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Autocraft EV Solutions has launched a diagnostic test designed to help original equipment manufacturers (OEMs) avoid costly electric vehicle (EV) battery recalls. The new technology, Latent-IQ™, identifies hidden, cell-level faults within high-voltage batteries before they can lead to safety issues or unnecessary waste. With EV battery-related recalls surging over 500% in recent years, this solution addresses what has become a “billion-dollar headache” for the automotive industry.
Key Highlights
- Autocraft EV Solutions has introduced Latent-IQ™, a new diagnostic platform to detect latent faults in EV batteries.
- The technology is designed to prevent massive, multi-billion-dollar recalls for vehicle manufacturers by identifying potential issues early.
- Latent-IQ™ can pinpoint internal defects that traditional diagnostics cannot, such as torn tabs, separator damage, and cracked welds.
- By enabling precision repairs instead of full replacements, the service helps avoid significant financial costs and reduces environmental impact.
Addressing a Critical Industry Challenge
Without deep diagnostic insight, manufacturers often have to replace entire battery packs, scrapping numerous functional sub-components in the process. Autocraft’s Latent-IQ™ utilizes a proprietary stress test integrated into its OptEVizer® platform to uncover these hidden defects. This deep-level analysis provides results within hours, allowing OEMs to effectively triage recalled battery packs, prioritize those with genuine risks, and avoid needless replacements.
Mike Hague-Morgan, Executive Director at Autocraft Solutions Group, noted that while rare, latent defects can lead to thermal events and costly recalls if not detected. “Major recalls can undermine public confidence in EVs, which Latent-IQ™ helps to restore,” he stated. “It’s about smarter, faster decisions that catch faults at the earliest possible stage.”
Proven Technology and Environmental Benefits
The development of Latent-IQ™ was informed by Autocraft’s extensive experience in battery repair and its pioneering use of digital twin technology. By analyzing thousands of datasets, the system identifies deviations from expected performance, pinpointing the root cause of faults with high precision. The technology has already been successfully piloted with multiple OEMs, including in blind tests where it correctly identified faults without prior information.
A significant benefit of this approach is its positive environmental impact. According to academically verified data from the RECOVAS project, repairing a single 82.5kWh EV battery prevents approximately 12 tonnes of avoidable CO₂ emissions compared to replacing it. When scaled across thousands of batteries, these savings represent a major environmental contribution.
Availability
Latent-IQ™ is now available through Autocraft’s REVIVE® outsourced battery repair and remanufacturing service, with operations in Grantham, UK, and Arnhem, Netherlands. The company has plans for further global expansion to meet the growing demand from vehicle and battery manufacturers worldwide. This scalable solution empowers OEMs to make better decisions, protecting them from the financial and reputational damage of large-scale battery recalls.
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