Unloading technology for high-voltage batteries
Safe, controlled unloading with the MTS from Baumann
Discharge technology is a key process step in the recycling and second-life preparation of high-voltage batteries. Controlled discharge to a maximum of 30% SOC in accordance with UN 3480/UN 3481 is necessary to ensure safe transport of the batteries. Controlled and safe discharge to 0 V is mandatory prior to further processing or dismantling.
With the Modular Test System (MTS) and Modular Contacting System (MCS), Baumann Automation offers a flexible, scalable platform for the automated unloading of HV battery blocks – safe, reproducible and process-integrated.
Controlled discharge before recycling and pre-treatment
In the pre-treatment or end-of-line (EOL) process, battery packs are specifically disconnected from the battery management system (BMS) after diagnosis and safely discharged.
The discharge technology includes, among other things:
Controlled opening of the battery, taking into account the determined condition
Disconnection of the battery blocks from the BMS
Safe discharge of undamaged battery blocks to 0 V
Feedback of stored energy via a sink with mains feedback
Transfer of fully discharged battery blocks to the recycling process
Electrical damages can be diagnosed at any time and controlled in a process-safe manner
Precise electrical contacting is essential for safe and reproducible high-voltage discharge. This is ensured by the Modular Contacting System (MCS), which enables reliable power transmission even at high voltages and currents.
Energy recovery not only ensures safety, but also enables efficient and sustainable use of stored energy.
Advantages of Baumann unloading technology:
- Modular, scalable system
- Flexible adaptation to customer and battery types
- High process reliability and repeatability
- Experience in e-mobility, automation and
Industry 4.0 - Integration into holistic recycling and second-life concepts
Holistic safety concept for HV batteries
Handling used high-voltage batteries requires the highest safety standards. The MTS also takes into account exceptional operating conditions and electrical damag such as thermal runaway.
The integrated safety concept includes:
Sensor-based temperature and status monitoring
Permanent monitoring of critical parameters
Integration of appropriate safety measures
Controlled process management even in safety-critical scenarios
The aim is to achieve maximum personal safety and maximum plant and process safety throughout the entire unloading and processing process.
Unloading technology as part of a modular overall system
Unloading in the MTS is not designed as a stand-alone solution, but as part of a modular overall process for:
Diagnosis
Second life (re-use)
Pre-treatment
End of life (EOL)
Within this modular approach, the Modular Contacting System (MCS) handles safe high-voltage contacting, while the discharge technology ensures controlled energy release in the recycling or second-life process.
Thanks to its modular design, the process can be flexibly adapted to different battery types, designs and safety requirements. A high degree of automation – up to and including robot-assisted dismantling – is possible depending on the application.