Electromobility is growing – and with it the demand for efficient solutions for the recycling and reprocessing of high-voltage batteries. Liebherr-Verzahntechnik GmbH has developed an industrial-grade system for the automated dismantling of high-voltage batteries with LHDismantle. At IFAT, the world's leading trade fair for water, wastewater, waste, and raw materials management in Munich, the company will present solutions from the automated unscrewing process to modular and scalable turnkey systems for dismantling and discharging from May 4 to 7, 2026.
OEMs and recycling companies face a common challenge: Regardless of whether battery components are being prepared for second use or sent for recycling, dismantling high-voltage batteries from electric vehicles is the first necessary process step. However, their manual dismantling is time-consuming, costly, and associated with safety risks. At the same time, return volumes are continuously increasing, while qualified personnel for handling high-voltage components is scarce.
There is also another reason why early, intelligent, and automated dismantling is a central building block for a functioning battery circular economy: After shredding, recovering valuable materials such as copper, nickel, cobalt, manganese, and lithium is usually only possible through elaborate metallurgical processes. Leading recycling companies are therefore increasingly relying on precise dismantling processes to achieve high recovery rates and material qualities. This is exactly where LHDismantle comes in.
From Research to Industrial Application
Based on the results of the research project 'ZIRKEL,' funded by the BMBF, which investigated the circular economy of battery systems in the electromobility sector in an interdisciplinary consortium, Liebherr-Verzahntechnik GmbH has developed an innovative dismantling cell for industrial application with LHDismantle. The system automates the non-destructive loosening of numerous screw connections – a safety-critical process that has so far been predominantly manual. The deactivation of the battery management system (BMS) is only possible after the battery housing has been opened, creating safety risks due to exposed high-voltage contacts. LHDismantle automates this process step, reduces the exposure of personnel to high-voltage hazards, and lays the foundation for safe, reproducible further processing.
Technical Challenges
Automating battery dismantling is challenging: Different battery types require high flexibility, as geometries, screw types, and positions vary widely. Contaminations, corrosion, and damage complicate the reliable detection of screws, which particularly challenges camera-based systems. Additionally, the high-voltage hazard places the highest demands on occupational safety.
LHDismantle: Automated Unscrewing
At its core, LHDismantle operates with a patented tactile unscrewing method with automatic position correction. This makes the system insensitive to dirt, corrosion, or damage and ensures the highest process safety. At the same time, the system achieves high productivity. An automatic tool change allows for the processing of different screw types without manual intervention. The removed screws are reliably transported via a swivel unit or an optional suction module.
Operation is via an intuitive user interface with a graphical live status of the entire unscrewing process. Battery types and unscrewing programs are selected directly from an integrated database; new component types can be quickly adapted, both programmatically and tool-wise. With a digital twin, Liebherr-Verzahntechnik GmbH can already digitize new battery variants in advance and simulate and validate the dismantling process before the corresponding programs are made available to system users. 'When a previously unknown battery pack is to be processed, we create a virtual twin of the battery pack using reverse engineering. From this, we derive the tools and the appropriate unscrewing program,' explains Viktor Bayrhof, product manager for automation systems. This shortens lead times and reduces risks when processing new battery variants.
Turnkey Solutions: Integration into the Process Chain
Beyond unscrewing technology, Liebherr-Verzahntechnik GmbH offers a comprehensive portfolio for handling, transporting, and storing high-voltage batteries. The LHDismantle cell can be seamlessly integrated into modular automation systems and forms a central building block within a continuous process chain. Pallet handling systems (PHS) connect automation cells, machines, and manual workstations. Additionally, discharging technology and manual workstations for downstream steps are used. Components from third-party providers, such as machining centers for milling or laser cutting processes, can also be flexibly integrated. 'We always think of the system as a whole and seamlessly integrate external process steps as needed,' says Viktor Bayrhof. This creates a holistic, scalable solution for the safe and efficient processing of high-voltage batteries.
Win-win: Practical Test Under Real Conditions
The dismantling cell can be viewed at the Kempten Tech Center of Liebherr-Verzahntechnik GmbH. The company is currently preparing for the deployment of the system with a test customer. The concept is based on mutual benefit: Recycling companies gain access to industrial automation technology and can test it under real conditions. Liebherr-Verzahntechnik GmbH, in turn, gains valuable insights from practical application and can continuously develop the system. 'Especially for companies that have had little contact with automation so far, our solution offers a risk-free entry into automated dismantling,' explains Viktor Bayrhof.
Positioning in the Growing Market
With LHDismantle, Liebherr-Verzahntechnik GmbH addresses the increasing demand for industrially scalable solutions for battery dismantling. In combination with the corresponding turnkey systems, a comprehensive overall concept is created that can flexibly adapt to increasing quantities and supports an efficient circular economy in electromobility.
Contact:
www.liebherr.com
