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As more and more drivers make the switch to #electricvehicles (EVs), an increase in the number of #electriccar battery faults will inevitably follow. Despite claims that EVs do not fail, there is a growing body of evidence to the contrary, with failure rates roughly equivalent to those of internal combustion engine vehicles. By Dr Sara Ridley – Engineering and Quality Director at Autocraft EV Solutions Faced with this unexpected reality, many automakers must now meet their warranty obligations while avoiding escalating warranty costs and reputational damage. These concerns must also be reconciled with the need to transition to a #greener future and tackle their impact on the environment. Many industry commentators see recycling as the best route to circularity, however, this belief is often founded on a flawed understanding of the possibilities of #EVbattery repair. The environmental potential of EV is enormous, however, unlocking this potential requires a commitment to maximising battery longevity. It is therefore crucial to tackle some of the prevailing myths and misunderstandings around managing EV battery health if the EV revolution is to fulfil its promise. It isn’t possible to repair EV battery repairs With the right testing capability, it is possible to diagnose and tackle the root cause of faults at a modular level, as we at Autocraft EV Solutions have shown by carrying out thousands of successful EV battery repairs. In very simple terms, a pack will perform to the level of its worst performing module and when one underperforms, this can cause a significant drop in performance or, in extreme cases, total failure. By replacing problematic cells with healthy ones, this restores a pack to its highest performance state, meaning that a supposedly ‘failed’ EV pack is no longer a terminal issue. To sustain this process, it is important to have access to a supply of replacement healthy modules. When we can identify which cells and modules with a failed pack are still functional, they can be incorporated into another pack to give it a new lease of life. This value is lost when battery packs containing healthy modules are prematurely recycled, underlining the need to squeeze every last bit of value from individual modules. Recycling EV batteries is inherently more ‘circular’ A common misconception is that recycling faulty batteries is the ultimate solution for electric vehicle circularity. While EV battery recycling has its place, it is better for the environment to take every possible measure to repair EV batteries in order to restore performance and maximise their #longevity. This view is consistent with the concept of the hierarchy of #waste, which advocates for preventing waste in the first instance before #recycling even enters the discussion. Defaulting to recycling, without repairing and repurposing batteries within second-life applications, is sub-optimal from a #sustainability perspective.

EV battery health – separating myth from reality

EV battery health – separating myth from reality

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