Battery replacement

Many electric car manufacturers have talked about upgrading battery packs - but so far this has been science fiction. NIO has made it possible to change batteries in a short time. In China there are 145 drive-in stations where NIO owners can change the battery pack in 3 minutes! The service is designed as an alternative to fast charging. Instead of waiting 20-30 minutes to charge, you can drive on with a fully charged battery after 3 minutes.

New batteries in a used car? Forget it!

Posted 21/05/2024 by Terje Bjørnstad

Imagine that the high-voltage battery is damaged or stops working. You are happy with the car and want to keep it for many years. But when you ask for a new battery, you may be met with a "no".

New batteries in a used car?

To get to the point, that's not what this article is about whose who pays – whether it is the guarantee, the insurance or yourself. The problem is of a far more serious nature. It will probably not be possible to buy a new battery. You can buy one used battery from a damaged car, or an overhauled battery - or you can have your old battery overhauled. You can probably just forget about a new battery.

Tesla, Norway's best-selling electric car, provides a warranty on the high-voltage batteries for 8 years or 160.000, 192.000 or 240.000 km depending on the model. But the warranty does not say anything about replacing it with a completely new battery. Tesla's own website states that you can get a refurbished battery. In practice, that is exactly what happens. There are several cases reported in the media where Tesla has replaced the battery under warranty with a used - and perhaps refurbished - battery. When it fails again after a much too short lifespan, the warranty period has expired and the car may have a new owner.

The situation is the same for all car manufacturers.

Many car buyers are concerned about battery life and how long warranties last. Few question whether they can really get one news battery should the need arise. It is taken for granted that all spare parts can be purchased throughout the normal life of the car.

Batteries age during storage

There is not much talk about whether high-voltage batteries can be obtained as spare parts. No one knows how big the demand will be, and very few car manufacturers have taken into account the possibility of supplying batteries for 10-year-old cars. Mechanical and electrical spare parts can be stored for 15 years without any problems. Batteries , on the other hand, are a chemical product that deteriorates during storage. In 15 years they will no longer be new. By then they may be in worse condition than the battery you want to replace it with.

Change to a newer battery?

If you have a current electric car that is 4-5 years old, your battery pack is probably already out of production. You cannot simply install newer version batteries in your old car, even if the external dimensions are the same. You have to expect upgrades in the BMS (Battery Management System) and possibly replacing several components. For example, if you are going to upgrade the Tesla 3 or Tesla Y from 75 kWh to 82 kWh, the chassis will also have to be upgraded. On a 4-5 year old car, the costs for all this will easily exceed the value of the car.

Reproduce outdated battery packs?

There are no manufacturers that reproduce new battery packs for older cars. Setting up the production equipment is very expensive, and today a significant proportion of the batteries' cost. Keeping production lines to produce older batteries in small quantities for spare parts weakens both production capacity and profitability.

A future requirement?

Will the future bring a storm of car owners wanting to change batteries? Will usable cars be sent for recycling due to lack of access to battery packs? If that happens, the environmental benefit of electric cars will be weakened, which could force demands from the authorities. However, the most important demand should come from the customers. It must be possible to obtain new spare parts during the cars' expected lifetime! And there are actually good ways to solve this – solutions that the car industry can be forced to follow.

Standards for batteries

Today, fortunately, there are standards with regard to charging contacts. One can imagine the same for batteries, similar to what we have today for batteries for household appliances - also rechargeable. A standard for battery packs may include physical dimensions, protocols and interfaces to cooling systems and control systems. The aim is for it to be possible to replace one battery with another – perhaps with different properties. Another important advantage of standardization is that it can open the way for independent suppliers to supply batteries in the aftermarket. You may not need the largest and most expensive batteries in an old electric car.

Replaceable batteries

Today, only NIO and Dongfeng have developed the technology and infrastructure to replace batteries outside the workshops. If the batteries can be replaced easily and inexpensively, car owners will be able to upgrade or downgrade batteries according to need and finances. NIO has introduced a battery-as-a-service (BaaS) concept that makes it possible to replace an empty battery with a full one in just 5 minutes – and thus not have to wait for charging. NIO owners with this scheme can also choose batteries with other characteristics – 75, 100 or 150 kWh – depending on needs and finances. Exchangeable battery schemes require the car manufacturer – or (in the future) independent battery suppliers – to have a selection of batteries available for replacement at all times.

Stick to current car brands!

