Our Process
BETTER BUILT HYBRID BATTERIES & REBUILD KITS
TECHNOLOGY – Maximizing the power, performance and longevity of your hybrid battery is all about technology. “Off-the-Shelf” high-end battery testing technology might provide a skilled hybrid pro with enough data to predict reasonable ranges of battery life, but the specialized equipment used by electric/hybrid car manufacturers doesn’t allow the power and performance of your battery to be maximized.
That’s why we developed our own proprietary hybrid battery testing technology. Our founder, who has pioneered technology and equipment designed specifically for hybrid and electric vehicles, in collaboration with our own electrical engineers developed sophisticated battery testing diagnostic technology that accurately measures the health related elements of every cell and every module of a hybrid battery pack.
The heart and soul of hybrid/electric vehicle electrical systems are their High Voltage Batteries (HVB). They are responsible for everything from powering all electronics to starting your hybrid’s engine.
If you’re concerned about the environment, gas mileage, performance and the power of your hybrid, then maximizing your batteries potential should be at the top of your list.
BELOW IS A SIMPLIFIED VERSION OF OUR HYBRID BATTERY REMANUFACTURING PROCESS
STEP 1 – Initial Testing
Batteries are received from our sources and put through a series of tests to determine its current state. 11 different tests are performed starting with the simple ones first; Capacity, voltage, internal resistance, separator degradation, etc. The tests show everything needed to understand the state of health (SOH) of the battery.
STEP 2 – Revitalization
Next is the Revitalization. This is where we restore the batteries. Just like with our bodies, specific exercises will make the battery healthier. Imagine if you only lifted weights with your legs and did nothing with the rest of your body, the same principle applies to revitalizing a hybrid battery.
We make the batteries, figuratively speaking, exercise properly and then feed it the right types of electricity to make sure it is well rounded and in the best shape as possible. We run different types of electricity through the batteries for just the right amount of time. They are charge to a set parameter and then drained to the precise standards to maximize each batteries efficiency. Doing these processes actually change the structures and chemistry inside of the batteries without opening them up. There are 9 different exercises that Electron does that bring back properties such as Capacity, Voltage, Internal Resistance, and so on.
STEP 3 – Final Battery Cell Testing
The final testing results are the most important numbers in this whole process. After the batteries have been reconditioned, we still need to test them to make sure none of them had a heart attack from the hard work out and see how strong each of them are now. We perform many of the same tests and a few additional ones. After that, we know everything about the batteries. We take out the batteries that do not have several years of life left. The batteries that are still usable but do not have long life remaining go to solar projects and electric bikes. The bad ones go to recycling so that nothing goes to landfills. Now that we only have good batteries left we need to do something called matching and balancing.
STEP 4 – Matching & Balancing
Matching is a process where you group like modules. Like modules are ones that have the same capacities, internal resistance, separator degradation, etc. If you do not match the battery modules, the battery will still work but we want to squeeze every bit out of them as possible to get the best performance and life.
Balancing is a process of making sure that all of the modules are charged to the same specifications. If you have a brand-new battery that is perfect but not balanced properly it will not work properly and can set all of the warning lights off and the car can go into limp mode. In severe cases the car will not even start. Precision balancing is another way to get the most out of a battery. This allows us to sell a product that we can stand behind and you can rely on.
TECHNOLOGY – It all starts with TECHNOLOGY!
Technology is where it starts. When we first began testing, reconditioning and remanufacturing hybrid batteries in 2010, the technology to accurately test, diagnose and properly refurbish electric/hybrid batteries didn’t exist. There’s no shortage of battery testing technology in today’s marketplace, but even the cheapest diagnostic systems need a trained professional to interpret the data.
“Off-the-Shelf” high-end battery testing technology provides hybrid pros with enough data to predict reasonable ranges of battery life, but the specialized equipment used by electric/hybrid car manufacturers doesn’t allow the power and performance of your battery to be maximized. That’s why Electron Hybrid Solutions developed our own proprietary hybrid battery testing technology. The technology was developed by our founder, who has pioneered technology and equipment designed specifically for hybrid and electric vehicles, in collaboration with our own electrical engineers.
The heart and soul of hybrid/electric vehicle electrical systems is their High Voltage Batteries (HVB). They are responsible for everything from powering all electronics to starting your hybrid’s engine. If you’re concerned about the environment, gas mileage, performance or power of your hybrid, maximizing your batteries potential should be at the top of your list.
Our proprietary technology was designed specifically for accurate, reliable and customizable electric/hybrid vehicle battery testing and diagnostics and is not available for purchase. Electron is the sole owner of this technology and no other hybrid battery reconditioning or remanufacturing wholesalers; retailers or businesses have authorization to use our technology to diagnose or test your hybrid battery. Be wary of any business or company that claims to use our technology.
Dealerships are obligated to replace your hybrid battery if it fails under warranty, 
