gained popularity due to their lower carbon impact. One of the most important components of an electric vehicle (EV) is its lithium-ion battery. Increased use of lithium-ion battery (LIB) packs has produced a possible concern in the form of excess LIBs unless adequate recycling or remanufacturing procedures are followed. To repurpose previously used LIBs in an eco-friendly and efficient way, it is essential to implement appropriate reverse logistics procedures. This field of research holds significant potential for the future of the automotive sector. In this study, we briefly reviewed spent LIB management, recycling procedures, demographic locations, remanufacturing concerns, transportation costs, deterioration, and regulations in North America. A brief review of the reverse logistics for lithium-ion batteries improves comprehension and paves the way for future research considerations in this evolving field. Full article

Given the increasing momentum globally towards sustainable transportation, the remanufacturing of used electric vehicle lithium-ion batteries (EV LIBs) emerges as a critical opportunity to promote the principles of the circular economy. Existing research highlights the significance of remanufacturing in resource conservation and waste reduction. Nevertheless, detailed insights into South Africa’s (SA’s) specific capabilities and strategic approaches in the context of used EV LIBs remain sparse. By utilizing in-depth interviews with fifteen key industry stakeholders and drawing on institutional theory, this qualitative study evaluates SA’s infrastructure, technical expertise, and regulatory frameworks in the EV LIB remanufacturing sector to address this gap. The findings reveal proactive strategies, including technical expertise, sustainable infrastructure, and robust regulatory frameworks aligned with global standards. This study proposes strategic initiatives like the Interdisciplinary Innovation Hub and Mobile Remanufacturing Labs, which are analytically derived from stakeholder insights and aim to predict potential pathways for workforce development, especially in rural areas. Innovative training programs, including the Virtual Reality Consortium, Circular Economy Institutes, and the Real-world Challenges Program, will ensure a skilled workforce committed to sustainability and circular economy principles. The conclusions highlight SA’s potential to become a leader in EV LIB remanufacturing by integrating circular economy principles, enhancing technical expertise, and fostering international collaboration. Full article

The disassembly of spent lithium batteries is a prerequisite for efficient product recycling, the first link in remanufacturing, and its operational form has gradually changed from traditional manual disassembly to robot-assisted human–robot cooperative disassembly. Robots exhibit robust load-bearing capacity and perform stable repetitive tasks, while humans possess subjective experiences and tacit knowledge. It makes the disassembly activity more adaptable and ergonomic. However, existing human–robot collaborative disassembly studies have neglected to account for time-varying human conditions, such as safety, cognitive behavior, workload, and human pose shifts. Firstly, in order to overcome the limitations of existing research, we propose a model for balancing human–robot collaborative disassembly lines that take into consideration the load factor related to human involvement. This entails the development of a multi-objective mathematical model aimed at minimizing both the cycle time of the disassembly line and its associated costs while also aiming to reduce the integrated smoothing exponent. Secondly, we propose a modified multi-objective fruit fly optimization algorithm. The proposed algorithm combines chaos theory and the global cooperation mechanism to improve the performance of the algorithm. We add Gaussian mutation and crowding distance to efficiently solve the discrete optimization problem. Finally, we demonstrate the effectiveness and sensitivity of the improved multi-objective fruit fly optimization algorithm by solving and analyzing an example of Mercedes battery pack disassembly. Full article

Efficient processing of end-of-life lithium-ion batteries in electric vehicles is an important and pressing challenge in a circular economy. Regardless of whether the processing strategy is recycling, repurposing, or remanufacturing, the first processing step will usually involve disassembly. As battery disassembly is a dangerous task, efforts have been made to robotise it. In this paper, a robotic disassembly platform using four industrial robots is proposed to automate the non-destructive disassembly of a plug-in hybrid electric vehicle battery pack into modules. This work was conducted as a case study to demonstrate the concept of the autonomous disassembly of an electric vehicle battery pack. A two-step object localisation method based on visual information is used to overcome positional uncertainties from different sources and is validated by experiments. Also, the unscrewing system is highlighted, and its functions, such as handling untightened fasteners, loosening jammed screws, and changing the nutrunner adapters with square drives, are detailed. Furthermore, the time required for each operation is compared with that taken by human operators. Finally, the limitations of the platform are reported, and future research directions are suggested. Full article