Standardization and replaceable batteries can help new car manufacturers enter new markets. If you buy one of the best-selling electric cars such as the Nissan Leaf, Tesla 3 or Tesla Y, you will always be able to have access to used batteries. If you hit the chassis hard on a sharp rock and damage the battery, it can be reassuring to know that the car can be repaired on the insurance. If you buy an unknown car brand that disappears or goes bankrupt after selling a few hundred cars, the accident could mean the end of the car.

See

A post about batteries from NIO House on Instagram

Rent or own batteries?

Posted 20/03/2022 by Terje Bjørnstad

NIO is the only supplier of battery rental with replaceable batteries

If you buy a NIO , you can choose between owning or leasing batteries. Currently, this is the only car manufacturer that offers leasing batteries. Renault ended the scheme in 2021. Leasing never caught on very well in Norway.

Should be able to change batteries

Renault Zoe and Kangoo ZE were electric car pioneers. When Zoe appeared in 2012, there was not much experience with how long the batteries would last. Evil tongues said that when the batteries were exhausted, the only thing to do was scrap the car. Renault offered battery rental to assure customers that they would never have to worry about just that. Another point was to be able to offer upgraded batteries with better range - when the time came. But when Renault came out with a 41 kwh battery it was not practically possible for owners of cars with a 22 kwh battery to switch. Thus, one of the advantages of renting batteries fell away.

NIO changes the battery in 5 minutes

Changing the battery on an electric car normally takes a full working day – maybe more. When the Møller chain had to change the battery boxes on its hybrid cars, the cars had to be in the workshop for 3-4 days. Tesla considered making arrangements for replaceable batteries for a while but abandoned it. Chinese Dongfeng was probably the first to offer replaceable batteries in its Aeolus E70 model when it came out as a 2017 model. NIO is, by comparison, a completely new car brand. They change batteries in 5 minutes from their own “battery swap” stations – the first of which was recently set up at Kjellstad in Lier outside Drammen. There, NIO owners can drive by to have their discharged battery replaced with a fully charged one.

Battery as a service

Battery replacement is reserved for NIO owners who rent batteries. It is a kind of subscription – Baas (Battery as a Service). The concept not only ensures that you save time on charging, but you always get a good battery – even when the car is 10 years old.

Do you need to change the battery?

Renault justified its termination of battery rental by saying that it was not necessary. There were practically no cars that needed a new battery. Tesla is experiencing the same thing – rightly so after a period of production errors. In any case, the batteries will gradually lose capacity after many charges, but that can be accepted with a car that is starting to age. Although there is currently no exact answer, since few modern electric cars have managed to be over 10 years old.

The problem with the oldest electric cars today is not that the batteries have run out of capacity, but that the original batteries had too little capacity. Early models such as the BMW i3, Mercedes B Electric, Nissan Leaf and Volkswagen e-Golf with a range of around 160 km do not keep up with today's electric cars. However, the cars could have been given a new lease of life if it were possible to upgrade the batteries with more powerful battery packs.

Always the latest battery technology

The NIO ES8 can be delivered with either a 75 kWh battery or a 100 kWh one. By renting batteries, you can change subscriptions during the life of the car. If you don't need 100 kWh, you can downgrade to 75 for a lower rental. The biggest advantage of NIO's scheme is that you can upgrade to newer battery technology. In Q4 (2022), NIO has said that they will come with a 150 kWh solid-state battery. The Dongfeng E70 was launched with solid-state batteries earlier this year, so there is every reason to trust NIO's plans. What is impressive is that cars with "old" battery packs will be able to upgrade to solid state - a promise made for the sedan version ET7 for now.

Profitability

If we look at it soberly, few electric cars will need to change the battery pack more than once during a lifetime of 15-20 years - most will get by with none. We take NIO ES8 Signature as an example, the following prices are available:

Car only: 609
Rental of battery 75 kwh: 1399 per month
Rental of battery 100 kwh: 1999 per month
Buy battery 75 kwh: 90
Buy battery 100 kwh: 160
Work to replace battery: 0

Keep the car for 5 years

Car with 100 kwh battery:
Purchase price without battery: NOK 609
– with battery: NOK 769
Assuming a car purchase financed with 35% cash and a 5-year loan with a loan interest rate of 2,95% pa
Monthly cost upon purchase: NOK 9
Monthly rental expense: NOK 9 (car: NOK 232 + battery: NOK 7)

-75 kwh battery:
Purchase price without battery: NOK 609
– with battery: NOK 699.
Assuming a car purchase financed with 35% cash and a 5-year loan with a loan interest rate of 2,95% pa
Monthly cost upon purchase: NOK 8
Monthly rental expense: NOK 8 (car: NOK 632 + battery: NOK 7)

The monthly sums are about the same. Profitability here is determined by what the sale/trade-in price will end up at. How will secondary market buyers value the battery rental scheme?

