A General Approach to Electrical Vehicle Battery Remanufacturing System Design

One of the major difficulties electrical vehicle (EV) industry facing today is the production and lifetime cost of battery packs. Studies show that using remanufactured batteries can dramatically lower the cost. The major difference between remanufacturing and traditional manufacturing is the supply and demand variabilities and uncertainties differences. The returned core for remanufacturing operations (supply side) can vary considerably in terms of the time of returns and the quality of returned products. On the other hand, because different contracts can be used to regulate suppliers, it is almost always assumed zero uncertainty and variability for traditional manufacturing systems. Similarly, customers demand traditional manufacturers to sell newly produced products in constant high quality. But, remanufacturers usually sell in aftermarket, and the quality of the products demanded can vary depends on the price range, usage, customer segment and many other factors. The key is to match supply and demand side variabilities so the overlapping between them can be maximized. Because of these differences, a new framework is needed for remanufacturing system design. This research aims at developing a new approach to use remanufactured battery packs to fulfill EV warranties and customer aftermarket demands and to match supply and demand side variabilities. First, a market lifetime EV battery return (supply side) forecasting method is develop, and it is validated using Monte Carlo simulation. Second, a discrete event simulation method is developed to estimate EV battery lifetime cost for both customer and manufacturer/remanufacturer. Third, a new remanufacturing business model and a simulation framework are developed so both the quality and quantity aspects of supply and demand can be altered and the lifetime cost for both customer and manufacturer/remanufacturer can be minimized. The business models and methodologies developed in this dissertation provide managerial insights to benefit both the manufacturer/remanufacturer and customers in EV industry. Many findings and methodologies can also be readily used in other remanufacturing settings. The effectiveness of the proposed models is illustrated and validated by case studies.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/143955/1/xrliang_1.pd