Used EV Battery Pack Refurbishment With Matched Battery Selection
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Solution Overview
Problem
Electric vehicle battery packs face challenges due to high costs and inefficiencies in maintenance, particularly when a single faulty battery can degrade the entire pack, and the need for continuous use leads to rapid wear and battery unbalancing.
Innovation Solution
A method and apparatus for refurbishing battery packs by testing individual batteries, selecting replacement batteries with similar parameters to maintain pack balance, and storing test results in a database for creating a refurbished pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single faulty battery is replaced in the battery pack, then the reliability of the battery pack is improved, but the manufacturing cost and complexity increase due to need for testing and matching
Solution Approach 1:
The battery pack is divided into individual battery modules that can be independently tested and replaced. Each battery within the pack can be individually assessed for health and performance, allowing selective replacement rather than replacing the entire pack or using complex diagnostic systems.
Solution Approach 2:
Batteries are tested for specific parameters (voltage, capacity, internal resistance) and replacement batteries are selected to match these parameters. This parameter-based matching ensures compatibility and balanced performance without requiring complex adaptive control systems.
2Productivity
If batteries are continuously used to maintain vehicle availability, then the productivity is improved, but the battery pack balance deteriorates due to rapid wear and unbalancing
Solution Approach 1:
Batteries are tested before installation into the pack to ensure they meet minimum performance criteria. Replacement batteries are pre-selected and pre-charged to match the voltage and state of charge of existing batteries, preventing immediate unbalancing when installed.
Solution Approach 2:
The system monitors individual battery voltages and states of charge during operation. When unbalancing is detected, the system can adjust charging currents or trigger maintenance alerts to restore balance before it affects overall pack performance.
3Manufacturing precision
If individual battery testing is performed to maintain pack balance, then the manufacturing precision is improved, but the time and cost for maintenance increase
Solution Approach 1:
Instead of testing every single battery parameter exhaustively, the system performs targeted tests on critical parameters (voltage, capacity, internal resistance) that most significantly impact pack performance. This partial testing approach achieves sufficient precision for maintenance decisions without excessive time investment.
Solution Approach 2:
Test results from individual batteries are stored and used to create a digital record or profile. This information is retained for future reference, eliminating the need to re-test batteries that have already been characterized, thus reducing repeated maintenance time while maintaining selection precision.
Data Source
AI summary
A method of repairing a used battery pack from an electric vehicle include removing the battery pack from the vehicle. Battery tests are performed on at least some of the plurality of batteries and a battery test result for each of the batteries tested are obtained and stored in a database. A plurality of replacement batteries are tested and test results for each of the replacement batteries are stored in the database. The battery test results from the database are retrieved and used to create a refurbished battery pack. An apparatus includes a database for storing test results.