Save instead of rent

After 5 years, the car will be paid off. Given that the person who chose to buy the batteries continues to save the corresponding rental amount to accommodate a battery replacement when the car is 15 years old. The savings will give the following amounts – given that the savings interest rate is 0,35% pa:

Savings for a 100 kwh battery:
10 years of savings with monthly payments of NOK 2 (equivalent to rent for a 000 kwh battery) will yield NOK 100. A 244 kwh battery costs NOK 278 today, but will probably cost quite a bit more in 100 years.

Savings for a 75 kwh battery:
10 years of savings with monthly payments of NOK 1 (equivalent to rent for a 400 kwh battery) will yield NOK 75. A 170 kwh battery currently costs NOK 994, but is expected to cost more in 75 years.

Noted in the margin

NIO's battery rental under the "BaaS" scheme consists of 2 free battery changes per month with 200 kwh of free electricity. Until recently, the first customers of the NIO ES8 received a pioneering package which included, among other things, 6 free battery changes per month. This has stimulated many to choose to rent rather than own.

The battery changes in the example are based on the fact that NIO can change the battery without an expensive workshop visit. For all other electric cars on the market, a battery change will take at least one day at a workshop - which we estimate at NOK 20 or more. This is in addition to the battery prices.

Even if you save for a possible battery replacement, many will find it unprofitable to carry out a battery replacement on a car that is, for example, 15 years old. The car will then very likely be worth less than the cost of switching. In this way, the owner can count the residual value of the car as lost. Seen from a life cycle perspective, this is a cost to take with you in favor of renting batteries.

nine norway — Interior ambiance in NIO ET7

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XBUS with interesting technology

Posted 22/11/2021 by Terje Bjørnstad

Prototype II. Variant "Freedom" without selected superstructure. (Source: Electric Brands)

It is reminiscent of the original Volkswagen bus but is not a retro model. Packed with ultra-modern solutions such as replaceable batteries, solar cells and an electric motor on each wheel, it could have an impact on future electric car models.

In the character of the Volkswagen bus

Next year, two German bus projects will start production. Volkswagen will open orders for its new ID.Buzz, while Electric Brands will start production of the XBUS. This summer, they showed off a rolling prototype that is reminiscent of Volkswagen's previous double cabins. The resemblance to old Volkswagen buses is striking – both in form and function. But the XBUS is no retro car – it represents innovative solutions. If the concept is successful in the market, we could see major changes in how future electric cars are built. It's all about light weight, shape and battery technology. Let's start with the latter.

Replaceable battery packs

Imagine that the battery packs are physical packs that you can lift out yourself and replace with new, fully charged ones - as quickly as you fill up with fuel. XBUS is supplied with 8 battery packs, each providing 1,25 kwh - a total of 10 kwh. It's not very much, but due to light weight and extremely low energy consumption, the stated range is a decent 200 km. The battery capacity can be increased afterwards if desired. There is room to triple the original capacity. With a maximum of 24 packs, you get 30 kWh and a range of up to 600 km.

xbus — All-terrain tyres, high ground clearance and off-road chassis

Light weight

It may seem that the development of electric cars is moving in the direction of increasingly larger and heavier vehicles to meet increasing demands for range, space and engine power. Electric Brands has done the opposite and reduced weight and energy consumption. XBUS has a consumption of between 5-10 kwh/100 km, which is less than half of what a medium-sized electric car uses. One motor placed at each wheel is considered energy-optimal. Total power is 20 HP with a boost effect of 75 HP. You thus get 75 horses to accelerate onto the motorway, but only 20 when you have reached cruising speed. But in the bottom draft there is a whopping 1000 Nm (!) so that you should be able to keep the speed both in headwinds and headwinds.

Can be registered as a motorcycle

Not surprisingly, the XBUS meets the requirements of EU vehicle class L7e – 4-wheel motorcycle. The net weight is stated to be between 500-800 kg without batteries - while the total weight is 1600. The largest version with a cabinet has a cargo space of 5,3 cubic meters and should be able to take 2 Euro pallets. As a motorcycle, you avoid tolls. The disadvantage is that there are not as high safety requirements for such vehicles. Safety is an aspect that many question in the XBUS concept - in the same way as in the first Volkswagen buses.

