PLUGGED IN #3: Repairability of electric car batteries

You have recently purchased an electric vehicle, thereby contributing to the development of greener mobility! But questions remain: what options will you have if your electric vehicle's battery breaks down or loses its range?

If this is a concern for you, you are not alone: according to a study conducted by Opteven in 2022, 69% of electric vehicle users pay particular attention to the wear and tear, range and recycling of their batteries. ¹

The good news is that an analysis carried out by Arval, a long-term vehicle rental service, on the health of its electric vehicle batteries shows that they last well beyond the manufacturer's guarantees. For more than 8,000 vehicles from 30 different brands tested, the average battery health was 93% after 70,000 km. After 200,000 km, it remained close to 90% on average.²

Although reliable and durable, lithium-ion batteries can still encounter several problems during their life cycle, such as reduced range or loss of power. Promoting battery repair not only extends the life of essential components, but also aligns with broader sustainability goals by minimising waste and resource consumption. The repairability of batteries is therefore emerging as a key issue at the crossroads of economic, environmental and technological imperatives.

Can my battery fail?

If they do exist, it should be noted that failures in electric vehicle batteries are rare! With a few exceptions, battery efficiency is not impaired until at least 200,000 kilometres or 1,000 charge cycles have been reached. Batteries have a long service life, often longer than that of the vehicle itself: a service life of 15 to 20 years can be expected, although this is influenced by various factors.

The disadvantages of a malfunctioning battery are generally as follows: shorter range, reduced vehicle performance, or longer charging times. Batteries can be damaged by overuse, so careful and responsible use of your battery will help to keep it in good condition!
Find our tips and practical advice on how to extend the life of your battery at the end of this article.

Electric vehicle batteries can also be damaged by impacts or accidents.
All electric cars are equipped with a ‘pyro-fuse’ system. This mandatory safety device activates in the event of a collision, accident or major malfunction to physically and irreversibly cut off the electrical connection. Essential in the event of an accident to protect users and emergency responders, prevent fires and preserve electrical components in the event of a short circuit, it must be replaced if it has been triggered. This will be necessary even if the battery is intact, in order to be able to use the vehicle again. It requires the expertise of a qualified professional.

In general, there are two types of battery failure: chemical and electronic.
The latter include connection or power faults in the electronic boards, which are easy to fix.
Chemical failures are more difficult to deal with: due to the soldering, if a cell is damaged, the entire module will need to be replaced. This is less expensive than replacing the entire battery. In fact, the more modules there are in an electric vehicle, the easier it is to repair its battery.

How to repair it?

Before repairing, it is necessary to carry out a diagnosis and draw up a repair plan: which parts are affected, and what tools and techniques are required. Special equipment is available to check the voltage of the cells.

The repair is then carried out, which may include replacing the faulty battery, repairing the charging system or repairing the electric motor. Each repair requires meticulous attention to detail to ensure the vehicle is functional and safe.

A common repair is also to repair worn regenerative brakes, a feature unique to electric vehicles that uses kinetic energy. If a brake fails, there is a risk of damage to other vehicle components, resulting in reduced safety and performance.

After the repair, operators test the vehicle's performance to verify that everything is as expected. This validates the success of the repair and ensures the safety of the vehicle for future use.

It is important to note that strict safety rules must be followed throughout the repair process to prevent risks associated with the vehicle's high voltage. These include electrical insulation of the battery, wearing personal protective equipment, and detailed knowledge of safety practices and repair techniques.

Barriers to repair: design, costs, spare parts and training

Battery repair is a viable alternative to replacement, saving energy and valuable resources. This is all the more important given that electric vehicles need to be used for several years to offset the carbon emissions associated with their manufacture. However, several obstacles remain.

Firstly, the design of the vehicle determines the battery's repairability: sealed batteries, long favoured by manufacturers, are difficult or even impossible to repair. For a battery to be repairable, access to components and battery management software (BMS) must not be restricted.

Furthermore, it may be necessary to replace a battery regardless of its condition: some manufacturers require this to be done if the airbags are deployed.

In addition, the cost of repairing a battery is generally between €1,500 and €6,000, depending on the type of work required. This is still a high cost, but it is still more advantageous than replacing the entire battery, which can cost between €10,000 and €25,000 – a price that may lead users to prefer buying a new vehicle.

This repair cost is also lower than the maintenance cost of a traditional vehicle, as the long-term operating costs associated with maintaining an electric vehicle are lower.

Replacing a module is a very time-consuming operation, which therefore incurs significant labour costs. Technicians who work on batteries have undergone extensive training on high-voltage systems and specific vehicle models, which must then be supplemented by ongoing training. It is necessary to have a thorough understanding of the equipment and protocols, as well as to be up to date with the latest safety practices and technological advances in the industry. This extensive training also justifies the high cost of repairs.

Manufacturers are setting up centres specialising in this type of repair, which requires specific skills and resources, such as Stellantis with its E-repair centres. ³

Finally, the cost of the repair will depend on several other factors: the power of the battery concerned, the parts to be replaced, and whether a new or used replacement part is chosen.

In general, battery repairers still find it difficult to offer inexpensive solutions due to design challenges, safety constraints and lack of access to spare parts. However, with a few changes to vehicle design (such as a protective shield under the batteries), a significant portion of the costs associated with repairing electric vehicles could be eliminated.

Initiatives and regulatory framework

Battery repair is a viable alternative, but still marginal. Nevertheless, given the growing number of electric vehicles on the road and the market's shift towards electrification, solutions are developing: independent battery repair centres are springing up, while manufacturers are also opening their own centres.

In order to avoid or delay significant costs associated with battery replacement, battery repair centres can offer solutions to increase their lifespan. They contribute to sustainable resource management through repair, but also by integrating into a reuse circuit for batteries that can no longer be used for automotive purposes. In the same vein, it seems necessary to provide more training for technicians in battery diagnostics.

The European Union is playing a key role in this transition. The new battery regulations, adopted in 2023 and gradually applicable until 2030, impose several obligations on manufacturers:
• Easier access to battery diagnostic data.
• An increase in the recycling rate of critical materials.
• Greater transparency on the composition and environmental footprint of batteries.

France, for its part, has included battery repairability in its repairability index, which could become binding in the coming years.

The move towards a circular battery economy seems inevitable, but its implementation will be gradual. Consumer pressure, regulatory requirements and technological innovations are converging towards a model where repair, reuse and recycling will be the norm. One thing is certain: the era of ‘disposable’ is coming to an end.
With this in mind, ACC is adopting an eco-design approach and supporting the development of a battery recycling industry.

Practical tips to extend the life of your battery

To extend the life of your battery and get the most out of your electric vehicle, we recommend following these simple tips:
- Keep the charge level between 20% and 80% as much as possible, which will cover most everyday journeys, with a 100% charge for longer but less frequent journeys.
- Avoid leaving your vehicle stationary for long periods with an almost empty battery.
- Limit the number of quick charges, which can accelerate battery wear.
- Have your battery checked every 1 to 2 years and find out about the warranty offered by your electric vehicle manufacturer.

You can find more tips on how to incorporate eco-driving into your daily routine in our dedicated article.

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