Hybrid battery equipment
EVc-30 hybrid vehicle battery reconditioning and cell balancing tools
The turnkey battery refurbishing equipment includes a software loaded laptop computer, battery pack cooling box, and cables.
For more information, click the following links:
The hands-on battery reconditioning short course: Recondition and balance a Prius battery with the EVc-30.
For USA Financing: Crest Capital Financing
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|
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 reversible degradation process that reduces battery capacity. This reversible failure mode (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 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
6 Modules sorting based on watt hour capacity
7 Block positioning of modules into a full pack
What tools are required for hybrid battery reconditioning and repair?
The required tools are (1) a menu driven charge discharge cycler, (2) database storage 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) including an Excel database. EVcharge imports module state-of-health data from the EVc-30. The database tracks modules and sorts for assembly of balanced battery packs. The sorting routines filter out bad modules 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.).
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 business model is to build up an inventory of reconditioned modules for replacement of customer packs and recovery of a core from the customer.
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.
Example EVc output files for popular traction battery packs are shown below.
Toyota Highlander (click on figures to expand)
Ford Escape (click on figures to expand)
Toyota Prius (click on figure to expand)
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 hybrid 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
|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|
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: 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.