Gear selector on the steering wheel and infotainment system from Google?

Reminds a lot of the Volkswagen buses

As mentioned, Volkswagen is in full swing developing its new electric Volkswagen bus, called ID.Buzz. The very first sketches gave the impression of a micro-vehicle, while today's prototype looks more like an upgraded Sharan. Today's Transporter and Caravelle have long since outgrown the class to which the first air-cooled models belonged. The XBUS, on the other hand, has many similarities with Volkswagen's original bus. First, it has an almost hidden drivetrain. The motors sit outside by the wheels and the batteries sit either behind or in the middle (optionally) under the load compartment. Another feature that links the XBUS to the original bus concept is its weight. It is a light bus that can be driven by modest engine power - just like the T1 which ran fine with the 1200 engine from the bobble.

Made in Germany

Electric Brands emphasizes that XBOX is a German project. The technology was developed in Ingolstadt – and it should not be ruled out that they have brought in smart heads from Audi. Production will take place in Itzehoe further north. Electric Brands has announced that production will begin in 3 months – that is, 2022 Q2. You can order online. Prices start at 146,600 kroner for the most affordable basic model without a body. There are two chassis to choose from – “offroad” and “standard”. The offroad chassis can make the car turn “on a dime” using individual power on the wheels. A double cabin of the “Open!” type costs 193,000.

This is a variant of Pickup called "Open!".

Flexible superstructure

One of the great advantages of XBUS is that it can be adapted to various utility needs by choosing add-ons. Imagine the original Volkswagen bus, then you have single cabs, single cabs with tipping, single cabs with cupboards, double cabs (two versions), van version and bus. In addition, there is a slightly crazy camping car with sections that can be pulled out in width and height. It must be possible for owners to rebuild from one extension to another using common tools.

Charging via solar cells

Some of the models with a certain roof area can be equipped with solar cells that add extra power to the batteries - a "range booster" that can provide up to 200 extra km per day. Charging the standard battery pack via 220 V is stated to take 2-5 hours. With Type2 cable, the car can take 11 kw. There are no options for fast charging, but the standard batteries may not be necessary either.

No representative in Norway

XBUS is represented all over Europe, including the neighboring countries of Sweden and Denmark. In Sweden, several representatives are also dealers for Volkswagen and Skoda. Could there be some hidden connections – or sympathies – between someone in the Volkswagen group and XBUS? In the electric car country of Norway, however, there is no representative. It's a shame, because this is a tough vehicle with a high utility value for both private individuals and traders in the field of goods distribution.

Updated 14.05.2023/XNUMX/XNUMX: Norwegian retailer chain on ElectricBrand's map – Autoria with headquarters in Ski.

If everyone is to buy electric cars by 2030, it is important to stimulate the development of lighter cars. What environmental benefit are we left with when the electric car fleet is dominated by increasingly heavier vehicles?

Facts about XBUS

Weights and Measures
Length, width, height in cm: 395 x 169 x 193(199)
Weight without driver and batteries: 500-800 kg depending on configuration
Total weight: approx. 1600 kg
Max loading volume: 5,3 cubic meters (box car)

Drivetrain
Electronically controlled 4-wheel drive with 4 separate motors.
Performance: 20 HP with a boost effect of 75 HP.
Torque: 1000 Nm
Top speed: approx. 100 km/h

Battery and charging
Power: Standard 8 battery trays each of 1,25 kwh for a total of 10 kwh. Expandable to 24 packages for a total of 30 kwh.
Range: Up to 200 km with standard batteries. Up to 600 km fully developed.
Charging (standard battery): 220V charger, 2-5 hours
11 kw Type2, "much faster".
Fast charging not possible.

About the vehicle

Brand: Electric Brands
Model: XBUS
Owner: emobs GmbH – electric mobility solutions
Planned production: Itzehoe, Germany
Price in Sweden: NOK 146 ("Freedom" - standard chassis), NOK 600 ("Open!" - standard chassis). The prices are e.g. VAT in Sweden. Electric motorcycles are exempt from VAT in Norway.
Source: electricbrands.de. The website emphasizes that all information is preliminary and may be changed during production.

