Presentation of the main ideas and first results of the European Project CarE-Service in the Women Day in Castilla La Mancha University (UCLM). This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 776851.

1. This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 776851
Circular Economy oriented services for re-use and remanufacturing
of hybrid and electric vehicles components through smart and movable modules

2. • Jobplaces and welfare
(12 million jobplaces, 780 billion
turnover, 140 billion value added)
• Citizens’ quality of life
• Environmental sustainability
• Sustains other supply chains
(materials, electronics, machine tools,
automation, …)
• Triggers innovation in other sectors
The paradigm shift in automotive industry
Automotive
industry
one of the most
relevant manufacturing
industries in Europe
By 2040
the 35% of the
newly sold vehicles
will be electric
Paradigm shift
Traditional
fuel cars
Electric &
Hybrid Electric
Vehicles
(E&HEVs)

3. High Total Cost of
Ownership of E&HEVs
€
Current and future challenges
• High initial cost of E&HEVs due to battery and
other high added-value materials and components
• Battery life
• Maintenance cost
Users’ experience • Vehicle performance and autonomy
• Maintenance need
• Recharging stations
• ….
End-Of-Life EU is not currently prepared to efficiently
manage the EOL of E&HEVs:
• No consolidated processes and
technologies for E&HEVs EOL
• No value chains for E&HEVs EOL

4. New high added-value
parts and components
in E&HEVs
Battery system
Techno polymers
Composites
Electronics
…
Circular Economy of E&HEVs:
technological barriers
What to do with them at the
EOL?
How to safely disassemble and
treat for re-use?
• Lack of consolidated processes
and technologies
• Components are not designed to
be re-used

5. Project philosophy

6. Three value chains
q Redesign E&HEVs for circular
economy
q Develop EU leadership in advanced
technologies for re-use of E&HEVs
q Reduce TCO of E&HEVs
q Create new value chains and
businesses in EU around Circular
Economy of E&HEVs

7. Re-use technologies for Li-Ion batteries
Dismantling technology for
disassembly of battery cells
Human-robot cooperation to
separate plastic, wires, electronic
controllers and cell batteries
Testing technology and
algorithms to predict
residual life
Charge/discharge cell behaviour
test, protocols and software for
assessing battery SoH
Compounds recovery
technology
Hydrometallurgy to sustainably
recover Li, Co, Mn, Al, etc. Re-use in other applications
Solar panels, e-bikes, pigments, etc.

8. Cavity for the
housing of the
dovetail guide
Two centering holes
for each side
Dovetail
section Positive pole
Negative pole
Optimized pattern
for the heat transfer
Accessible terminals
for testing procedures
Realization of product prototypes: batteries
• Non-destructive disassemble design:
§ 2 tools: allen key and wrench
§ Time: 2’30’’ approx.
• Modular and reconfigurable structure
• Reversible connections
• Increased safety for the operator
Re-designed LIB Module

9. Engineering of solutions for batteries: recycling
Grinding step
Expected output: metal oxides in the
finest fraction (<300 µm), the current
collector foil in 0.7-2 mm and the
plastic in the coarsest fraction (>2 mm).
Separation step
Black
mass

10. Engineering of solutions for batteries: recycling
Black
mass

11. Re-use technologies for metal parts
New flexible joining
technologies
Disassemble and re-assemble
modules of structural metal parts
as spares or restyled models
elements
Cold reforming of external
non-structural elements
Obtain new parts to use as spares or to
upgrade vehicles aesthetics at sustainable
conditions

12. Realization of product prototypes: metals
Design of the Demonstrator part
brake disk cover
Design of the Laser brazed flange connection
Demonstrator

13. Re-use technologies for techno-polymers
New recycling process
for techno-polymers
• Separation of metal sub-parts
• Grinding of new formulation
compounds
• Extrusion for transformation of
new parts (for automotive and
other sectors such as furniture,
design, etc.)
• Testing of materials properties

14. Realization of product prototypes: techno-polymers
Demonstrator prototype geometry. a) top view; b) bottom view; c) prospective view
a)
b)
c)

15. Engineering of solutions for techno-polymers: re-use and recycling
2 – Cleaning and metal separation
3 – Polymer Selection
Visual
technique
1- Dismantling*

16. 4 – One step grinder 6 – Drying in the stove
9 – Production (Extrusion)
Finished product
7 – Lab analysis of
the raw materials
8 – Formulation tuning
5 – Metal separation
Engineering of solutions for techno-polymers: re-use and recycling

17. Smart Mobile Modules
Mobile units bringing advanced technology for on-site
disassembly and testing/certification where is the demand
Disassembly Module
• DSS suggesting which
components to disassemble
based on car sensors data,
manufacturer product data and
market
• Disassembly guidelines
• Robotics cooperative
disassembly
• Mechatronics tools
Testing Module
Functional, geometric, mechanical
and electric testing methods and
technologies for:
• Certification of re-usable parts
• Testing of components and parts
for remanufacturing
• estimation of the type and
content of high value-added
materials for recycling

18. Smart Mobile Modules: Disassembly Module
AGV with top mounted robot used for
disassembly components from the
car.
The AGV can give more flexibility
adapting the position depending on
the car model or part to disassembly.

19. Smart Mobile Modules: Testing and Certification Module
Parts SMM Testing
SMM Disassembly
Car dismantler
ICT platform
Identification
Requests
Battery
Metal
Technopolymer
Test a)
Test b)
Test a)
Test b)
Test a)
Test b)
Compile
Results
Parts
Validation

20. CarE-Service ICT Platform
ICT Platform connecting demand and supply
of re-usable parts and allowing the coordination
and optimization of the re-use value chain

21. CarE-Service ICT Platform
Main components of the ICT Platform:
§ CarE-Service marketplace for:
ü Batteries
ü Metal parts
ü Techno-polymers
§ Application/data base
dedicated to logistic providers
(linked to CarE-service
marketplace through a web
service) to enable services
selection and quotation for the
transportation of the goods.
§ Sophisticated logistic component
for the booking and the
transportation of the SMMs from
one location to another.

22. The new mobility services
Commuters in a condominium
living in rural areas (with no
free-floating car sharing
offering) working in cities.
Workers of rural corporates or
public administrations that
lives in cities
Use of other car
sharing/pooling, taxi, micro-
sharing and public transport
• have the car during the
night and weekends
• share/pool
URBAN
RURAL

23. Project figures
No Name Country
1 CONSIGLIO NAZIONALE DELLE RICERCHE* - Coordinator Italy
2 LINKOPINGS UNIVERSITET Sweden
3 ENVIROBAT ESPANA SL Spain
4 PRODIGENTIA - TECNOLOGIAS DE INFORMACAO SA Portugal
5 AGENCIA ESTATAL CONSEJO SUPERIOR DEINVESTIGACIONES CIENTIFICAS Spain
6 CIRCULAR ECONOMY SOLUTIONS GMBH Germany
7 COBAT SERVIZI Italy
8 FIAT CHRYSLER AUTOMOBILES ITALY SPA Italy
9 RADICI NOVACIPS SPA Italy
10 IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK GMBH Germany
11 FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V Germany
12 AVICENNE DEVELOPPEMENT France
13 CIA AUTOMATION AND ROBOTICS SRL Italy
14 E-VAI SRL Italy
15 JRC -JOINT RESEARCH CENTREEUROPEAN COMMISSION Belgium