Self-reconfiguration of a robotic workcell for the recycling of electronic waste

Project Information

ReconCycle

Grant agreement ID: 871352

DOI

10.3030/871352

Project closed

EC signature date 11 October 2019

Start date 1 January 2020

End date 31 July 2024

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies - Information and Communication Technologies (ICT)

Total cost

€ 3 853 958,75

EU contribution

€ 3 853 958,75

Coordinated by

INSTITUT JOZEF STEFAN
Slovenia

Periodic Reporting for period 3 - ReconCycle (Self-reconfiguration of a robotic workcell for the recycling of electronic waste)

Reporting period: 2022-10-01 to 2024-07-31

Summary of the context and overall objectives of the project

The ReconCycle project tackles critical issues in the recycling of electronic waste (e-waste), which often involves manual pre-processing to remove hazardous components such as lithium-ion batteries before employing the “crush-and-separate” method. Batteries and other delicate parts present significant safety risks if handled improperly, leading to fire hazards and environmental contamination. Manual disassembly is labor-intensive, costly, and sometimes even outsourced to developing countries. This approach has severe ethical and ecological consequences. The need for automated solutions to safely pre-process e-waste and reduce reliance on hazardous manual labor is therefore both urgent and economically compelling.

The core objective of ReconCycle was to develop a self-reconfigurable robotic workcell with modular hardware and AI-driven software to automate the disassembly of electronic devices. The project followed a two-step strategy: (a) Guided, interactive reconfiguration by engineers when changing between distinct device types, and (b) Autonomous adaptation through AI-based sensorimotor learning when processing different models within a specific device category. By advancing the state of adaptive and reconfigurable robotics, ReconCycle aimed to facilitate safer, efficient removal of dangerous components, such as embedded batteries, preparing the material for subsequent automated crushing and separation.

The project successfully demonstrated a versatile workcell capable of dynamically handling diverse devices, such as heat cost allocators and smoke detectors. Through the integration of innovative hardware components, advanced learning algorithms, and soft fixtures and end-effectors, the project delivered a functional system that can execute complex disassembly tasks with minimal manual intervention, setting a new standard for automated e-waste processing.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The ReconCycle project’s primary focus was to create a fully modular, adaptable robotic system for e-waste disassembly. Central to this was the development of a standardized module that serves as the building block for various specialized components, including robot modules using a torque-controlled manipulator, and a suite of soft grippers and fixtures such as the qb SoftHand 2, Variable Stiffness Gripper (VSG), and SoftClamp. The system also included functional units like cutter modules, CNC milling capabilities, and tool exchange mechanisms. The innovative Plug-and-Produce (PnP) connector allows for reliable, stable integration of different modules, providing mechanical stability, electrical and pneumatic power, and data connectivity. This feature enables rapid and seamless reconfiguration of the disassembly workcell.

The software architecture, based on the Robot Operating System (ROS), was designed to facilitate easy control and reconfiguration of the workcell, even for non-experts. Tools like the FlexBE behavior engine and simulation environments such as Rviz and Gazebo enable efficient programming, testing, and refinement of disassembly tasks. A key focus of the project was on the development of advanced tactile manipulation capabilities, using a unified force-impedance control strategy. This approach dynamically adjusts manipulation forces based on real-time sensory feedback. This way precise and safe handling of both fragile and rigid components during disassembly can be ensured.

Advanced AI techniques, including computer vision and neural networks, played a crucial role in guiding the robotic system. Object recognition, pose estimation, and scene analysis were enhanced by integrating the latest vision-language models (VLMs), which provide context-aware action prediction. This allows the system to interpret complex and varied structures of electronic devices, improving its ability to adapt dynamically to different disassembly tasks. The use of soft robotics, with sensorized end-effectors and adaptable tool exchange systems, expands the functional range of the workcell, enabling tasks like removing snap-fit parts without special components.

The developed workcell underwent extensive testing against predefined Key Performance Indicators (KPIs), demonstrating significant improvements in adaptability, efficiency, and safety. The project was able to meet most of its targets, proving the robustness and readiness of the system for industrial applications.

The consortium also made extensive dissemination efforts, with the project partners publishing numerous scientific papers, presenting at industrial fairs, and engaging with the broader research community through open-source software releases and collaborative events. Business and commercialization efforts identified several promising results, including the market potential of soft robotics solutions and modular PnP connectors, laying the groundwork for future industrial applications.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The ReconCycle project has made substantial progress beyond the current state of the art in robotic disassembly and electronic waste recycling by developing a fully modular, reconfigurable workcell equipped with advanced AI-driven software and adaptive soft end-effectors. These innovations enable the safe removal of batteries embedded in electronic devices, thus preventing fire hazards and mitigating environmental risks associated with improper handling. This way recycling facilities can optimize subsequent crushing and separation processes without the dangers posed by embedded batteries.

ReconCycle has significantly advanced the field of adaptive and reconfigurable robotics by developing a recycling workcell that dynamically adapts to various electronic devices, greatly enhancing the versatility and efficiency of automated disassembly processes. Key technical innovations include advanced sensorimotor learning techniques, AI-driven software, and the integration of vision-language models for precise contextual action prediction. The use of unified force-impedance control strategies allows the system to perform adaptive manipulation tasks even in complex scenarios. The incorporation of novel soft robotics cpmponents alongside a suite of modular hardware components, enables the workcell to handle diverse and delicate components with precision. These enhancements have led to a highly adaptable robotic system capable of partially autonomous disassembly across different device models and conditions, which reduces the need for manual intervention while significantly improving the efficiency and safety of the disassembly process.

ReconCycle’s socio-economic impact is substantial, as the project addresses the pressing challenges in e-waste management and contributes to a safer, more sustainable recycling approach. The automation of hazardous disassembly tasks, particularly the extraction of lithium-ion batteries, reduces the dependence on manual labor in unsafe conditions. By improving the safety and efficiency of pre-processing, the project increases material recovery rates. This makes e-waste recycling more economically viable and reduces the volume of waste sent to landfills. These innovations support the transition to a circular economy, aligning with EU sustainability goals by promoting resource conservation and minimizing environmental pollution. Through these advancements, ReconCycle not only benefits the recycling industry but also drives a societal shift towards responsible electronic waste disposal and sustainable resource utilization.

ReconCycle modular, reconfigurable robotic cell