EV batteries that go the extra mile
7 minute read
When you think of sudden internet stars, an EV battery is probably not the first thing that comes to mind. Yet, this was the case for one robust IONIQ 5 battery and its delighted owner, who clocked over 660,000 kilometers (410,000 miles) in just under three years without a single major issue! This remarkable achievement was shared in an online automotive forum, which set the story in motion. We took a closer look.
A 410,000-mile milestone
The benefits that EVs offer drivers are now well known. But when Yongheum Lee posted online that he's driven over 660,000 kilometers (410,000 miles) with his Hyundai IONIQ 5, the absolute scale of EV battery performance and potential became apparent. Lee stated in his post: 'I drove 580,000 kilometers (about 360,000 miles) for over 2 years and 9 months without any breakdowns.' It's a genuinely impressive claim. To put it in perspective, that's like driving nearly 580 kilometers (360 miles) daily for 1,000 consecutive days.
At first, the claim seemed too fantastic to be true, prompting heated discussions regarding its authenticity. However, the statistics were accurate, and Yong-heum Lee put that astounding mileage on his IONIQ 5 while driving across the country as a sales representative. His reasons for choosing the IONIQ 5 were both practical and nostalgic: 'At first, I drove a compact, but 90% of my driving was on the highway. I wanted a smoother, more powerful ride with optimal comfort, spaciousness, and cost-effectiveness. The IONIQ 5 checked all the boxes.'
He continued, 'As someone who remembers the original Hyundai Pony, I loved the retro-modern design of the IONIQ 5. In the end, I chose the long-range single-motor variant because I needed to drive 800 to 900 kilometers (500–560 miles) daily. For me and my job, range was everything.'
High performance meets low maintenance
As impressive as Lee's mileage with his IONIQ 5 is, it should not come as a total shock. EVs like the Hyundai IONIQ 5 bring both range and minimal maintenance to the table. With fewer moving parts, there is less wear and tear, and inconveniences like oil changes are a thing of the past. Lee recalled: 'When I drove a conventional car, I changed the engine oil every 15 days. However, with the IONIQ 5, I only had to swap out the basic consumables. Thanks to regenerative braking, even the brake pads lasted much longer than on my previous cars.'
Savings around every corner
The statistics would have looked very different if Lee had driven 410,000 miles in a conventional car. To achieve the same goal, he would have undergone 66 oil changes, eight sets of spark plugs, 13 brake fluid flushes, and 11 dual-clutch transmission oil changes—not to mention regular inspections of hoses, belts, and other drivetrain components. This totals around $9,000–10,000 USD in maintenance costs. And that doesn’t even include the amount he would have spent on gasoline for that distance, which is roughly USD 58,000. If you add that to the maintenance costs, the choice for an EV becomes clear.
Designed to go the distance
An IONIQ 5 going almost 60,000 kilometers without issues naturally caught the eye of all those at Hyundai. Senior Research Engineer from Hyundai Motor Group, Dal-young Yoon was intrigued but not surprised by this achievement. He stated, 'The story about this IONIQ 5's battery and motor replacement definitely got attention.' Yoon added that the team has long studied high-mileage EV components and creates durability prediction models to compare with real-world data, ensuring accuracy across battery generations.
We evaluate every collected battery. The resulting data influences our new battery's design and helps us improve our durability models and engineering guidelines. Senior Research Engineer from Hyundai Motor Group, Dal-young Yoon
The car that became a case study
For Dal-young Yoon, the 410,000-mile feat was a perfect chance to study the car that made it possible. Data collection is an invaluable tool, so he and his team reached out to Yong-heum Lee, and, in no time, his IONIQ 5 went from a humble business car to a thoroughly examined case study.
One of the first discoveries was that despite logging 580,000 kilometers in just 33 months, Lee's IONIQ 5 still retained 87.7% of its original battery health (SoH). This showed that battery degradation was not a significant issue, even under extreme conditions. For Yoon, the secret was how the batteries are engineered, particularly concerning durability targets. He explained how Hyundai designs EV batteries for even the most demanding performance needs. When tested, Lee's IONIQ 5 battery almost exactly matched the durability model.
Hyundai durability targets far exceed the warranty requirements. Senior Research Engineer from Hyundai Motor Group, Dal-young Yoon
Charge and take charge
Building robust, high-performance EV batteries is essential for advancing new mobility and achieving sustainability goals. This process starts with thorough testing. At our Namyang R&D Center, we conduct various durability tests, including charging and discharging cycles, as well as long-term storage simulations, to consider every condition an EV may encounter. Our passion for EV battery research and development has earned HMG vehicles a reputation for best-in-class performance.
Of course, every battery experiences wear over time. Even when an EV is not being driven, there's a natural, microscopic decline. A common theme among many EV owners is fast charging, which is beneficial for busy drivers, yet is perceived as something that can reduce battery life. That's why at HMG, we engineer our batteries to perform under the harshest conditions, including frequent fast charging. Our Battery Management System (BMS) continuously monitors and balances each cell to optimize charging.
The fact that Lee used fast chargers almost exclusively while driving, without significant battery decrease, proves that we are on the right path. Yoon shared his thoughts: 'We've been developing EV, hybrid, and fuel cell technology for a long time, and we have the advantage of working with Korea's top battery manufacturers. But the real key isn't just having great hardware—it's about unlocking 100% of its potential through great engineering.'
Our mission is to deliver top-tier performance, safety, and longevity in every battery system we create. Senior Research Engineer from Hyundai Motor Group, Dal-young Yoon
Better batteries for more possibilities
At Hyundai, we are fascinated by how new mobility is shaping our lives. Our commitment to advancing its technological, environmental, and social potential drives us to give our best every day. We will continue to invest in cutting-edge EV technology and design exceptional vehicles that enhance the driving experience, whether for short trips or long hauls.
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