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Hybrid battery repair equipment

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Hybrid and electric vehicle battery reconditioning and cell balancing tools

EVc-30 battery reconditioning tool connected in parallel to a 28-module Prius pack. One connection does the job.

Consumers pay over $3000 for replacement hybrid battery packs when the P0A80 code appears.  Refurbish up to 120 hybrid battery packs a month with an EVc-120. Our hands-on battery reconditioning short course teaches anyone to recondition, balance and replace a prismatic battery module using our EVc battery repair system. The payback period for an EVc system is less than 2 months.

Battery reconditioning and cell balancing is a well understood process developed for NiCad batteries decades ago. NuVant eliminated the electronic complexity, applied it to hybrid vehicle batteries, and now enable you to bring electrochemistry to your shop!  The EVc units are for street shops (push one button after wire-up and the P0A80 code vanishes), for researchers (using high speed GITT and recipe editor) and for high volume shops servicing private and government vehicle and bus fleets.  Transit authority bus fleets managers are cancelling contracts with energy storage system providers because EVc units provides reliable battery storage recovery at a fraction of the cost.  A new Allison ESS bus battery is over $50K.  Our EVc-120 channel will refurbish a 240 module core with less than 12 hours of labor and 1 day of unit processing time.

We ship world-wide! Over 100 EVc battery reconditioners operate in 14 countries / 6 continents!

Niagara Frontier Transit Authority has initiated use of reconditioned modules (240 modules/pack) on their public transport buses. 

The turnkey system includes:

  • software configured laptop computer (USB connection to the EVc unit)
  • battery pack cooling box
  • free software upgrades

EVc info sheetProvide your full information and NuVant will respond within 24 hours.


  EVc-12  EVc-30  EVc-120*  
No. of Channels 12 30 120
Monthly throughput 360 modules
12 Prius packs
900 modules
32 Prius packs
3,600 modules
128 Prius packs
 MSRP: $17,250 $32,500 $123,500
*Toyota dealers and fleet owners call this unit “The Big Boy
Lease with option to buy.  Call for details.
NuVant provides on-site training for your team. Call for details.

Equipment for hybrid vehicle battery reconditioning, repair and balancing 

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. A hybrid vehicle traction pack battery consists 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 the battery capacity. The unused capacity undergoes a correctable degradation process that reduces battery capacity. This failure process (i.e., module-to-module variation of amp-hour (Ah) capacity) is referred to as an “out of balance” pack. The modules have a memory of the small capacity demanded, thus resulting in the term “memory effect”.

What is battery cell balancing?

Reconditioning recovers lost capacity. When reconditioned modules are sorted and positioned for optimum performance, the battery pack is 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 the EVc-30 (see photo above)
4  Press the start button.

The output report:
identifies high resistance modules (e.g., > 10 mΩ for a 6-cell module).
b enables sorting and selecting of modules for pack assembly based on amp-hour or watt-hour capacity.
pairs up modules into blocks based on module rest voltage.
archives all data for your warranty  management program.

EVc units are priced for a payback period of less than 2 months when fully deployed. The EVc tools are simple to use.

What tools are required for hybrid battery reconditioning and repair?

The required tools are (1) a menu driven charge discharge cycler (the EVc tool),  (2) software for analysis of 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.

Hybrid battery repair tool:  EVc-30
Includes EVc unit, training and EVc software (EVcharge). EVcharge imports module state-of-health data from the EVc-30.

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 on the EVc tool. 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 business model is: 1. Establish an inventory of reconditioned modules archived with watt-hour capacity and nominal module voltage data. 2. Replace customer hybrid batteries. 3. Recovery the battery core from the customer.

What kind of data does the EVc output file provide?

NuVant EVc units are the only systems on the market that provide:
(1) internal resistance
(2) amp-hour capacity
(3) watt-hour capacity
(4) nominal module voltages

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

How can I rapidly start up my battery replacement and installation business? 

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.

 

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
    • BRIMS package for business management.
  • Additional 5-hour EZtime tickets can be purchased for $450.

Call 219-644-3231 for more details!

For zero down payment alternate to the NuVant financing plan, consider Crest Capital Financing for US buyers.

For USA Financing: Crest Capital Financing 

Crest Capital finances NuVant products