REBELION has released five technology briefs, each presenting one solution developed within the project. Read in sequence, they follow a battery from dismantling to traceability. Lithium-ion batteries from electric mobility are reaching end-of-life in growing numbers. Many still hold enough capacity for a second use, and all contain critical raw materials worth recovering. Getting there […]
REBELION has released five technology briefs, each presenting one solution developed within the project. Read in sequence, they follow a battery from dismantling to traceability.
Lithium-ion batteries from electric mobility are reaching end-of-life in growing numbers. Many still hold enough capacity for a second use, and all contain critical raw materials worth recovering. Getting there safely and at scale, however, means solving problems at every step: opening batteries that were never designed to be taken apart, judging which cells are still usable, moving damaged modules without risk, and keeping track of each battery’s history.
1. Semi-automatic disassembly and reuse of LEV batteries
1. E-bike, scooter and motorcycle batteries are often replaced while still retaining around 80% of their original capacity, yet most go straight to recycling. REBELION is developing a semi-automatic line that:
- disassembles these compact packs down to cell level;
- assesses each cell’s State of Health in minutes using Electrochemical Noise Analysis;
- reassembles healthy cells into second-life batteries with robotic support;
- deep-discharges exhausted batteries to recover residual energy before recycling.
The line is designed to handle up to 1,200 cells per day, and more than 80% of residual battery energy can potentially be recovered.
Relevant for: LEV operators, recyclers, second-life battery integrators.
→ Download the technology brief: Semi-automatic disassembly and reuse of LEV batteries
2. Robotic disassembly of EV batteries
EV batteries are complex, unstandardised and hazardous, which makes manual dismantling slow and risky at the volumes expected in the coming years. REBELION researchers have advanced autonomous robot skills, including:
- vision- and force-guided motion planning;
- grasping, cutting and unscrewing;
- multi-robot coordination.
They have combined these skills with human-in-the-loop interfaces using VR/XR and haptics. In this AI-assisted teleoperation, operators guide robots remotely while autonomous functions provide guidance and safeguarding. The work, at TRL 3–5, has been demonstrated on a full-scale industrial cell using a Nissan Leaf battery.
Relevant for: recyclers, robotics and automation developers, battery designers.
→ Download the technology brief: Robotic disassembly of EV batteries
3. Capacity estimator for cells and small modules
Capacity is one of the first criteria for deciding whether a cell can be repurposed or should be recycled. REBELION’s modular demonstrator combines two diagnostic methods with data-driven models:
- an EIS test, safe for degraded cells, taking less than 4 minutes;
- an ENA-CI test, usable immediately after operation, taking less than 3 minutes.
Hardware costs start from €700 (EIS) or €1,600 (ENA-CI) per channel, plus one shared mini-PC. The system can work with robotic handling and feed results into digital battery passports.
Relevant for: repurposing companies, testing laboratories, dismantling-line operators.
→ Download the technology brief: Capacity estimator for cells and small modules
4. SAFEBOX: smart transport container for second-life batteries
A single cell in thermal runaway can cause a toxic, explosive fire, and today’s passive steel drums cannot detect warning signs. SAFEBOX is a lightweight, stackable container built on a UN-certified 1200 × 800 mm HDPE pallet. It combines:
- mineral-board insulation between modules;
- temperature and gas sensors;
- active gas extraction;
- an alarm system with GPS and automatic e-call to first responders.
It holds up to 12 modules and triggers an alarm within seconds of a 10 °C abnormal temperature rise or gas detection.
Relevant for: logistics providers, recyclers, battery collection schemes.
→ Download the technology brief: SAFEBOX
5. Digital Battery Passport for second-life batteries
Fragmented data systems make it hard for recyclers, refurbishers and regulators to access the battery information they need. Developed by the ADMEC team at Nottingham Trent University, the REBELION Digital Battery Passport covers the full lifecycle, from manufacture through dismantling and diagnostics to recycling. It offers:
- QR-coded battery records with role-based access via web and mobile;
- blockchain-secured lifecycle data;
- dynamic ecolabels with a PEF-based A–E ranking.
It currently supports four battery types and eight standardised data categories, and is designed to support compliance with the EU Battery Regulation (EU) 2023/1542.
Relevant for: recyclers, testing laboratories, second-life operators, regulators.
→ Download the technology brief: Digital Battery Passport for second-life batteries
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