Electric Car Battery Repairs and Health Checks: Keeping Your EV on the Road

Electric vehicles (EVs) are increasingly seen as the future of the automotive industry. However, doubts about battery longevity and repairability persist. Understanding electric car battery health can revolutionize the EV market and help keep thousands of vehicles operational. In this article, we'll delve into the complexities of EV battery health, necessary repairs, and how innovative technologies are paving the way for a more sustainable electric vehicle ecosystem.

The Importance of Battery Health in EVs

At the heart of every electric vehicle is its battery pack, which operates much like a larger version of the lithium-ion batteries found in smartphones. These batteries are costly, containing rare-earth metals and complex chemical components. As of 2024, the manufacturing cost for a new battery pack is approximately £110 per kilowatt-hour, making the average 60 kWh battery around £6,500. Adding labor costs can quickly increase the total price to £20,000 or more.

Repairing EV batteries is not a straightforward task. Many mechanics lack the specialized knowledge necessary to diagnose and repair battery issues safely and effectively. This lack of expertise has contributed to a general perception that EV batteries are irreparable or that their repair is not financially viable.

But hope is on the horizon. With advancements in technology, batteries can now be repaired, and consumers can gain better insights into their vehicle's state of health. This not only enhances the longevity of EVs but also reduces depreciation rates for electric vehicles.

Understanding State of Health (SOH)

The State of Health (SOH) of an EV battery is a metric that measures its condition compared to its original performance when new. This involves assessing both the capacity of the battery (how much energy it can store) and the resistance (how easily it transfers electricity in and out). By comparing these metrics with a digital twin of the vehicle, service providers can determine how well a battery is functioning.

Currently, tools like dongles can access basic battery information, but comprehensive diagnostics require advanced technology. For instance, Autocraft's OptEVizer system allows technicians to analyze individual battery cells down to millivolt fractions, identifying not just existing problems but also potential issues before they escalate. This level of detail is akin to an MRI scan rather than a simple X-ray, providing critical insights into battery health.

The Role of Battery Passports

One of the latest developments aimed at improving battery transparency is the concept of a battery passport. This innovative technology will allow consumers to understand their battery’s detailed composition, state of health, and environmental impact through a QR code affixed to the battery. As a result, battery passports empower consumers with essential data, increasing confidence in purchasing older EVs and contributing to a more informed market.

In the European Union, battery passports will be required for all new electric vehicles by 2027. While the UK's approach to this technology may still be emerging, there's a push from industry experts, like Dr. Sara Ridley of Autocraft, for implementing battery passports. These passports will need continuous updates and maintenance to ensure they remain accurate as batteries undergo servicing.

Can Electric Vehicle Batteries Be Repaired?

Yes, EV batteries can often be repaired or remanufactured, although the intricacy of this task adds to the challenges. Most technicians require advanced training and specialized equipment to work on lithium-ion batteries safely. Autocraft's experience suggests that, on average, 92% of battery modules remain functional even after faults are detected. This means that it’s often possible to replace just a single module in a battery, restoring significant capacity and functionality.

While it's crucial to understand that a remanufactured battery may not achieve 100% of its original performance, a capacity of over 90% is attainable in many cases. Importantly, Autocraft can perform this work while preserving the manufacturer's original warranty, offering peace of mind to electric vehicle owners.

Supporting Local Garage Repairs

Autocraft currently remanufactures approximately 1,500 EV batteries annually, with plans to expand this capacity to 4,000. As demand for battery repairs grows, Autocraft is exploring partnerships to make its technology and processes available to independent garages. This initiative could enable more local technicians to perform battery remanufacturing, bringing down costs for consumers.

Using a method called the Revive Workshop, technicians can be guided through the battery repair process, minimizing the risk of errors and enhancing safety by detecting harmful gases. As more manufacturers opt for designs that allow easier module replacement, EV battery repairs have the potential to become standard practices in local garages shortly.

Repairing vs. Recycling: Understanding the Choice

While recycling batteries is vital for an environmentally sustainable circular economy, repairing batteries can be more cost-effective. Autocraft estimates that remanufacturing costs about half of what a new battery would cost, with goals to reduce this further by 2030. As more EVs exit their warranty periods, affordable and reliable remanufacturing could significantly bolster both new and used car markets.

Moreover, battery recycling is energy-intensive and often yields materials that aren't reusable in the same capacity. The CO2 emissions associated with manufacturing new batteries are also substantial. Thus, if a battery issue arises, it’s essential to consider repairs before resorting to recycling, especially if only a single module requires replacement.

Conclusion

Advancing technologies in electric vehicle battery repairs, such as health checks and battery passports, are crucial in reshaping perceptions of EV battery longevity and repairability. With over 2.6 million batteries projected to fail prematurely by 2033, addressing these concerns head-on is imperative for sustainability.

As electric vehicles become more commonplace, we must shift the mindset around battery maintenance and repairs, seeing them as manageable tasks rather than insurmountable problems. For battery health diagnostics and repairs, consider exploring our cutting-edge software for online, fast AI car diagnostic—your efficient solution for keeping your EV on the road longer. Experience faster diagnosis here.