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Introduction
Almost every device we use these days, from smartphones to vehicles, relies heavily on batteries. With technology becoming more advanced, battery demands are only increasing. Unfortunately, batteries have a limited lifespan and need to be replaced after some time. However, did you know that old batteries don’t necessarily need to be thrown away? Battery rebuild service can potentially give your old battery a new lease of life.
What is battery rebuild service?
Battery rebuild service involves completely dismantling an old battery and rebuilding it from scratch. The process involves rebuilding each individual cell within the battery. Technicians carefully inspect each cell for damage. Any damaged or worn out components are replaced. Cells are then reformed using sophisticated machinery to restore their holding capacity. The battery is then reassembled and quality tested before being returned.
Why opt for a battery rebuild?
There are several advantages of opting for a battery rebuild over a new replacement:
Cost savings
A rebuilt battery costs significantly less than a brand new one. For example, rebuilding a car battery can cost 40-60% less than purchasing a new unit of the same specifications. This provides substantial savings, especially for expensive battery types like those used in commercial vehicles.
Environment friendly
Rebuilding batteries is more eco-friendly than constantly disposing of old units and producing new ones. It reduces battery waste ending up in landfills. The process reuses components from the original battery wherever possible.
Extended lifespan
A properly rebuilt battery, when installed and maintained correctly, can potentially last as long as a new unit. The rebuild restores the battery’s charge holding capacity close to its original rated performance. This effectively extends the useful working life of the battery.
Availability of discontinued models
Some obsolete or niche battery models may no longer be manufactured but can still be rebuilt to like-new condition. This ensures continued availability and usability of batteries that would otherwise become non-replaceable.
The battery rebuild process
Here are the key steps typically involved in professionally rebuilding an old battery:
Disassembly – Technicians disassemble the battery by carefully removing each individual cell compartment. All inter-cell connections are cataloged for accurate reassembly.
Inspection – Each cell is inspected under magnification for cracked or damaged casings, worn plates or separators, and other visible flaws. Cells are also performance tested.
Plate cleaning – The positive and negative plates within good cells are thoroughly cleaned using an acid bath to remove any build-up or debris.
Plate/separator replacement – Any plates or separators found to be damaged or worn out during inspection are replaced with new high-quality components.
Cell reformation – Cells are reformed using controlled overcharging to restore their charge holding ability. On-board microprocessors precisely monitor and optimize the process.
Reassembly – Cells are reassembled in their original configuration with all inter-cell connections restored as per the cataloguing done during disassembly.
Quality assurance testing – Finally, stringent testing ensures the rebuilt battery meets or exceeds its original rated performance specifications before release.
Types of batteries suited for rebuild
Some common battery types that are well-suited for professional rebuilding include:
– Lead-acid batteries used in vehicles, machinery, UPS systems, etc. These account for the majority of rebuilds due to their widespread use.
– Flooded lead-acid batteries are more rebuildable than sealed AGM/Gel variants but both can be effectively rebuilt.
– Bulk storage batteries used in solar/off-grid, telecom, and industrial applications.
– Forklift batteries regularly serviced and monitored for rebuild are good candidates.
– Some niche battery types like motive power and marine batteries can also be rebuilt by specialized shops.
– Lithium-ion batteries are becoming increasingly rebuildable with advances in techniques but require more specialized skills.
How to identify a battery for rebuild
Here are some signs that indicate an old lead-acid or flooded lead-acid battery may be a good candidate for professional rebuilding:
– Over 3 years old but has at least 50% of its original charge holding capacity remaining.
– Has no physical cracks or leaks in its casing or terminals.
– Individual cells are performing relatively equally without any bad ones.
– Has been regularly monitored and properly maintained with correct water and charging levels.
– Gives its original rated reserve capacity and cranking amps during performance testing.
Batteries beyond 6-7 years, or those showing uneven cell performance or physical flaws, may not be cost-effective to rebuild. It is best to get an expert assessment.
Factors affecting rebuild cost and lifespan
The cost of a professional battery rebuild can vary based on the:
– Battery type (cars cheaper than commercial trucks usually)
– Battery size and number of cells
– Extent of repairs and component replacements needed
– Quality of components used during rebuild
– Warranty period offered on the rebuilt battery
Provided it receives correct maintenance post-rebuild, a professionally rebuilt lead-acid battery can last 3-5 years, matching a new battery’s lifespan. Proper charging, water levels, and storage conditions are key to maximizing the rebuild’s life.
Conclusion
In conclusion,Battery rebuild service offers an eco-friendly and cost-efficient solution for continuing the use of old batteries that would otherwise be discarded. When done by an experienced technician, rebuilds can essentially restore a battery to like-new working condition at a fraction of replacement cost. For the right candidates, rebuilding is a very viable option worth considering over direct replacements. It extends product and battery life through reuse.
*Note:
1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it
