> The battery pack isn't a single module. It's not as simple as the
> entire pack being scrapped just because one or two fail.
> > The individual
> > cells won't die off all at once.
>
> True, however the individual cells are all the same age and have seen
> the same usage so they will all die within the span of about one year.
I really don't see that happening. I would expect that a few might
fail here and there; more like a increasing distribution rather than
a cliff. Possibly one might go next month or three years down the
line. It's not like a bad apple where the one failing one alerts all
the others that they need to execute some massive die-off.
I think of it more like an older house that's been well taken care of.
I live in a 50+ year old house with some of the original wiring. Some
hardware has worn down with age and needs to be replaced, but the
house as a whole hasn't fallen apart. When older components fail, they
can be repaired as needed. We don't walk into the house expecting
that all the original doors are going to start failing in short order
if just one needs to be repaired or replaced.
> > 250,000 miles and 15 years shouldn't
> > be out of the question for the large majority of the packs in a stack.
>
> In commercial taxi service perhaps. Not for the typical consumer.
The biggest enemy of NiMH battery life are excessive heat,
overcharging, and deep-discharge cycles. The latter two are handled
by the system design. The stacks are fan cooled. Most of the tools
I've worked with use simple dumb chargers, and I'd expect that
the batteries would show the signs of overcharging and or deep
discharge use after 10 years.
> > I would imagine that there will be some mechanics that might
> > specialize in overhauling hybrid batteries.
[quoted text clipped - 4 lines]
> in the manual tells them to try. The few good mechanics that actually
> understand a vehicle are mostly employed by racing teams.
I'd expect to see semi-automated equipment. Break down the old
battery and insert several cells into the analyzer. Analyzer gives a
report and the cells are marked and/or graded. It might not even be
all that different than the equipment that the manufacturer uses to
test new batteries.
> > NiMH technology has
> > been around for a while. Equipment to analyze and recondition
[quoted text clipped - 6 lines]
> battery packs it still doesn't make much sense due to the minimal life
> extension it might provide.
I only bring a "conditioner" as an example of the technology out there.
What I had in mind was an analyzer to detect which cells are likely
to have a long, useful life and to discard (i.e. recycle) the cells
that might fail.
> > I see the sale of reconditioned battery packs like we find
> > rebuilt engines or starters. Of aftermarket drop-in modules.
[quoted text clipped - 12 lines]
> cells in a big steel case (whole thing weighs 1,571#). You simply don't
> replace an individual cell, when one fails the others aren't far behind.
Typically lead-acid batteries that aren't fan-cooled during the charge
and discharge cycles, right? I expect the failure characteristics of
a fan cooled NiMH battery (that's kept well between fully charged and
fully depleted) to very different.
> > The hybrid
> > systems seems to do a fairly simple thing that maximizes the life of
[quoted text clipped - 8 lines]
> old and they are showing signs of impending failure such as reduced
> capacity.
Again - how many applications are designed to keep a NiMH battery
from being deep-discharged AND fully-charged? While being fan
cooled. That environment is far more conducive to longer life than
a tool battery pack.
Now I don't expect that every last battery pack in every car is going
to be perfectly reliable over the course of 15 years and 250,000 miles.
That's unrealistic for any car part. I do believe that these hybrid
systems are set up to maximize rechargeable battery life better than
almost any other use to date. I wouldn't expect that amount of
monitoring/cooling would be worth it for typical consumer electronics
where I could get another set for less than $10.
> > > With the conventional economy car you simply don't have this
> > > catastrophic end of life scenario. The conventional economy car gets
[quoted text clipped - 11 lines]
> will be tires, brakes, wheel bearings and oil changes, all far less
> expensive than a battery pack.
No room for other parts failures? I had a coolant hose go at 110K
miles. The radiator tank cracked at 130K miles. There were also
other little things that probably needed servicing. It was stolen,
recovered, and declared a total loss. I got a great settlement that
was more than I could have sold it for.
> No comment on the Subaru Justy? It was a 3 cylinder 50 some odd HP
> conventional IC economy car that had plenty of pep, proving your gutless
> claim false.
I remember the Justy. That sucker was tiny.
