Work

Risk Assessment of Retired Lithium-Ion Battery Packs: FMEA and Pugh Matrix Integration

Year: 2025

Type: article

Abstract: The widespread use of lithium-ion batteries across various applications, from automotive to heavy vehicles and energy storage systems, has made assessing the structural condition of these components a complex challenge. The harsh operating environments and diverse usage patterns during their first life turn these batteries into a "black box," making it difficult to evaluate their integrity and safety, especially when considering their potential for circularity. This paper seeks to identify potential failures in retired lithium-ion battery at different levels (i.e. pack, module and cell) and assessing their impact and severity. First, adaptive Failure Modes and Effects Analysis (FMEA) is applied to evaluate battery system failures. Furthermore, the Pugh Matrix is used to compare and select the appropriate non-destructive testing (NDT) methods, considering factors such as cost and time with the severity at different levels. The proposed approach is validated with the industrial partner and the results will contribute to the development of safety protocols, ensure efficient disassembly and support decisions related to battery circularity.

Source: Procedia CIRP

DOI: 10.1016/j.procir.2024.12.127

Authors: Niraj Chauhan, Shun Yang, Sebastian Thiede

Institution: University of Twente

Language: English

Topic: Advanced Battery Technologies Research

Subfield: Automotive Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Responsible consumption and production, Industry, innovation and infrastructure

Open Access status: diamond

Funder: European Regional Development Fund