Toyota Is Recycling Old EV Batteries to Help Power Mazda's Production Line

Re:Toyota Is Recycling Old EV Batteries to Help Power Mazda'... by DanielHB on Thursday August 28, 2025 @07:43AM (#45050970)

Balancing multiple battery packs at different wear levels is a huge nightmare. You have to run rebalancing operations all the time and on used packs it can be quite dangerous to trigger a thermal runaway.

If they do it with different types of batteries it is even more complicated, like you need to write some custom software to sync all that up. This is not a trivial project.

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Re:Toyota Is Recycling Old EV Batteries to Help Power Mazda'... by rojcyk on Thursday August 28, 2025 @08:07AM (#45051163)

So? They considered it to be worth while for them. Thus are working on it.

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Re:Toyota Is Recycling Old EV Batteries to Help Power Mazda'... by DanielHB on Thursday August 28, 2025 @08:18AM (#45051263)

I know, it seems it is fairly large operation however, if it wasn't I would assume it was a PR stunt.

This is definitely not worth doing for small scale operations. As far as I know there is no generic solution for doing this kind of thing (I used to work in the area, but not directly on the BMS systems).

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Re:Toyota Is Recycling Old EV Batteries to Help Power Mazda'... by rini17 on Thursday August 28, 2025 @08:53AM (#45051587)

They reuse inverters too. So the packs are separated, no need to balance.

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