> > And you're still hauling around that weight and heating up a
> > full-sized engine block.
[quoted text clipped - 5 lines]
> weight, that is minimal for a car engine and is less weight than the
> battery pack the hybrid hauls around.
I thought the typical weight difference between a V8 and an I4 is about
200-250 lbs. A battery pack is about 100-120 lbs. The battery can be
placed anywhere you can find it, while a V8 would require more volume
under the hood.
Pete C. - 16 Jan 2007 07:23 GMT
> > > The individual
> > > cells won't die off all at once.
[quoted text clipped - 15 lines]
> that all the original doors are going to start failing in short order
> if just one needs to be repaired or replaced.
It's a predictable electro-chemical thing, no analogy whatsoever to home
electrical.
> > > 250,000 miles and 15 years shouldn't
> > > be out of the question for the large majority of the packs in a stack.
[quoted text clipped - 7 lines]
> the batteries would show the signs of overcharging and or deep
> discharge use after 10 years.
If they have dumb chargers you're using cheap tools. The quality tools
have smart microprocessor controlled fast chargers and the battery packs
have built in temperature sensors. Some battery packs have built in
intelligence as well with flash memory to track the packs history.
> > > I would imagine that there will be some mechanics that might
> > > specialize in overhauling hybrid batteries.
[quoted text clipped - 10 lines]
> all that different than the equipment that the manufacturer uses to
> test new batteries.
You can analyze and grade all you want, but you're still going to have a
90%+ reject rate because all the cells will be about equally worn out in
almost every case.
> > > NiMH technology has
> > > been around for a while. Equipment to analyze and recondition
[quoted text clipped - 11 lines]
> to have a long, useful life and to discard (i.e. recycle) the cells
> that might fail.
Look at some of the battery management chips from Microchip and Dallas
Semi. The intelligence is intended to be built right into the pack.
Helps maximize the life expectancy of a pack, but either way, all the
cells will be near death at about the same time.
> > > I see the sale of reconditioned battery packs like we find
> > > rebuilt engines or starters. Of aftermarket drop-in modules.
[quoted text clipped - 17 lines]
> a fan cooled NiMH battery (that's kept well between fully charged and
> fully depleted) to very different.
Yes, big honkin' lead-acid, but not relevant to the point about not
replacing individual cells in the pack.
> > > The hybrid
> > > systems seems to do a fairly simple thing that maximizes the life of
[quoted text clipped - 13 lines]
> cooled. That environment is far more conducive to longer life than
> a tool battery pack.
Quality tools have smart chargers and the battery packs have internal
temperature sensors. Indeed my packs and chargers are all indoors in a
relatively controlled environment, not bouncing around in a car in the
Texas heat.
> Now I don't expect that every last battery pack in every car is going
> to be perfectly reliable over the course of 15 years and 250,000 miles.
[quoted text clipped - 3 lines]
> monitoring/cooling would be worth it for typical consumer electronics
> where I could get another set for less than $10.
The Ni-MH packs for quality tools are typically around $70.
> > > > With the conventional economy car you simply don't have this
> > > > catastrophic end of life scenario. The conventional economy car gets
[quoted text clipped - 15 lines]
> miles. The radiator tank cracked at 130K miles. There were also
> other little things that probably needed servicing.
Those are simple, inexpensive failures and the hybrid is equally subject
to them (a pure EV wouldn't be).
> It was stolen,
> recovered, and declared a total loss. I got a great settlement that
> was more than I could have sold it for.
I don't think a stolen vehicle has much relevance to this discussion.
> > No comment on the Subaru Justy? It was a 3 cylinder 50 some odd HP
> > conventional IC economy car that had plenty of pep, proving your gutless
> > claim false.
>
> I remember the Justy. That sucker was tiny.
Tiny yes, but inexpensive, peppy (chirp tires at will) and pretty
reliable. Rather comparable to the mini cooper, but without the hype or
price tag.
> > > And you're still hauling around that weight and heating up a
> > > full-sized engine block.
[quoted text clipped - 8 lines]
> I thought the typical weight difference between a V8 and an I4 is about
> 200-250 lbs.
