HEV battery reconditioning equipment and training
Hybrid electric vehicle (HEV) battery reconditioning/refurbishing equipment.
What is an HEV battery module?
Modules are nickel metal hydride (NiMH) battery cells connected in series. An NiMH cell has a nominal voltage of 1.2 V. A Ford Escape has 5 cylindrical NiMH cells per module. A Toyota Prius has 6 prismatic NiMH cells per module. A traction battery pack comprises modules that are configured in series. A Ford Escape has two 25-module traction battery packs. A Prius has a single 28-module pack. Modules must be reconditioned in parallel, not in series. One cannot control individual module voltages when they are connected in series (as in the vehicle).
|cells/module||module V||type||modules/pack||pack V|
|Ford Escape||5||6||cylinder||25||150 V|
What does “out of balance” mean?
Hybrid electric vehicle (HEV) battery modules undergo shallow depth of discharge. Unused electrode material becomes physically separated and unavailable. This reversible failure mode causes module-to-module variation of amp-hour (Ah) capacity. Ah capacity variations are characteristic of “out of balance” battery pack modules.
What is reconditioning (or conditioning)?
Reconditioning is (1) removal of the traction battery pack from the vehicle, (2) removal of the series connection high voltage cable, (3) connecting all the modules in parallel to an EVc reconditioning unit, (4) rapidly identifying and removing high resistance batteries and finally (5) subjecting the remaining pack modules to a series of deep, split-current, cycling.
What tool is used for reconditioning?
The EVc-10, EVc-30 and EVc-40 are fully automated battery cyclers that are used to recondition or repair modules that have undergone reversible failure modes such as the acquisition of memory effects due to repetitive shallow depths of discharge. Reconditioning is also known as battery refurbishing, or conditioning.
How long does it take to recondition an HEV pack?
An EVc-40 can recondition 120 modules in 2 days with a labor requirement of 5 person-hours.
What data output does the EVc provide?
The EVc gives internal resistance, amp-hour and watt-hour capacity for every module. This enables the ranking of modules for pack rebuilding. Output files are exemplified below:
Toyota Highlander (click on figures to expand)
Ford Escape (click on figures to expand)
Toyota Prius (click on figure to expand)
Battery-sorting software module
How do I learn more prior to an EVc purchase?
Hands-on hybrid electric vehicle battery reconditioning short course enables hands-on participation in a reconditioning demonstration. After the purchase of an EVc unit, NuVant provides a deep training that will be all you need to start you business.
For EVc specifications and prices click here.
|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|
|Measured DC Potential Ranges||10 V/channel (Customized up to 20V)|
|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|
How do I get complete training after an EVc purchase?
EVc training in Crown Point, Indiana or on-line with TeamViewer: $1000/person
- 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.
- In-house training is one-on-one with NuVant experts.
Start with a low-cost EVc-05 or EVc-10. Trade up to the EVc-30 or -40 as you gain experience and confidence.
Call 219-644-3231 for more details