Test HV packs and modules reducing cost more than half and using a fraction of the power
0.5% to 1.5% of new released EVs will experience some traction battery related issue that would require repair or replacement. This need to repair and remanufacture batteries lags new car sales by 2-3 years and will continue to grow because battery warranties last 8 years / 100,000 miles and OEMs must hold parts up to 15 years. A key challenge in the next 5 years will be scaling up testing and battery remanufacturing capacity to meet this growing demand as right now it requires long test times and complicated equipment.
Four major automakers choose ReJoule to increase revenue from used batteries by optimizing the remanufacturing process. ReJoule’s rapid testing technology reduces the number of tests and workload required to assess batteries, enabling shorter test times, lower operational costs, and more remanufactured packs ready for resale. Faster testing also means a shorter time to revenue.
Who benefits: Automakers, Original Equipment Manufacturers (OEMs) and automotive dismantlers.
Current testing method for remanufacturing: Cycle testing is a de facto standard for understanding state of health (SOH) and making critical financial decisions about whether to repair, remanufacture, or recycle a battery. It takes 6-24 hours testing, need skilled workers and requires high equipment and power investment. Also, it can fail to provide the detailed, cell-level information needed for efficient remanufacturing. Analyzing these results requires manual analysis by an experienced battery engineer.
ReJoule’s Solution vs cycling:
Shorter test time and faster decision making. Each battery can be tested in less than 15 minutes compared to several hours of cycling with over 98% accuracy, suitable for any battery type and chemistry.
Lower energy and facility opex. Cycling requires heavy energy consumption which adds to OpEx. ReJoule’s EIS method reduces energy and power requirements by at least 90% compared to cycling. Furthermore, faster testing means less facility and warehousing costs.
More detailed battery analysis: imbalance is flagged with a rapid test when paired with BMS data enabling identification of a single degraded module that can restore up to 16% more usable capacity whereas cycling can still be blind to issues such as cell-to-cell imbalance.
Faster time to revenue. Fast test time and reliable results means that a battery pack can be rebuilt and shipped to an end-user or customer as quickly as possible.
Want to learn more about our technology?
Issued battery testing process with ReJoule technology:
If you want to know all insights download ReJoule’s White Paper
Scaling Battery Remanufacturing: Challenges and Opportunities
Impact
Today, a facility may process close to 4,000 battery packs in a year, resulting in about 13 packs a day. Let’s assume a scale up scenario when a facility needs to process 10,000 battery packs in a year, that’s now 31 battery packs a day. Using some basic assumptions, we estimate time and cost savings from adopting ReJoule’s approach at scale. Two separate processes are then evaluated:
Baseline (Cycling): the process of dismantling a battery pack to modules and cycling modules individually. This requires the most testing time, but provides an accurate SOH of each module.
Pack and Module EIS (ReJoule): Pre-sort batteries with rapid pack test, then extract modules with an EIS test rather than dismantling all battery packs to modules. Only battery packs meant for remanufacturing are partially disassembled.
Another way to look at the benefits of ReJoule’s rapid test is to look at the throughput that could be generated with 2 technicians. We have made an assumption about the value of remanufactured packs, based upon conversations with leading companies and reviewing industry market places. As you can see, ReJoule’s tech produces significant additional value.
