Tag Archives: Battery

News

Volkswagen ID.3 Retains 91% Battery Capacity After 160,000 km Endurance Test

In a landmark assessment of long-term EV durability, Germany’s ADAC has completed a rigorous four-year endurance test of the Volkswagen ID.3 — and the results are a major win for the electric mobility movement. After covering more than 160,000 kilometres under demanding conditions, the ID.3 Pro S retained an impressive 91% of its original battery capacity, far exceeding expectations.

Tested at the ADAC’s Test and Technology Centre in Landsberg am Lech, the ID.3 Pro S — equipped with a 77 kWh battery — was subjected to an aggressive usage profile designed to accelerate battery wear. Over 40% of its charging sessions used DC fast chargers, and the vehicle was often left fully charged for days at a time, both conditions known to stress lithium-ion cells. Despite this, the ID.3’s battery degradation remained minimal.

Martin Sander, Volkswagen Board Member for Sales, Marketing and After Sales, commented on the results: “A high battery capacity of over 90 per cent after 160,000 kilometres confirms that our ID. models are also very attractive as used cars and continue to meet the requirements of our customers.”

Notably, this was the first endurance test conducted by the ADAC on a member of Volkswagen’s all-electric ID. family. Between test drives, engineers frequently inspected the car’s battery health, chassis, and software performance — areas that could show early signs of wear in EVs subjected to extreme usage.

Volkswagen’s commitment to over-the-air updates also played a pivotal role in the ID.3’s performance. Throughout the test, the vehicle received several software upgrades, including the Electric Vehicle Route Planner. This intelligent feature calculates the most efficient charging stops on long routes, considering traffic and energy usage forecasts. Other updates improved power consumption, especially during short trips and colder weather conditions — a critical factor for European buyers facing winter range anxiety.

Beyond the battery, the ID.3’s mechanical integrity also stood strong. ADAC engineers reported that the chassis, axles, and steering remained in solid condition, with no major faults or weaknesses despite the high mileage.

For consumers still wary of the longevity of electric vehicles, the ID.3’s performance is a reassuring data point. Volkswagen backs the battery of every ID.3 with a guarantee of at least 70% capacity after eight years or 160,000 kilometres — a threshold the tested vehicle surpassed with ease.

ADAC’s recommendation is clear: keep your software up to date to enjoy the full potential of your EV. And if you’re in the market for a used electric car, the ID.3 might just be one of the most reliable choices out there.

Source: Volkswagen

News

Daimler Truck Advances Circular Economy with Reworked High-Voltage Batteries

Mercedes-Benz Trucks is advancing its commitment to sustainability and circular economy principles with the launch of the CB400 reworked high-voltage battery, a genuine spare part now available for the first-generation eActros 300/400 and the eEconic. This initiative marks a significant step in extending battery lifecycles and reducing CO₂ emissions across Daimler Truck’s electric commercial vehicle portfolio.

Developed at the Kompetenzzentrum für emissionsfreie Mobilität (KEM) in Mannheim, the CB400 project underscores a strong push toward resource-efficient vehicle maintenance. Used batteries are collected, disassembled, cleaned, and rebuilt to meet current series standards—ensuring like-new performance, verified safety, and full software compatibility.

Cost-Effective, Carbon-Conscious

Compared to producing brand-new units, each reworked CB400 battery helps cut CO₂e emissions by approximately one third, thanks to the reuse of high-quality components. Those batteries deemed unfit for refurbishment are recycled responsibly, and many are earmarked for future second-life applications, such as stationary energy storage systems.

“With the CB400 reworked concept, we offer our customers a cost-efficient and sustainable solution that reuses high-quality components, thereby reducing resource consumption and greenhouse gas emissions — all while maintaining consistently high quality,” says Christian Vrbek, Team Leader for Remanufacturing Zero Emission Vehicles at Daimler Truck.

Tested, Trusted, and Backed by Warranty

Each CB400 battery is thoroughly tested for function and leaks, updated with the latest software, and backed by the Mercedes-Benz Trucks parts warranty. Compatibility across various power levels ensures a seamless fit with the installed battery packs in both the eActros and eEconic models.

Bridging Past Innovation to Future Vision

Although production of the current-generation eActros 300/400 ends later this year, demand for reliable spare parts remains high. The CB400 offering ensures that fleet operators have an economically and ecologically viable solution to support vehicle uptime and performance. Simultaneously, insights from this project are already informing the development of future batteries, including the CEB500, destined for the next-gen eActros 600.

The roots of the CB400 project stretch back to a student initiative in 2021. It has since evolved into a multi-disciplinary innovation blueprint, setting new standards in commercial vehicle battery refurbishment.

The Backbone of Battery Innovation

Mannheim plays a crucial role in Daimler Truck’s electrification strategy. The Battery Technology Center (BTC), spread over 10,000 square meters, combines development and prototyping under one roof. This facility focuses on cell manufacturing knowledge, pilot-scale production, and the creation of test batteries for validation.

The broader Mercedes-Benz Mannheim plant, founded in 1908, is now a cornerstone for electric powertrain development and production. With over 4,600 employees, it supports engine and component manufacturing, training over 11,000 apprentices to date.

As Robert Braun, Head of the KEM, notes: “Every Daimler Truck vehicle with an alternative drivetrain carries a piece of KEM expertise.” With three decades of experience and a dedicated focus on alternative powertrains, the KEM is central to shaping the future of zero-emission mobility.

Source: Daimler Truck

News

AI Extends Battery Life in Porsche’s Next-Gen Electric Vehicles

Artificial intelligence (AI) is rapidly reshaping the automotive industry, and Porsche is at the forefront of this transformation. As vehicles become increasingly digital and electric, AI has emerged as a vital tool in managing complex systems—particularly high-voltage battery storage.

Modern electric vehicles are equipped with a vast array of sensors that generate massive amounts of data. Traditional software systems can no longer handle this volume efficiently. Porsche leverages machine learning and AI to sift through this data, uncovering valuable insights about battery performance, aging, and safety.

High-voltage batteries are intricate systems influenced by a range of internal and external factors. Porsche engineers now use AI to better understand how these influences affect the battery’s energy system. This analysis helps identify anomalies and optimize the design and operation of the battery—ultimately enhancing vehicle performance and longevity.

One of the most significant breakthroughs is AI’s ability to detect irregularities in the battery early in the development process. By analyzing the charge balance—known as “balancing”—between individual battery cells, AI algorithms can spot deviations that suggest deeper issues. This insight accelerates troubleshooting and improves the reliability of battery data gathered from real-world driving.

AI also plays a key role in identifying previously unknown contributors to battery aging. Using advanced analytics and physicochemical modeling, Porsche can forecast how batteries will degrade over time. This enables developers to fine-tune performance criteria such as charging speed, range, weight, and durability.

To ensure transparency and trust, Porsche employs “explainable AI” methods. These tools allow engineers to clearly understand how conclusions are drawn from complex data, ensuring every decision is grounded in reliable, interpretable insights.

A standout innovation is Porsche’s “preventive anomaly detection,” used for the first time in the upcoming electric Macan. This system analyzes battery behavior in real time, identifying anomalies in individual cells and assessing their technical relevance. If an issue is found, Porsche proactively informs the driver via the MyPorsche app, offering tailored guidance.

By combining cutting-edge AI with engineering expertise, Porsche is setting new standards in electric vehicle development. The result: longer battery life, enhanced safety, and smarter, more responsive vehicles for customers worldwide.

Source: Porsche