The Battereverse project is divided into four phases:
- Phase 1 (M1-M6) Definition of requirements and the base line scenario
- Phase 2.1 (M7-M18) R&D of the core components and first validation
- Phase 2.2 (M19-M30) R&D and integration of the components into functional prototypes
- Phase 3 : (M31-M38) Integration and pilot of the next generation RL process
- Phase 4 (M39-M42): Assessment of the pilot, recommendations, and replication
The current report refers to Period 2, that is phase 2.2. The Battereverse project has reached main achievements that can be projected onto the canvas of the main project’s objectives.
1. Battery Data Space
An industrial‑grade system now tags each battery with a QR code linked to metadata for repurposing, dismantling, and recycling.
Next up (Period 3): plug this into the life‑cycle demo (WP6) and push adoption among stakeholders.
2. DSCHG Safe‑Discharge Tool
Prototype 1 (M19‑M30): Performs controlled discharge of end‑of‑life EV batteries while harvesting residual energy at the module level.
Prototype 2 (planned for Period 3): Will add State‑of‑Health (SoH) and State‑of‑Safety (SoX) diagnostics, delivering a full classification in under 8 hours (vs. today’s up to 48 hours).
Early tests show the hardware can handle multiple battery chemistries.
3. Transport Safety (DENIOS)
Developed and validated two demonstrators: a safe‑transport packaging and the “AmbiGuard®” monitoring system.
Both reached TRL 7 (operational validation). The packaging meets ADR standards for defective Li‑ion batteries, and AmbiGuard® provides real‑time thermal runaway detection during transit.
4. Automated Dismantling (D4.2 / D4.4)
Transitioned from lab‑scale human‑robot collaboration to an industrial‑grade dismantling station.
Robots take on hazardous/repetitive tasks; operators intervene for high‑dexterity steps.
Successfully tested on different battery packs (Nissan Leaf mock‑up, Škoda), showing clear safety and speed gains over manual work.
Integrated vision system (RGB‑depth + thermal cameras + AI) classifies modules into three groups—critically damaged, non‑critical, safe—preparing for the full‑scale opening‑dismantling‑sorting prototype (D4.4).
5. Acoustic Profiling & Remaining Useful Life (RUL)
Lab‑scale acoustic measurement methods are set up. In Period 3 the team will develop algorithms to turn those acoustic signatures into precise RUL estimates for battery modules.
6. Digital Twin & Economic Optimization
A digital twin of the future reverse‑logistics model (TO‑BE) has been built, embedding all the new tech advances.
Upcoming work focuses on final integration of the modules, process validation, and generating recommendations to make the circular battery supply chain economically viable and sustainable.
Bottom line: The project is moving fast from isolated prototypes to an integrated, industrial‑ready solution. Key wins are dramatically cutting assessment time, boosting transport safety, automating dismantling, and laying the groundwork for data‑driven economic optimization via a digital twin. All of this sets the stage for a more efficient, safer, and greener battery‑reuse ecosystem.
