Multistage Revival and Diagnostic Requalification of Severely Imbalanced High Voltage LFP Battery Packs for Electric Vehicles
DOI:
https://doi.org/10.15377/2409-5826.2025.12.8Keywords:
Electric vehicle battery revival, Lithium Iron Phosphate (LFP) battery, Battery diagnostics and requalification, Sustainable mobility and circular economy, Electrochemical impedance spectroscopy (EIS)Abstract
Severely imbalanced or zero voltage (LiFePO₄, LFP) traction battery packs often fail at system level even though most cells remain mechanically intact. In present work, a stepwise revival and diagnostic re qualification method develop that combines soak, CC, and CV charging stages, each operated under strict electro thermal safety control. A 108 cell (63 Ah) HV-LFP pack, disabled due to ΔVstring > 300 mV and BMS lockout, gradually restored using low current soaking (C/40 C/20) followed by CC CV activation. Recovery progress followed through thermal imaging, EIS, and incremental capacity (dQ/dV) analysis to observe changes in resistance and charge transfer kinetics. Across three independent revival experiments (n = 3 HV-LFP packs), recovered capacity ranged from 82 94% (mean 88.1 ± 4.7%), with post balancing ΔVstring reduced to <25 mV and charge transfer resistance decreasing by ~35%, and coulombic efficiency exceeded 98 %. revived packs operated safely under traction load without thermal or insulation issues. Economic evaluation showed roughly 80 % cost saving compared with new module replacement. Embedding revival logic within a BMS can enable safe reuse of aged HV-LFP packs and supports circular economy and sustainable mobility targets.
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