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

Hybrid battery training class

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Hands-on hybrid electric vehicle battery course

The 2-day nickel metal hydride (NiMH) hybrid battery class demonstrates split current charge-discharge cycling, internal resistance measurements and hybrid battery cell balancing. No prior knowledge of hybrid batteries is required. The hands-on experience includes use of the EVc-30 hybrid vehicle battery reconditioning unit. Anyone can learn!

 

Hybrid battery class schedule (2019):

Crown Point, IN:

130 N. West St.
Crown Point, IN 46307

 Dec. 12-13
Jan. 16-17

Register now!

Course fee:
$590/person

Course fee includes a 2-night stay at the Holiday Inn Express Merrillville.

Registration and payment must be made 2 weeks before course date.

Certificate of course completion is provided to attendees.

Limit: 5 attendees per class

Alternative sites/pricing available upon request!


Call 219-644-3231 for class registration help.


Course time schedule
Day 1 8:30AM – 3:30PM (Central Time)
Day 2 8:30AM – 1:30PM (Central Time)

Course registration includes:

  • Course work materials
  • Two night stay at the Holiday Inn Express Merrillville (with breakfast)
  • Use of NuVant EVc units for charge-discharge, internal resistance measurements and complete reconditioning

Hybrid battery class 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.
  • The dangers of over-charging and over-discharging.

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

Battery-sorting software module
Battery-sorting software module

Background

Hybrid battery packs have 28 to 40 NiMH modules assembled in series. A Prius type prismatic module consists of six individual NiMH cells (1.2 V each) assembled in series. Detailed specifications for these modules are available.  

7.2 V hybrid battery prismatic module with individual cell marked 1 – 6


28 prismatic modules with a series nominal voltage of 202 V

NiMH modules are configured in series for high voltage hybrid vehicle battery packs. These packs undergo shallow depth-of-discharge (about 10%): They are for power assist, not electric drive.  Unused electrode material undergoes structural changes that effectively reduces amp hour (Ah) capacity. This reversible failure mode (“memory effect”)  takes modules out-of-balance with neighboring modules, especially those that are near the center of the pack. Out-of-balance modules undergo cell voltage reversal during discharge. Voltage reversal can permanently damage a module.  High-rate charging generates gaseous oxygen at the positive nickel oxyhydroxide electrode that can pressurize and rupture the module.   Modules, reconditioned by a series of deep charge-discharge cycles with tapered currents, will recover lost capacity and have extended lifetime.  Hybrid vehicle batteries that have overheated may have vented electrolyte water. This permanent failure mode increases the module internal resistance. Such  modules substantially increase reconditioning time. Modules suffering from permanent failure modes are identified and removed before full reconditioning.   


Syllabus

Part I: Introduction

a) Battery aftermarket and geopolitics
b) How NuVant reconditioning technology differ from others

Part II: Terminology, definitions and usage

a) Coulombs, amps, voltage, amp-hour, watt-hour
b) Cells, modules, packs, cylindrical versus prismatic cells
c) NiMH batteries vs. Li-ion batteries

Part III: Underpinning science behind battery reconditioning

a) Reversible and irreversible capacity losses
b) NiMH memory effect – effect of shallow depth of discharge
c) Use of state-of-health data for module sorting and battery pack assembly
d.) Refurbishing packs vs Reconditioning modules

Part IV: Hands-on experience with the EVc-30 reconditioning tool

a) EVc-30 overview
b) Prius modules, clamping, cooling box and connections to EVC-30
c) EVcharge software: Opening/writing project file, starting/storing project files
d) NuVant reconditioning plans – Prius and Honda modules
e) Before and after reconditioning discharge profiles
f) Dangers of reconditioning – Module swelling, overheating, pack explosions

Part V: Interpreting EVc-30 data output 

a) Results –Diagnostic discharge profile, Exporting summary files
b) QR code reader – Tracking inventory
c) Module pairing after reconditioning (Battery pack balancing)

Part VI: Summary:

a) Business models
b) Electric versus hybrid vehicles
c) Specifications look-up table
d) EVc operation glossary