Manufacturers and Models

Chevrolet

Chevrolet Tahoe (2008 – 2013) Chevrolet Silverado (2008 – 2013)

Honda

Honda Civic

Lexus

Lexus RX450H (2011 – 2015) Lexus HS200 Lexus CT200H (2011 – 2016)

Nissan

Nissan Altima

Toyota

Toyota Prius (2003 – 2015) Toyota Highlander (2006 – 2009) Toyota Camry (2007 – 2015) Toyota Avalon (2012 – 2015)

Process

Products

HYBRID Battery Manufacturing & Re-Manufacturing flow chart


All HYBRID and Electric Vehicle (EV) battery re-manufacturing is not made equal. Because this is still an unregulated industry, there are a lot of steps involved in doing it correctly and those steps cover a few vital areas:

STEP 1.

  • Battery Pack (BP) disassembling
  • Recording Initial voltage of each Cell
  • Separating the Cells
  • Cleaning each Cell with proper cleaning Agent
  • Assembling the Cells

 

STEP 2.

  • Recording the Internal Resistance (IR) of each Cell
  • Starting the Discharge and Charge sequence
  • Recording the Discharge and Charge values
  • Identifying Unusable Cell(s)
  • Replacing Unusable Cells with Healthy Ones
  • Discharge and Charge to determine the health of the Cells
  • Cell Grouping
  • Record the Grouping
  • Balancing the Pack

At this point the Cell Pack is ready for final assembly

 

STEP 3.

  • Cleaning the Fan
  • Cleaning the Cover and inside the Battery Pack
  • Cleaning and DE-rusting all Copper Contacts and Cell Nuts
  • if necessary, replacing Copper Contacts and  Cell Nuts with new ones

 

STEP 4.

  • Assembling the Battery Pack
  • Torquing all Nuts and Bolts to manufacturer’s recommended values
  • Recording the Voltage and Capacity of the Pack
  • Generating the Final Report
  • Shrink Wrapping the Pack

At this point the Healthy Re-Manufactured Pack is ready for shipping