Summary of Key Points
Recently, a large number of owners of GAC AION S vehicles used for ride-hailing services have encountered battery failures: the 177Ah lithium iron phosphate batteries produced by Zhongxin Innovation Aviation have developed issues such as swelling, liquid leakage, and sudden power outages while driving (these batteries have been jokingly referred to as "banana batteries"). Many of these vehicles have traveled 150,000 to 250,000 kilometers, leaving owners to bear the cost of replacing the batteries at their own expense, which can amount to 80,000 yuan. GAC AION has extended the warranty period (8 years/300,000 kilometers) but has not initiated a recall; Zhongxin Innovation Aviation is involved in providing maintenance services for these batteries. This incident exposes an industry flaw where the battery design and testing for commercial vehicles did not differentiate from those for passenger cars, as well as a safety hazard associated with existing batteries due to the new national standards not having retrospective effect.
Detailed Analysis
The "Banana Battery" Nightmare for Over a Hundred Drivers: 80,000 Yuan for Swollen and Leaking Batteries?
Mr. Wu, a ride-hailing driver in Zhejiang, experienced battery swelling and liquid leakage after just over a year of use (230,000 kilometers), and the 4S store required him to pay 80,000 yuan to replace the battery. There are hundreds of drivers in his situation; the common issues are consistent: all AION S vehicles involved have Zhongxin Innovation Aviation's 177Ah lithium iron phosphate batteries, and they have traveled between 150,000 and 250,000 kilometers. The symptoms include battery swelling, liquid leakage, sudden power outages, or a significant drop in range.
Why are these batteries called "banana batteries"? It's because the swollen batteries resemble bananas in shape, which is a joking term used within the industry for these faulty units. Experts believe that the problem likely lies with the battery cells themselves: either the design was not thoroughly verified, or there were manufacturing defects (possibly due to shortened testing cycles rather than cost-cutting measures).
Commercial Vehicle Batteries Cannot Handle the Strain: The Lack of Special Consideration in Early Years
The battery requirements for commercial and passenger vehicles are vastly different. Ride-hailing vehicles need to be charged multiple times a day, resulting in three to five times the electrolyte consumption compared to passenger cars, requiring a much longer cycle life (e.g., 500,000 to 1,000,000 kilometers). Therefore, the design had to compromise range in exchange for durability by reducing energy density and using more electrolyte.
However, when the 2023 AION S was produced, the industry had not yet differentiated between commercial and passenger vehicle batteries. Both automakers and battery manufacturers used the same testing standards for both types of vehicles without conducting additional tests beyond 200,000 kilometers. At that time, there were no specific regulations for commercial vehicle batteries, leaving the issue to the companies' discretion, which has now led to these failures.
The Challenges of a Recall
Why has GAC AION only extended the warranty period rather than initiating a recall? Cost is a major factor. Batteries account for nearly 60% of the vehicle's cost, and replacing a battery in a car worth 120,000 yuan costs around 70,000 to 80,000 yuan. If all 100,000 affected vehicles needed to be replaced, it would amount to at least 3 billion yuan, a significant financial burden for both the automaker and the battery manufacturer. Although companies like Li Auto, BYD, and Geely have previously recalled batteries (e.g., Li Auto recalling the MEGA due to coolant issues, and BYD recalling the Qin PLUS due to battery consistency problems), recalls are legally required and must be registered with regulatory authorities. GAC AION and Zhongxin Innovation Aviation are still investigating the cause of the failures, so they have opted for extended warranties and free inspections/repairs to avoid the high costs associated with a formal recall.
It's worth noting that GAC used Zhongxin Innovation Aviation batteries as part of a strategy to balance its supply chain by diversifying its battery suppliers, reducing its reliance on CATL. GAC is also developing its own batteries (called "Pai Batteries") to reduce this dependency.
The Safety Hazards of Existing Batteries: New Standards Apply to New Vehicles Only
The new national standards for power batteries were implemented in July this year, but they do not have retrospective effect, meaning the over 30 million new energy vehicles already on the road (including these AION S models) are not subject to the new requirements. The warranty periods for these early-model vehicles will gradually expire starting in 2024, exacerbating the safety concerns associated with existing batteries.
Experts suggest three approaches to address this issue:
- Regulatory Level: Implement differentiated management based on battery age and charging frequency, conducting targeted inspections or recalls for high-risk vehicles without a one-size-fits-all approach.
- Industry Level: Establish unified safety standards for older batteries and share data among companies.
- Corporate Level: Upgrade battery management systems (BMSs), limit charging power, and reinforce protective layers to address the issues.
These measures can ensure safety while minimizing the financial burden on companies and alleviate concerns for vehicle owners.
Conclusion
This incident is not an isolated case; it reflects the challenges associated with the rapid development of new energy vehicles. The needs of commercial vehicles were neglected, and the regulatory and testing standards did not keep up. Solving this problem requires collaboration among automakers, battery manufacturers, and regulatory authorities to address both the existing safety issues and prevent similar problems from occurring in the future. For vehicle owners, the most pressing question is when they will be able to have their batteries replaced for free without bearing the cost of 80,000 yuan. This will depend on the outcome of the ongoing investigations and recall processes.