Fisker Karma Hybrid battery replacement

Fisker Karma Hybrid battery replacement.

The North American manufacturer Fisker Automotive, based in California, began manufacturing its extended-range electric sports sedan, the Fisker Karma.

Fisker Karma, extended range electric car. (see the picture)

The Fisker Karma is a four-door, four-seat, 4.99 m long (1.33 m high) sports sedan with rear propulsion. It has two electric motors of 150 kW each (204 HP) and a two-liter, four-cylinder, direct injection and turbo gasoline internal combustion engine of 260 HP (191 kW).

It has a 20 kWh lithium-ion battery pack that allows it to have a range in exclusively electric mode of about 83 km. When the batteries run out, the gasoline engine comes into operation to generate electricity and keep the two electric motors running.

It has two modes of operation:

In Stealth mode, that is, electric only, the maximum speed is 153 km/h and acceleration from 0 to 100 km/h is 7.9 seconds.
In Sport mode, this is with the gasoline engine running to feed electricity to the electric motors, the top speed is 200 km/h and acceleration from 0 to 100 km/h is 5.9 seconds.
The batteries recharge in about six hours from a 230 V (16 A) outlet.

The brakes are regenerative and recharge the batteries somewhat when braking gently (by the way, they are Brembo).

Photovoltaic solar cells

The glass roof incorporates photovoltaic solar cells to provide a small amount of additional electrical energy to power the air conditioning system.

(see the picture about photovoltaic solar cells)

This car arrived from Switzerland a our company Servo Motors Adjust  with a problem in HVB system.

The car has problem on the HVB system. Sometimes that car stops, while you’re driving it. And then to get back to run could be after some hours or somedays. And the car it’s new, just 4000km.
We proceed to diagnose the vehicle and after this, to remove the HVB, and test module by module all the cells and the capacity, internal resistance, etc….

 

The following images show the hybrid battery have 15 moduls.

 

The Fisker Karma we pay a lot of attention since we unfortunately know the routine problems in these cars of early battery failure a like this case 4.000km only.

How did we perform the hybrid battery repair?

The first step was to carry out a diagnosis of the symptoms that the hybrid vehicle presented, in order to identify the main cause. In this phase it is essential to carry out an exhaustive analysis to get to the bottom of the problem. Some of the tests we performed were:

High Voltage Hybrid Battery Cooling System inspections.
Inspection of the high voltage cable.
Insulation test.
Removal and replacement of the hybrid electric battery.
Checking the status of the electronic power systems.

Programming vehicle control module (VCM)

 

Once the hybrid system had been repaired, we could see that the vehicle already worked in EV (electric)