Lithium Ion Battery Analysis and Repair
A Cradle To Cradle Approach
SYBESMA’S ELECTRONICS has been innovating repair solutions for the electronics industry since 1958.
Our advanced equipment allows for deep cycling and thorough testing of battery cells and associated control electronics.
SYBESMA’S ELECTRONICS is an approved repair and re-manufacturing facility for lithium ion batteries in West Michigan, including battery sources for pure electric and plug-in hybrid vehicles.
At SYBESMA’S, you can be sure that your batteries will be repaired to industry standards, re-purposed to the full extent of their lives, and recycled properly by the strictest of environmental and safety standards.
Benefits of Li-Ion Battery Reuse
Sybesma’s Electronics are experts in the field of Lithium-Ion battery analysis and repair. Our patented process quickly diagnoses battery packs, repairs them, and thoroughly tests them to meet top quality standards.
Sybesma’s Electronics has the ability to provide a complete cradle-to-cradle approach by offering repair, re-manufacture, re-purposing, and recycling options for automotive li-ion batteries.
Battery Repair Overview
Global Battery Solutions is uniquely positioned to provide the solution to the dilemma of creating a cost reduction in electric vehicles. The ability to provide a cradle-to-cradle approach to Li-ion automotive batteries will create a successful electric vehicle market by keeping costs down for li-ion battery manufacturers and distributors.
Global Battery Solutions can help provide a cradle-to-cradle approach by offering repair, remanufacture, repurposing, and recycling of Li-ion automotive batteries.
Quick diagnoses of battery packs, repair, and thorough testing to meet top quality standards.
Replacing the battery pack with a remanufactured battery can cut the replacement cost by over 70%.
Repurposing gives a battery the chance to have a second life.
When battery cells will no longer hold a charge, they cannot be repaired, remanufactured, or repurposed. They must be scrapped.
GLOBAL BATTERY SOLUTIONS
The first step in keeping costs down for the manufacturers and distributors is to lower warranty costs. The cost to replace a battery pack with a new pack can be more than $5000.00.
Replacing the battery pack with a repaired battery can cut the replacement cost by over 90%.
Within the first few years of life, “defective” battery packs maintain their battery cell health, but can be affected by the electronics controlling them. Repairing the electronics can restore the battery pack to full functionality. Creating a process to repair the electronics of the battery packs can dramatically reduce warranty costs.
Sybesma’s Electronics has a process that quickly diagnoses battery packs, repairs them, and thoroughly tests them to meet top quality standards. Sybesma’s has successfully repaired batteries for A123 for over four years.
Though many batteries can be repaired due to defective electronics in the first years, as time goes on, battery cells begin to lose their capacity. The repair process cannot bring these packs back to full capacity and a different process must be used.
To continue keeping costs down, remanufacture of battery cells must also be used.
GBS – A CRADLE TO CRADLE APPROACH
The next step to keeping costs of li-ion batteries down is remanufacturing the batteries. Replacing the battery pack with a remanufactured battery can cut the replacement cost by over 70%.
After a few years, battery cells begin to lose capacity. Remanufacturing the battery packs can restore the battery pack to full functionality. Creating a process to remanufacture the battery packs can dramatically reduce warranty costs and replacement costs for the end user.
Sybesma’s Electronics has patented a process to diagnose defective cells within a battery pack, remove the defective cells, replace the cells with recovered-healthy cells, and balance all the cells within the pack to ensure a quality product. These remanufactured cells are currently used by BAE corporation. Currently, data is being collected to find accurate life expectancies of remanufactured packs. Sybesma’s will continue to collect data, and modify the process as needed.
Using repaired and remanufactured batteries will help keep costs down for replacement batteries during the warranty and out of warranty periods. However, eventually, the battery packs will degrade to a point below automotive standards. These batteries still have enough health to be used in other applications. Rather than scrap these packs, repurposing them for other use can give them a second life and increase profits for both the manufacturer and repurposing company.
GBS – CREATING THE SOLUTION
After a battery pack has reached a state of health that can no longer be used in the automotive industry, it has been common practice to pay to scrap the packs. Repurposing these packs for other uses can create additional cash flow for both the repurposing company and the manufacturer.
Repurposed packs can be sold at less than 50% of the cost of a new battery. The lower prices will create a market for automotive batteries beyond vehicle use. Battery Manufacturers and/or Automotive Manufacturers would receive a percentage of sales for each pack sold. This process would turn the expense of scrapping into profits.
Global Battery Solutions is partnering with Grand Valley State University to form a team of engineers with the purpose of creating secondary uses for automotive batteries. Focusing on safety, the team designs packs that are able to fit a variety of other applications. GBS supports small-scale manufacturing of the repurposed packs and sells the packs to distributers. All packs will pass strict quality testing before shipping.
Each pack receives a validation number verifying all quality standards have been met. This validation is sent to the battery manufacturer and/or automotive manufacturer along with a percentage of profits. This number will serve as a tracking number for future service needs and eventual recycling.
At the end of the life of battery cells, scrapping must take place. To continue keeping costs down of li-ion batteries, a recycling process is implemented that will allow for the recovery of the materials.
GBS – EXPERTS IN THE FIELD OF LITHIUM ION ANALYSIS AND REPAIR
The final step in keeping costs down for the manufacturers is to lower material costs. The best way to lower the cost of materials is to recycle all batteries that reach “end-of-life”.
Recycling battery cells can generate materials that can be sold at a lower rate than the original mined materials.
“There are a number of challenges that are likely to impact lithium supply in the future. Although there is sufficient amount of lithium resources available globally to meet the demand, almost 70% of the global lithium deposits are concentrated in South America’s ABC (Argentina, Bolivia and Chile) region. This poses an inherent risk due to the accessibility of the raw material that is available only in a specific geography. Unrest or instability of the governments in these regions can greatly affect the supply and have impact on the battery price and in turn, the vehicle cost. Lithium is also consumed by a number of other applications or sectors like construction, pharmaceuticals, ceramics and glass and so far the consumption by the automotive industry has been only a small fraction. At present, batteries account for only about one quarter of the current lithium consumption, which is expected to reach about 40% by 2020. Lithium constitutes only a small portion of the cost among other raw materials needed for battery manufacturing. However, with more than one million EVs expected by 2015, there will be a significant pressure on lithium suppliers to cater to demand.” - Waste Management World
When battery cells will no longer hold a charge, they cannot be repaired, remanufactured, or repurposed. They must be scrapped. GBS has partnered with Grand Valley State University to create a recycling process that will recycle all parts of a battery pack. Currently, the process is being tested and is being brought to scale. Recycling the components will provide manufacturers with the materials they need at a lower price and without the inconvenience of political barriers.