The recent announcement by the European Union of the Fit for 55 Package and a prospective ban on the sale of new internal combustion engine vehicles by 2035 has prompted a notable surge in the electric vehicle (EV) market. The shift toward EVs concurrently presents challenges, namely the resource management of used EV batteries, particularly their reuse, recycling, and remanufacturing. Accordingly, this study aims to analyze the effects of the reduced environmental impacts of a remanufactured portable power station (RPPS) compared with those of a new portable power station (NPPS) using life cycle assessment (LCA) and the economic benefits gained from reusing used EV batteries. The results of the LCA of the RPPS indicated a notable environmental advantage, with reductions of 42.01% in GWP and 41.91% in ADP compared with those achieved by the NPPS. Moreover, the economic benefits of the waste battery remanufacturing business amounted to USD 593,212 at an annual sales volume of 1000 units. The environmental benefits of remanufacturing practices represent valuable support for policies centered on remanufacturing and reusing used EV batteries. The findings of this study could stimulate a future market for products repurposed from used EV batteries, thereby further fostering sustainability in this sector. Full article

Consumers typically exhibit loyalty unless swayed by decisions rooted in rational choice theory, encompassing preferences, information, costs, and gains. Convincing newness-oriented consumers to shift beliefs and embrace ‘like new’ products, especially those drawn to novelty, is difficult. While consumer orientation might seem tied to purchase intention, this study delves into the potential of disruptive information to encourage consumers to revise their perceptions of remanufactured products that may have previously escaped their consideration. Doing so aims to enhance consumers’ openness to embracing a circular economy. The research was conducted with a sample size of 1200 Japanese consumers. Remanufactured batteries were used as an illustrative example. The findings suggest that educating consumers through infographics could increase the acceptance of remanufactured batteries. We observed that when infographic information and consumer orientation work together, they produce a synergy effect, resulting in more impact than expected if they were considered separately. This approach could influence purchasing decisions and promote sustainability by emphasizing the economic and environmental benefits. Full article

As the market share of electric vehicles continues to rise, the number of battery systems that are retired after their service life in the vehicle will also increase. This large growth in battery returns will also have a noticeable impact on processes such as battery disassembly. The purpose of this paper is, therefore, to examine the challenges of the battery disassembly process in relation to the required increase in the degree of automation. For this purpose, a survey of various experts along the battery value chain was conducted, and product-side hurdles, such as the wide range of variants, and process-side challenges, such as the opening of the housing cover or the removal of cables and connectors, were identified. Together with an assessment of the potential degree of automation in the context of downstream processes (reuse, repair, remanufacturing, and recycling), this results in a variety of streams for future research in the field of automated battery disassembly. The core aspect in this context is data availability consisting of product and component data as well as process-relevant parameters. Full article

Life cycle strategies for traction batteries, such as remanufacturing, reuse, and recycling of retired automotive lithium-ion batteries (LIBs), have received growing attention, as large volumes of LIBs will retire in the near future and the demand for LIBs continues to grow. At the same time, the relevance of the sustainability of a battery system over its entire life cycle is increasing as factors such as the EU Battery Regulation provide greater market and product transparency. As a result, research and industry require forecasts in order to assess the future market situation and to make well-founded decisions. Therefore, this paper provides forecasts of the return volumes of battery systems from BEVs and PHEVs up to 2035. Additionally, a representative European battery pack for PHEVs and BEVs was evaluated for each year since 2013, based on the ten vehicles with the largest market share in each year until 2021. In addition, the battery return streams are divided into three different 3R strategies based on expert interviews in order to evaluate the upcoming workload in these areas. The term “3R” refers to the sum of the currently existing pathways around reuse, remanufacturing, and recycling. In 2030, about 38.8 GWh will return and enter the recycling process annually. For battery reuse, about 13 GWh will return every year from 2030 onwards, ready to be used in stationary storage for energy transition. Compared to this, battery remanufacturing is expected to be supplied with a slightly lower volume of approximately 11 GWh per year. Full article

A rapid growth in electric vehicles has led to a massive number of retired batteries in the transportation sector after 8–10 years of use. However, retired batteries retain over 60% of their original capacity and can be employed in less demanding electric vehicles or stationary energy storage systems. As a result, the management of end-of-life electric vehicles has received increased attention globally over the last decade due to their environmental and economic benefits. This work presents knowledge and technology for retired electric vehicle batteries that are applicable to the Thai context, with a particular focus on a case study of a retired lithium-ion battery from the Nissan X-Trail Hybrid car. The disassembled battery modules are designed for remanufacturing in small electric vehicles and repurposing in energy storage systems. The retired batteries were tested in a laboratory under high C-rate conditions (10C, 20C, and 30C) to examine the limitations of the batteries’ ability to deliver high current to electric vehicles during the driving operation. In addition, the electric motorcycle conversion has also been studied by converting the gasoline engine to an electric battery system. Finally, the prototypes were tested both in the laboratory and in real-world use. The findings of this study will serve as a guideline for the sorting and assessment of retired lithium-ion batteries from electric vehicles, as well as demonstrate the technical feasibility of reusing retired batteries in Thailand. Full article