Fast Repair Solutions for Power Battery Packs | BattFix Lithium Battery Maintenance

Driving range has become a key indicator of an electric vehicle’s overall value, and the performance of lithium-ion power batteries directly determines critical factors such as range, safety, lifespan, and charging efficiency. In daily use, battery degradation caused by improper maintenance has become one of the major issues in after-sales service.

To address these challenges, BattFix introduces an innovative rapid repair solution for new energy lithium power battery packs. This solution focuses on precise State of Health (SOH) evaluation, scientific module replacement matching, and efficient module equalization repair — effectively restoring battery performance and improving maintenance efficiency.

Solution Overview

This solution integrates four key steps to achieve fast, safe, and systematic power battery pack repair:

1. Accurately evaluate battery SOH to identify root causes

2. Verify replacement module SOC to ensure balance

3. Perform module equalization repair to fix cell inconsistencies

4. Discharge before shipment to ensure transport safety

1. Accurate SOH Evaluation — Locate the Fault Source

When users report range reduction, the first step is to accurately determine whether a battery fault exists.

Procedure:

• Use the FGCD Series Charge-Discharge Unit to perform a full charge/discharge test on the battery module.

• Analyze discharge data and BMS feedback to calculate the module’s SOH (State of Health) — comparing current capacity with its original rated value to identify the defective section.

SOH reflects a battery’s health level, expressed as the percentage of its current capacity relative to its factory-rated capacity.

2. Verify SOC of Replacement Modules — Ensure System Balance

To speed up repairs, service centers can directly replace faulty modules with pre-tested backup modules.

Procedure:

• Before installation, use the FGCD equipment to adjust the SOC (State of Charge) of the spare module to match the other modules.

• Read cell data through the BMU protocol to ensure all modules within the battery pack are balanced, preventing performance loss due to inconsistent charge levels.

SOC indicates the remaining charge percentage of the battery.

3. Module Equalization Repair — Resolve Cell Inconsistency

Not all faulty modules require scrapping. Many can be restored through equalization repair to recover lost performance.

Technical Advantages:

• Bidirectional synchronous balancing: Increases efficiency by 2–3 times, restoring capacity lost from cell imbalance.

• Voltage clamping stabilization: Maintains target voltage with small current to prevent voltage drop-back.

• Targeted balancing: Supports independent repair of single or multiple cells, ensuring precise recovery.

Repaired modules can be reused as backup modules, reducing maintenance costs.

Note: Modules with physical damage or welding defects should not be repaired to avoid thermal runaway risks.

4. Discharge Before Shipment — Ensure Transport Safety

After repair, discharging the battery to a safe voltage is crucial for transportation safety.

Procedure:

• Use the FGCD Charge-Discharge Unit to lower the repaired module’s energy to a safe transport level in compliance with shipping regulations.

Conclusion

BattFix is dedicated to providing comprehensive intelligent testing and maintenance solutions for new energy lithium power batteries.
By optimizing testing workflows and strengthening quality assurance systems, BattFix helps improve the reliability, safety, and service life of lithium battery products — empowering customers with efficient, professional, and sustainable after-sales service experiences.

Follow BattFix for more professional lithium battery testing and maintenance solutions.