Fraunhofer Institute for Production Technology IPTResearch project "ModuRep"
Non-repairable batteries are not sustainable
Individual cells in most battery modules today cannot be replaced because manufacturers bond or weld the cells together, making removal difficult. This design increases safety risks and forces users to replace entire modules. As a result, costs, the amount of electronic waste, and resource consumption rise significantly. At the same time, the European Union is tightening its requirements to make products not only easier to repair but also more sustainable, durable and environmentally friendly.
Replace instead of throwing away
In the ModuRep research project, scientists are developing new battery modules that enable defective cells to be replaced safely and efficiently. The reduced need for new modules lowers energy consumption and cuts the carbon footprint by up to 87 percent, which extends the modules’ service life, increases resource efficiency, and significantly improves their environmental performance. With this approach, ModuRep combines technical innovations with the principles of the circular economy, thereby addressing both ecological and economic challenges.
Integrated “Design for Repair” approach
The project team is developing a comprehensive design concept that is consistently geared toward high reparability from the very beginning. The participants are relying on optimized connection techniques that facilitate repairs. To this end, they are defining mechanical and electrical interfaces that allow skilled workers to easily and safely disassemble individual cells.
In addition, the project partners are integrating balancing methods such as ETA leveling (Efficiency Through Accuracy), which take into account the individual efficiency of each cell. This technology uses software to control charging and discharging processes so precisely that all cells age uniformly and no harmful imbalances arise. This intelligent control improves the modules’ efficiency and significantly extends their service life.
Development of prototypes and tools
The scientists are developing a prototype on which they can test the design principles they have developed in practice. In addition, they are designing specialized tools and concepts that allow technicians to safely remove individual cells. These solutions take all relevant safety requirements into account and enable controlled, low-risk disassembly.
Analysis and requirements for repairable battery modules
Fraunhofer IPT is analyzing existing modules, assessing repair limits, and defining requirements for safety, standards, and repairability. Based on this, it is developing various ideas for repair-friendly designs, as well as tools and processes for cell replacement. In addition, Fraunhofer IPT is conducting a comprehensive techno-economic-ecological assessment and prepares the results for industry and the public.
Key to the circular economy
Replacing individual cells instead of entire modules can significantly lower CO₂ emissions, material consumption, and hazardous waste. At the same time, life-cycle costs for manufacturers, operators, and end customers are significantly reduced. Repairable modules enable new business models, such as refurbishment services, and improve the acceptance of sustainable energy systems.
Project Consortium
- Albert Seine GmbH, Dülmen
- BHFM Technologies GmbH, Willich
- EJOT SE & Co. KG, Bad Berlebrug
- Fraunhofer-Institut für Produktionstechnologie IPT, Aachen
- PEM Motion, Aachen
Project coordination: Fraunhofer Institute for Production Technology IPT
Funding
The ModuRep research project is funded by the European Union and the state of North Rhine-Westphalia as part of the ERDF/JTF program GreenEconomy.IN.NRW.
Funding code: 20801734
Project sponsor: PTJ Projektträger Jülich