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Equipment

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EVc-30 and EVc-10 hybrid vehicle battery reconditioning units

EVc-30 hybrid vehicle battery reconditioning unit

Toyota Prius battery pack EVC reconditioning data

EVc-30 data: Toyota Prius battery pack after reconditioning

Includes software, battery pack cooling box, and fully configured laptop computer.

For more information, please click on the following links:

Provide your full information and NuVant will respond within 24 hours.

 

Take the battery reconditioning short course to learn more about using the EVc battery reconditioning units!

For USA Financing: Crest Capital Financing 

Crest Capital finances NuVant products


Equipment for hybrid vehicle battery reconditioning, repair and maintenance 

What is a hybrid battery module?

Modules are nickel metal hydride (NiMH) cells connected in series. NiMH cells have a nominal voltage of 1.2 V. A Ford Escape module has 5 cylindrical NiMH cells in series. A Toyota Prius module has 6 prismatic NiMH cells. The full traction pack battery consists of a pack of modules configured in series. A Ford Escape has two 25-module traction packs. A Prius has a single 28-module pack.

  cells/module module V type modules/pack pack V
Ford Escape 5 6 cylinder 25 150 V
Prius 6 7.2 prismatic 28 202 V
Honda 6 7.2 cylinder 26 187 V

What does “out of balance” mean?

The driving cycle of a hybrid vehicle subjects the battery pack to repeated shallow depths of discharge of less than 10% of battery capacity. The unused capacity undergoes a reversible degradation process that reduces battery capacity. This reversible failure mode (i.e., module-to-module variation of amp-hour (Ah) capacity) causes the battery pack modules to become “out of balance”. This known as the “memory effect”.

What is battery cell balancing?

Reconditioning recovers lost capacity. When reconditioned modules are sorted and positioned for optimum performance in a pack, the system has been balanced. The steps are:
1 Extract the hybrid battery pack from the vehicle
2 Remove the high voltage cable
3 Connect modules in parallel to a charge discharge system
4 Identify and replace high resistance modules (e.g., > 10 mΩ for a 6-cell module)
5 Split-current cycling at deep depths of discharge
Modules sorting based on watt hour capacity
Block positioning of modules into a full pack

What tools are needed for battery reconditioning and pack assembly?

The required tools are (1) a smart menu driven charge discharge cycler,  (2) a database to store amp-hour capacity and midpoint voltage data on every module maintained in inventory, (3) a QR code reader and (4) a 50 inch-pound torque limited nut driver.

Charge/discharge tool:  EVc-30
Includes EVc unit, training and EVc software including an Excel database. EVcharge imports module analysis data from the EVc-30. The database tracks modules and sorts for assembly of battery packs.  Advanced sorting routines filter out bad modules for pack assembly based on end-user set parameters. The database tracks installation of modules to vehicles using VIN number, customer ID or 3rd party shop identity. Inventory is segregated based on module format (e.g., prismatic, cylindrical, etc.).

EVc-30 hybrid vehicle battery reconditioning unit connected in parallel to a 28-module Prius pack

How long does it take to recondition a hybrid battery pack?

High quality cell balancing requires a minimum of 20 hours instrument time. NiMH modules have system parameters specific to the form factor (e.g., prismatic versus cylindrical) and number of cells in series (e.g., Ford Escape: 5; Prius prismatic: 6; etc.). These parameters govern the choice of recipe parameters. Balancing recipes and their automated implementation are covered in the NuVant battery reconditioning course.  The correct business model is development of an inventory of characterized modules for instant replacement of customer packs.

What cell balancing data does the EVc archive as Excel files?

The EVc provides internal resistance, amp-hour, watt-hour capacity and real-world nominal voltages for every module. The software ranks and position modules for pack assembly. The chart below is a real time display of module parameters during the cell balancing process.

 

Critical battery parameters are calculated

Real time display of comparative battery parameters and charge/discharge curves

Example EVc output files for popular traction battery packs are shown below.

Toyota Highlander (click on figures to expand)

EVc-30 provides complete data for every module reconditioned.

EVc-30 data: Toyota Highlander pack before reconditioning.

Note the uniformly low internal resistance of the EVc-30 reconditioned pack.

EVc-30 data: Toyota Highlander pack after reconditioning.

Ford Escape (click on figures to expand)

Before reconditioning there is wide variability in the amp hour capacity in internal resistance.

EVc-30 data: Ford Escape pack before reconditioning

Pack reconditioning removes variability in Ah capacity and internal resistance.

EVc-30 data: Ford Escape pack after reconditioning

Toyota Prius (click on figure to expand)

There is wide variance in Ah capacity and internal resistance prior to reconditioning.

EVc-30 data: Toyota Prius pack before reconditioning

Reconditioning removes Ah and internal resistance variability.

EVc-30 data: Toyota Prius pack after reconditioning

 

The EV database analyzes the above data and suggests modules from your QR coded inventory for assembly of packs.  Addition information concerning the PackBuilder will be provided in the short courses.

How do I learn more about battery repair prior to purchasing an EVc?

The hands-on hybrid electric vehicle battery reconditioning short course allows participants to connect Prius pack modules to an EVc reconditioning unit for cell balancing. During the reconditioning process, the terminology required for understanding cell balancing will be thoroughly explained.  On the second day, results of the overnight process are thoroughly discussed along with data processing.

Testimonials from existing EVc users

 

EVc Specifications

Load
Max Load Voltage  10 V/channel (Customized up to 20V)
Max Load Current 5A per channel
Number of channels  10, 30 or 40 channel systems
Applied Current Accuracy 0.5% of the Applied Current
Applied Current Resolution .3 mA
Potential Measurement
Measured DC Potential Ranges 10 V/channel (Customized up to 20V)
Resolution  .6mV
Accuracy 0.08 or 0.03% of FSR
Current Interrupt Resistance 
Data Acquisition Speed 12.5 kS/s
Serial Resistance Precision 0.5 %
Measurement logging time 1 second

What if I need additional training after an EVc purchase?

New owners of EVc reconditioning equipment receive a complementary 5-hour EZtime ticket. This complementary on-line (TeamViewer) training provides sufficient time for remote reconditioning of your first 2 packs simultaneous with the suggested training agenda.

  • On-line training provided after customer receives purchased EVc unit. Training includes:
    • Unpacking and set-up of EVc unit.
    • Connections to prismatic or cylindrical modules
    • Use of EVc to identify high resistance modules
    • Module reconditioning
    • Database module sort and pack build-up.
  • Additional 5-hour EZtime tickets can be purchased for $175.

Call 219-644-3231 for more details!

EZtime training

EZtime: On-line EVc battery reconditioning training |consulting with NuVant experts.  All EVc purchases (after April 30) include a complementary 5 hour EZtime ticket. EZtime  is purchased on-line.