An example of a batteries reconditioning line is shown below:

Acceptance station – The battery enters the line, is placed on a mobile work table (which is used to move the battery from one station to another one) and the first electrical safety tests are performed (measurement of the insulation voltage and the battery pack), to understand if the analysis and reconditioning process can start or not and a leak test to evaluate any leaks in the cooling circuit or in the housing.

Diagnostic station – First-level diagnostic analyses are carried out with specific instrumentation in order to assess which maintenance and/or repair operations need to be carried out on the battery.

Battery pack opening station – Workstation equipped with tools useful for removing the battery cover.

Repair Station – Workstation equipped with tools and electronic instrumentation useful for conducting the following operations: assembly/disassembly of battery modules, electrical balancing tests of the modules, leak tests, cleaning and repair.

Validation Station – Electrical and functional tests are performed to evaluate the success of the battery repair. The station is equipped with an automation system capable of automating the execution of each test, parameterizing the tests according to the need and post-processing, always automatically, the results produced:

• Functional test: verification of communication with the internal components of the battery (BMS, sensors, etc.)
• Pulse test: simulation of the maximum load that the battery pack can withstand, in order to evaluate the impedance of each individual battery cell.
• Capacity test: battery charge/discharge cycles in order to validate the battery itself through the calculation of the status of health (SoH).

Battery pack closing station – Workstation equipped with tools useful for closing and sealing the battery cover.

Leak test station – Final leak tests are performed on the battery housing.

Packaging station – The battery is placed inside a crate/pallet and finally packed.

Second life station – In the event that the battery cannot be repaired, it is disassembled and partially disassembled and the working components are recovered.