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RegenVolt
Lead-Acid Recovery Platform
12V / 24V platform for lead-acid batteries

Restore lead-acid batteries with hybrid treatment.

RegenVolt is an industrial system concept that combines active titanium rods, ultrasonic excitation, desulfation pulses, and advanced electronic monitoring to reduce plate crystallization, restore internal conductivity, and extend the useful life of lead-acid batteries used in vehicles, fleets, workshops, and 12V / 24V applications.

The approach primarily targets flooded and serviceable batteries. For AGM, GEL, and VRLA formats, the recommended mode is non-intrusive external treatment with model-specific validation.

View the design Review the BOM
12V / 24V Multi-profile architecture for cars, light trucks, marine use, and workshop service.
Hybride Ultrasound + pulse control + sensors + thermal management and optional recirculation.
QC / CA Designed for manufacturing, assembly, and certification in Quebec and Canada.
Investor pitch

A battery-recovery platform, not a garage gimmick.

RegenVolt targets a concrete market: garages, fleets, service workshops, marine operators, and refurbishers already paying to diagnose, sort, and replace 12V/24V lead-acid batteries. The product is positioned as a measured, safe, and traceable recovery station.

Differentiation Combination of ESR diagnostics, pulsing, ultrasonics, internal actuators for compatible formats, and before/after reporting.
Business model Workshop-station sales, service contracts, consumables/jigs, reporting software, and a premium refurbishment version.
Canada advantage Local production, traceability, compliance, proximity support, and a sustainability narrative for the QC/Canada market.
Investment thesis If the system proves repeatable and safe recovery, it transforms replacement expense into a margin-bearing service with proprietary data.

Why the project can matter

  • The market already knows the sulfation problem, but lacks credible and traceable tools.
  • The product does not try to save every battery: it classifies, treats, and rejects intelligently.
  • The before/after report creates commercially useful proof of value.
  • The platform can be deployed as a premium bench, workshop station, or field-service version.
  • The same electronics base can support diagnostics, recovery, and field data collection.
Operating principle

A combined strategy instead of a single treatment.

Sulfation is not only an electrical problem. It affects the plate-electrolyte interface, stratification, ion diffusion, and internal resistance. The most robust solution is a modular platform that attacks several causes at once.

01

Initial diagnosis

Measure open-circuit voltage, loaded voltage, absorbed current, temperature, internal resistance, and estimated sulfation state.

02

Targeted activation

Titanium rods act as a controlled activation interface between plates on accessible batteries, with strict current and polarity limits.

03

Hybrid desulfation

The ultrasonic transducer is synchronized with electronic pulses to weaken sulfate crystals and improve their re-dissolution.

04

Stabilization

End the cycle with recharge, balancing, thermal monitoring, and a recovery report to decide whether the battery remains usable.

Additional solutions

Modules that reinforce real recovery performance.

A serious product must go beyond the simple "ultrasonic + rod" narrative. Durable gains come from orchestrating agitation, pulsing, adaptive charging, thermal control, and the sorting-out of unrecoverable batteries.

P1

Pulsed desulfation

Electronic stage generating controlled pulses to break part of the sulfate crystals without overheating the plates.

U2

Modulated ultrasonics

Frequency sweep with amplitude ramping to avoid acoustic dead zones and limit enclosure fatigue.

F3

Pump / mixing

Gentle electrolyte circulation on suitable batteries to reduce stratification and homogenize the chemical reaction.

A4

Local sorting AI

On-board decision algorithm to classify batteries as recoverable, partially recoverable, uneconomic, or unsafe for service.

T5

Adaptive temperature control

Automatic power reduction when the enclosure, electrolyte, or MOSFET exceeds the defined threshold.

Z6

Impedance measurement

Injection of test signals to track internal-resistance evolution and prove the effect of the regeneration cycle.

C7

Integrated charger

CC/CV charging and maintenance mode with 12V, 24V, AGM, GEL, Flooded, and workshop-specific profiles.

R8

Traceable report

Before/after report: estimated capacity, internal resistance, temperatures, cycle duration, verdict, and lot history.

Before / after visualization

Fast reading of measured impact.

These charts are illustrative for the product page. They show the type of visualization expected after real test campaigns: ESR reduction, better retained capacity, and fewer premature rejections among recoverable batteries.

Internal resistance Example 12V serviceable battery
18.4 mOhm
11.9 mOhm
Recovered capacity After stabilization and recharge
41 Ah
66 Ah
Saved-battery rate Intelligently sorted workshop batch
36%
63%
Before treatment
After treatment

What the charts must prove in reality

  • A repeatable ESR decrease on the targeted battery families.
  • An observable capacity gain after a standardized rest and recharge phase.
  • Lower premature replacement rates on compatible workshop batches.
  • Controlled result dispersion, without depending on an expert operator for each battery.
  • A clear distinction between recoverable batteries and batteries that must be rejected immediately.
In a commercial version, these charts should be fed by real test results exported from the station and segmented by chemistry, nominal capacity, age, and applied protocol.
Laboratory dashboard

Time-series curves and advanced diagnostic reading.

