Robotics Review
Appliance Manufacturer Uses Robots and AI to Disassemble Products
Panasonic is using AI technology to tackle sustainability challenges.
Every year, millions of household appliances are replaced and discarded. As old products pile up, it’s creating a big problem in landfill.
To address the issue, manufacturers are developing sustainability programs that focus on recycling and reuse. The goal is to create a circular economy that features closed-loop programs where disassembly lines are strategically positioned near final assembly lines.
One of the companies leading the way is Panasonic Corp. That’s because the firm known for batteries and consumer electronics also produces a variety of home appliances, including air conditioners, dishwashers, microwave ovens, refrigerators, toasters and washing machines.
Engineers at Panasonic’s R&D facility in Osaka, Japan, recently developed an automated disassembly process that uses robots to precisely separate metals, plastics and other materials. It’s part of the company’s Green Impact initiative.
“The circular economy is the transition from a make-use-dispose model to systems that maximize customer value while minimizing virgin resource use,” says Andrea Murphy, director of environmental affairs and sustainability at Panasonic North America.
According to Murphy, disassembly is increasingly important for manufacturers due to several factors, such as:
- Regulatory pressure. “Global regulatory pressure is increasing and there are market advantages to being an early adopter that can help lead thoughtful and actionable regulation,” explains Murphy.
- Risk avoidance. “The availability and cost of critical materials is on the rise,” notes Murphy. “We want to ensure that we will have materials for our businesses. Recovering critical materials, such as copper, cobalt, nickel and rare earths metals, reduces risk and reduces exposure to price volatility and supply shocks.”
- Customer convenience. “Consumer convenience is core,” claims Murphy. “We can save money and we can help secure a sustainable future for society. But, these will not be successful if our efforts do not provide that extra value to the customer.”
Robots are used to remove and install heat pumps used in washing machines. Photo courtesy Panasonic Corp.
Optimizing Disassembly
Panasonic’s disassembly CPS (cyber-physical system) simulates and optimizes processes using 3D CAD tools. The resulting data influences both new product design and automation efforts, contributing to efficient part reuse and remanufacturing.
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“Precise disassembly enables high-purity separation of materials, allowing the production of high-quality recycled materials and advancing the recycling process,” says Murphy. “By incorporating design principles that enhance maintainability, [we are able] to achieve longer product lifespans and resource recovery.
“A disassembly CPS is a cross-industry technology solution that integrates advanced technologies such as generative AI, IoT and sensors to digitally reconstruct physical environments, thus enabling visualization, standardization and optimization,” Murphy points out.
“These insights are then used to create new value, including improved efficiency, productivity and quality,” adds Murphy. “Built on [our] manufacturing expertise, we can apply this to many areas to enable fundamental, root-cause-driven problem solving, such as autonomous disassembly.”
Murphy defines autonomous disassembly as “robotic or hybrid human‑robot workcells that identify parts, choose tools and execute safe removal sequences without preprogramming for a single, fixed product state. They can adapt in real time with artificial intelligence and machine vision technology.”
Panasonic’s circular economy strategy involves design for disassembly and design for repair and maintenance.
“We strive to improve our design in providing easier access to components that require maintenance or replacement, with features such as improved tool access and the use of mechanical fasteners instead of adhesives,” says Murphy. “[We are also] leveraging simulation and AI-driven optimization to further evolve the design for robotic disassembly.
“By using AI to run extensive trial-and-error simulations, we can identify the most effective design configurations for both assembly and disassembly,” notes Murphy. “With some of our home appliances, for example, we are looking at redesigning them to enable robots to carefully dismantle them in a way that allows valuable components to be harvested for recycling or possibly re-use.”
Panasonic engineers are using six-axis robots to disassemble air conditioners, microwave ovens and washing machines. Photo courtesy Panasonic Corp.
Design for repair or maintenance incorporates designs that can extend a product’s lifecycle and simplify part swaps.
“After analyzing repair data and current designs, we have developed circular friendly improvements,” explains Murphy. “A great example are the heat pumps used in washing machines.”
Panasonic pioneered the use of heat pump technology for drying efficiency. By moving the device from the bottom to the top of their machines, engineers made this key component more easily accessible for repair.
The heat pump can now be easily cleaned and maintained to provide a longer life time for the entire washing machine. The design change also resulted in a 50 percent reduction in the amount of time it takes to repair a machine.
Role of Robots
Panasonic engineers are programming six-axis robots to disassemble air conditioners, microwave ovens and washing machines. Magnetic grippers lift the cover off appliances, while screwdrivers remove fasteners. End effectors equipped with other types of tools cut wires and carefully remove components.
“Robots are pivotal to automating disassembly, especially at scale,” says Murphy. “On the human side, using robots for repeated high-impact tasks help prevent injuries.
“Additionally, robots distance people from electrical, thermal and chemical risks during battery and capacitor removal,” adds Murphy. “By using AI, the robots are able to self-train and adapt. They can run different scenarios for dismantling or find better ways to design appliances for disassembly.”
Artificial intelligence technology determines the optimal way to take a product apart without damaging any sensitive components. Controls provide feedback so that parts can be easily removed, reused or repaired. They also provide the robots with precise positioning control to replicate manual work.
A dismantling database stores data on each model. The data is used to improve equipment utilization rates and lay the foundation for automating the process further.
“The automatic dismantling equipment use machine vision technology to capture images,” says Murphy. “By using AI, the cameras accurately detect screws even with dirt or rust on the units. Then, it positions a robotic arm equipped with a screwdriver to remove the fasteners.”
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