Automated assembly for e-bike batteries

Challenge

Cobot speeds up bicycle battery refurbishment

Bikebat gives electric bikes a second life by fitting worn-out batteries with new cells and a new battery management system. This is up to 50% cheaper than a new battery and often the only option if original batteries are no longer available. However, refurbishing a battery pack is custom work that is done almost entirely by hand.

Technologies

Automation of cell placement

Together with Flanders Make, a feasibility study was carried out to make the refurbishment process more efficient. The focus was on placing battery cells in a grid: a cobot lifts the grid, takes it to the sorting machine and presses the cells into the correct positions.

Robotics, sensors and actuators

Improving the core components of robotics and smart machines.

Result

More output with the same team

By automating the repetitive cell placement, productivity increases without the need for additional staff. Employees can concentrate on finishing steps such as spot welding, while the cobot takes over the monotonous work. This allows Bikebat to reduce costs and give more electric bikes a new lease of life.