A Robotic Teleoperation System with Integrated Augmented Reality and Digital Twin Technologies for Disassembling End-of-Life Batteries

Disassembly is a key step in remanufacturing, especially for end-of-life (EoL) products such as electric vehicle (EV) batteries, which are challenging to dismantle due to uncertainties in their condition and potential risks of fire, fumes, explosions, and electrical shock. To address these challenges, this paper presents a robotic teleoperation system that leverages augmented reality (AR) and digital twin (DT) technologies to enable a human operator to work away from the danger zone. By integrating AR and DTs, the system not only provides a real-time visual representation of the robot’s status but also enables remote control via gesture recognition. A bidirectional communication framework established within the system synchronises the virtual robot with its physical counterpart in an AR environment, which enhances the operator’s understanding of both the robot and task statuses. In the event of anomalies, the operator can interact with the virtual robot through intuitive gestures based on information displayed on the AR interface, thereby improving decision-making efficiency and operational safety. The application of this system is demonstrated through a case study involving the disassembly of a busbar from an EoL EV battery. Furthermore, the performance of the system in terms of task completion time and operator workload was evaluated and compared with that of AR-based control methods without informational cues and ‘smartpad’ controls. The findings indicate that the proposed system reduces operation time and enhances user experience, delivering its broad application potential in complex industrial settings.