See

Manufacturer's websites

Child — NIO changes the battery in 3 minutes

NIO changes batteries in 3 minutes

Posted 21/03/2021 by Terje Bjørnstad

3 months ago we wrote about the Chinese car brand NIO, which is shooting up the Chinese sales charts. We then wrote that the brand had no Norwegian representative. Now they have - NIO Norway.

The automobile industry in China has a huge domestic market. So big that Western car manufacturers have established their own factories for the Chinese market, and of course there are many Chinese brands we have barely heard of here at home, which produce cars at high speed to meet domestic demand. China has introduced a "New Energy" program to stimulate the production of zero-emission cars. This has provided good conditions for the development of models that are also interesting for Norway.

Chinese cars at full speed to Norway

For now, it seems that it is Chinese MG, XPeng, BYD and Maxus that have gained a hold on the buyers. The model series DFSK and Seres from Dongeng-Sokon will soon be sold through the Gill/Subaru chain. RøhneSelmer was relevant for a while as a dealer, but seems to have withdrawn. The former luxury car brand Hongqi is in the process of establishing car sales in Norway. NIO is currently the last brand to have a Norwegian representative.

boy es6 — The NIO ES6 is an electric SUV with 4-wheel drive and a large battery pack

NIO Norway

The company was registered earlier this month (March 2021). The general manager is Marius Hayler who until recently was general manager of BC Norway - importer of Jaguar and Land Rover. Considering the success of the Jaguar I-Pace, it's safe to say that Hayler has succeeded in bringing an electric car outsider high up the sales charts. NIO Norway is currently a newly started small company apparently subject to a European umbrella organisation. But NIO Norway is not without importance. According to press reports, it is Norway that has been designated as NIO's first export market. It is currently uncertain how the company will organize marketing, sales and follow-up.

NIO Norway on Facebook

Leading battery technology

Last year, NIO came out with the model ES6. This year, a larger model, the ES8, has been launched. Both can be delivered with either a 70 kw or 100 kw battery – on par with Tesla's largest battery. NIO has announced that it plans to launch a 150 kw "solid state" battery in Q4 2022 for its new self-driving "Tesla-killer" ET7. Car owners with 70 and 100 kW batteries will be able to upgrade their cars with the new super battery. If this is true, NIO will be one of the very first to offer "solid state" battery technology - and the first electric car manufacturer to make it possible to upgrade battery packs.

Battery change in 3 minutes

Many electric car manufacturers have talked about upgrading battery packs – but so far this has been science fiction. NIO has made it possible to change batteries in a short time. In China, there are 145 drive-in stations where NIO owners can change the battery pack in 3 minutes! The service is designed as an alternative to fast charging. Instead of waiting 20-30 minutes to charge, you can continue driving with a fully charged battery after 3 minutes. According to NIO's own video, everything happens automatically, but in reality it requires a lot of manual work. For example, you are not allowed to reverse the car into the changing station yourself. It is true that there is a machine that unscrews the battery, but in the video below you can clearly see a guy in the background operating a lever or something similar. The actual change takes place in 3 minutes, assuming there is no one ahead of you in the queue – and assuming the station has fully charged batteries available. Each station can only have 14 battery packs inside at the same time. In practice, there can sometimes be long waiting times for this service.

Hardly for Norway

Changing batteries "on the go" is hardly something you should do unless you rent battery packs. Who wants to replace the battery pack from their new car to continue driving with the battery pack from a 2-year-old taxi? Renault is one of the car manufacturers that has come the furthest in offering battery rental. It is available in the rest of Europe, but not in Norway. We prefer to own – not rent.

Extended service offer in China

Like Tesla, NIO offers free roadside charging via its own charging network. They can build that in Norway too. But one of the offers that is unlikely to be implemented in Norway is a mobile charging service where car owners can order charging at the touch of a button, no matter where they are. The electricity is then delivered from a van – an electric van of course. Another service is “24/7 On-Call Valet Charging” where someone will come and pick up the car and return it with a fully charged battery. With the well-developed charging networks we have in Norway, it is difficult to see any need for anything other than self-service charging stations.

It will be interesting to follow the development in NIO. Maybe in two years we can buy premium electric cars with "solid state" battery technology and a range of 1000 km?

Facts

NIO ES6 100 kw
Range converted to WLTP: 480-520 km
Range NEDC: 610 km
544 HK
0-100: 4,7 sec.

NIO ES8 100 kw
Range converted to WLTP: 460-500 km
Range NEDC: 580 km
544 HK
0-100: 4,9 sec.