• 130 N. West Street Crown Point, Indiana 46307
  • Toll Free:   866 894-7337
    219-644-3231

Hands-on hybrid vehicle battery reconditioning course

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Hybrid vehicle battery repair training

130 N. West Street, Crown Point, Indiana 46307


2017 Short course (1½ days) dates (limited to 6 participants):
May 11/12       Sold out!
May 24/25      Register now!
June 8/9         
Register now!
June 15/16     Register now!
June 22/23     Register now!

 
Call 219-644-3231 for registration help.


Day 1:  8:00 AM – 5:00 PM

Day 2:  8:00 AM – noon PM


Course Fee: $500/person


Click images to enlarge

 "Out of balance" Ford Escape battery pack
Ford Escape “out-of-balance” battery pack

 Ford Escape reconditioned battery pack
Ford Escape reconditioned battery pack

EVc-30 connected to a 28 module Toyota Prius packEVc-30 hybrid vehicle battery reconditioning unit Battery-sorting software module
Battery-sorting software module


This course teaches hybrid electric vehicle (HEV) battery safety and reconditioning. The focus is cylindrical (Honda, Ford Escape) and prismatic (Toyota, Camry, etc.) nickel metal hydride (NiMH) modules.

Course Benefits

  • Experienced instructors provide in-depth knowledge on hybrid battery cycling, reconditioning and safety issues.
  • Real time demonstration of charge-discharge cycling and battery internal resistance measurements.
  • Learn to identify bad modules prior to reconditioning
  • Work the database for inventory maintenance and pack assembly.
  • The dangers of over-charging and over-discharging.

Background

HEV battery packs have 28 to 40 nickel metal hydride (NiMH) modules assembled in series. A module comprises six individual NiMH cells (1.2 V each) assembled in series.  The left image is a 7.2 V prismatic module with individual cell marked 1 – 6. Detailed specifications for these modules are available.  The right image is a pack of 28 prismatic modules with a series voltage of 202 V.   


 

Toyota Prius hybrid electric vehicle module and pack.

Left: Toyota Prius battery module (6 cells). Right Full Toyota Prius 28 module pack.

NiMH modules undergo shallow depth-of-discharge (less than 10%) because they are used for power assist, not electric drive.  Unused electrode material develops a resistive barrier that reduces amp hour (Ah) capacity. This reversible failure mode (“memory effect”)  causes modules to become out-of-balance with neighboring modules, especially those that are near the pack center.  Out-of-balance modules can undergo cell voltage reversal during discharge, which results in permanent damage.  During a charge cycle, excessive oxygen evolution can pressurize and rupture the module casing.  Modules must be balanced by a series of deep charge-discharge cycles: The life of “failed” module can then be recovered and extended. 

Module overheating causes venting of battery electrolyte water.  This irreversible failure mode permanently increases the module internal resistance. High resistant  modules must be removed: They substantially increase reconditioning time. Modules with reversible failure modes must be separated from those with irreversible failure modes before reconditioning.   

About the course

This one and a half day course introduces NiMH batteries at a layman’s level and provides demonstration of split current charge-discharge cycling, internal resistance measurement, and battery pack module balancing. 

Course Fees:  $450/person (6 person maximum)

Registration includes

  • Course work materials
  • Continental breakfast, snacks & coffee breaks.  Lunch on your own in the historic Crown Point district!
  • Use of NuVant electronics for charge-discharge and internal resistance module evaluation

Syllabus

  • Lectures
    • Prismatic battery pack structure
      • cell (1.2 V)
      • module (7.2 V)
      • pack (202 V)
    • Terminology
      • C-rate
      • Recombination
      • Memory effect
      • Charge-discharge protocols
      • Internal resistance
      • Capacity
      • Cut-off voltage
      • Split current cycling

 

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