Peugeot has released a brief but interesting description (with photos) of the assembly and testing process for the battery packs that go into its plug-in cars and vans.
Peugeot Product Director Jérôme Micheron described the automaker’s plug-in offerings: “Peugeot provides a wide range of electrified vehicles with the full-electric e-208 and e-2008. The New 408, the New 308 (hatch and SW) as the 3008 and 508 (fastback and SW) come with plug-in hybrid engines. The LCV [light commercial vehicle] offer is complete with 100% electric versions, with e-PARTNER, e-EXPERT and e-BOXER.”
More than 70% of Peugeot’s current models are available in electrified versions, and this proportion will grow to 100% by 2025. This will require a substantial increase in the supply of batteries—Peugeot estimates that it will assemble up to 10,000 batteries per month for its car range by next year, and as many as 7,000 batteries per month for its LCV range.
Peugeot assembles battery packs at its factories in Spain, Slovakia and France. Technicians, each of whom undergoes a month-long special training period, take roughly 60 minutes to assemble each 50 kWh battery pack from pre-assembled cells and components. The larger 75 kWh packs take about 90 minutes.
Peugeot guarantees that its battery packs will retain 70% of their capacity for 8 years or 100,000 miles.
Each battery is tested to ensure its reliability, performance and lifecycle before going to the assembly stage. The first test simulates operation of the battery in a vehicle to validate reliability, then a performance test “stimulates the battery at full rate.” In the last test, the battery unit is pressurized by gas to check for leaks by monitoring pressure loss. A proper seal prevents water or dirt from getting inside the pack and compromising its lifecycle or performance.