Perhaps comparing an aluminum I4 to a cast iron big block V8. There is a
great variety of V8 engines out there covering a huge weight range and
huge displacement range. There are also very nice aluminum V6s that are
more appropriate in a car.
An aluminum V6 with variable displacement is probably not more than 50#
heavier than the engine and electric motor in a hybrid.
> A battery pack is about 100-120 lbs. The battery can be
> placed anywhere you can find it, while a V8 would require more volume
> under the hood.
The battery pack may be 120#, but the framework required to hold it and
give it some protection in an accident adds a lot more weight. Again, an
aluminum V6 is more applicable to a car than a cast iron V8 which
belongs in a truck.
y_p_w - 16 Jan 2007 22:34 GMT
> > The biggest enemy of NiMH battery life are excessive heat,
> > overcharging, and deep-discharge cycles. The latter two are handled
[quoted text clipped - 7 lines]
> have built in temperature sensors. Some battery packs have built in
> intelligence as well with flash memory to track the packs history.
Still - typically no fan cooling which is rare in most applications.
Most people have different expectations for rechargeable batteries.
Charge the battery to full capacity and try to get as much use out
of a single charge is the most typical pattern.
> > I'd expect to see semi-automated equipment. Break down the old
> > battery and insert several cells into the analyzer. Analyzer gives a
[quoted text clipped - 5 lines]
> 90%+ reject rate because all the cells will be about equally worn out in
> almost every case.
Depends on the expectation. Much like there are reconditioned
batteries for low/medium-duty forklifts, I'd expect that there might
be different grades of used batteries for people looking to get the
last 3-5 years out of a hybrid car. The usage pattern is also way
different with only a shallow discharge. I would retire a set of
camera batteries if they were down to maybe 50% of original capacity.
For a hybrid car battery that stays between a small window of charge/
discharge, that might still be acceptable. The meaning of "failure" is
considerably different. The way the batteries are used leads me to
believe that the large majority should be adequate for the intended
duty after 15 years and 250K miles. Those that aren't can be
replaced with known good cells matching the condition of the
original ones.
> > > > NiMH technology has
> > > > been around for a while. Equipment to analyze and recondition
[quoted text clipped - 16 lines]
> Helps maximize the life expectancy of a pack, but either way, all the
> cells will be near death at about the same time.
Again - a much different usage than the fully charged then discharged
pattern that's typical with most consumer/industrial electronics cells.
> > Again - how many applications are designed to keep a NiMH battery
> > from being deep-discharged AND fully-charged? While being fan
[quoted text clipped - 5 lines]
> relatively controlled environment, not bouncing around in a car in the
> Texas heat.
You forgot the part about the battery cooling fan.
> > Now I don't expect that every last battery pack in every car is going
> > to be perfectly reliable over the course of 15 years and 250,000 miles.
[quoted text clipped - 5 lines]
>
> The Ni-MH packs for quality tools are typically around $70.
Just an example. The 7.2V NiMH battery pack for a Canon 1D-MkII
is about $150. However - I think most people can understand what I
was getting at. The expense of replacing a single battery pack for
a camera is considerably less than an entire stack for a hybrid car.
I still contend that the average owner isn't going to need that full
replacement down the line. Those who do will likely have options
other than a complete, brand-new stack that will get it in working
condition for several years.
The Honda Insight battery is rather interesting. I know the car is
rather small, but still an interesting battery design. Essentially 120
D-cells selected specifically because it was a standard size with the
likelihood of multiple sources down the line.
> Perhaps comparing an aluminum I4 to a cast iron big block V8. There is a
> great variety of V8 engines out there covering a huge weight range and
> huge displacement range. There are also very nice aluminum V6s that are
> more appropriate in a car.
I was comparing an aluminum block I4 (typically around 200 lbs) to
an aluminum block V8 (400-450 lbs).
> An aluminum V6 with variable displacement is probably not more than 50#
> heavier than the engine and electric motor in a hybrid.
So far I haven't heard of any. I thought it was mostly used in the
large V8s in GM SUVs. I thought that Cadillac's early attempts were
massively unreliable.