These SVG charts show the direction of a real laboratory dashboard: time curves, multi-cycle comparison, and cross-reading between voltage, temperature, and internal resistance. This level of presentation is what makes a technical dossier credible for a workshop or an investor.

90-minute recovery cycle

0 25 50 75 100 125 0 15 30 45 60 75 90 min Tension Temperature Recovered capacity
Expected reading: voltage stabilizes, temperature remains under controlled thresholds, and recovered capacity increases across the sequence without thermal runaway.

Comparative workshop-batch signature

Capacity CCA Maintien Stability Rendement Inverse ESR Before batch After batch
The radar is useful because it shows that recovery should not improve just one isolated indicator: meaningful workshop recovery must progress across several operational axes.
Workshop economics

Costs, ROI, and revenue scenarios.

Commercial credibility also comes from the numbers. This section frames a plausible workshop scenario to show how the station can become profitable without promising miracle recovery on every battery.

Base workshop hypothesis

Illustrative scenario: station sold between CAD 7,500 and CAD 14,500 depending on version, 25 to 60 batteries processed per month, with a useful recovery rate of 30% to 55% on truly compatible batteries and a service billed in the workshop.

65 to 140 CAD Plausible billing per diagnostic + recovery cycle
8 to 18 months Target payback window
3 levels Mobile service, workshop station, premium refurbishment bench

Revenue scenarios

Scenario Volume/month Estimated service revenue Interpretation
Cautious workshop 25 batteries 1,625 to 2,250 CAD Validates local demand and gradually amortizes the station.
Established workshop 40 batteries 2,600 to 4,200 CAD Interesting break-even point if recovery rates remain documented.
Fleet / refurbisher 60 batteries 3,900 to 6,900 CAD Justifies a premium version with reporting and dedicated tooling.

Costs to watch

  • Electronic and mechanical BOM, especially ultrasonics, safety hardware, enclosure, and harnessing.
  • Operator time and workshop procedure: if the process is too heavy, margins collapse.
  • Maintenance, calibration, gabarits, consommables et SAV.
  • Maintenance, calibration, jigs, consumables, and after-sales support.
  • Certification and documentation cost if the product moves upmarket industrially.
  • Opportunity cost: sometimes it is better to diagnose and reject quickly than to over-treat too long.

Profitability logic

The strongest model is not just machine sales. It combines hardware, reports, jigs, service, maintenance, and data. The more the station reduces false positives and documents its decisions, the more its economic value rises.

The right KPI is not "how many batteries were connected", but "how many recoverable batteries were treated usefully with margin and before/after proof".
Product compatibility

All models, yes, but with distinct operating modes.

To avoid an unrealistic promise, the best positioning is "broad compatibility with a mode adapted to the format." Lead-acid batteries should not all be treated in the same way.

Serviceable flooded batteries

Premium mode with internal access, titanium rods, ultrasonics, optional recirculation, and full diagnostics.

Voiture Pickup Marin Agricole

AGM / GEL / VRLA

Recommended external mode: non-intrusive excitation, pulsed charging, thermal monitoring, and automatic refusal if risk is high.

Start-Stop UPS Mobility Leisure

12V / 24V workshop mode

Service cart or fixed station with locked profiles, operator report, and standardized safety procedure.

Light truck Fleet Workshop Refurbishing
Design and electronics

System architecture for a credible industrial prototype.

The product core must be conceived as an intelligent regeneration station, not as a gadget. Electronics drive the cycle, watch operational limits, and make the process repeatable. The internal titanium-rod module should only be activated on compatible batteries, with mechanical fixturing, chemical isolation, and a secured sequence.

Power input

Isolated AC-DC supply, PFC for higher-power versions, overvoltage/overcurrent protection, contactor, fuses, and emergency stop.

Charge / pulse stage

MCU-driven buck or buck-boost converter, programmable pulse generation, measurement shunt, and low-Rds(on) MOSFETs.

Ultrasonic

Half-bridge or full-bridge driver, typically in the 20–40 kHz band to be validated, with transducer coupled to the enclosure or treatment tool.

Sensors

Enclosure temperature, heatsink temperature, current, voltage, polarity, pressure/gas for advanced versions, and possibly indirect density or conductivity indicators.

Actuators

Active rods, polarization relays, optional acid-resistant pump, filtered ventilation, and audible/visual alarms.

Control

Industrial STM32/ESP32-class MCU, HMI display, logging, battery profiles, operator lockouts, and USB/Wi-Fi reporting depending on version.

Detailed technical file

Block diagram, control sequence, and industrialization points.

This section provides a foundation for engineering discussion. It turns the marketing concept into an implementable architecture: subsystems, power chain, measurement chain, cycle sequence, and safety interlocks for a workshop or laboratory product.

Functional chain
AC/DC Input EMI, fuse, PFC, contactor Power Board Buck, shunt, PWM, pulses Battery 12V / 24V under test Ultrasound Driver + transducer Rods / Pump Chemical actuators Measurement Board ESR, T°, polarity, safety MCU / HMI Profiles, logs, decisions

1. Input and protection

  • Isolated AC-DC, fuse, MOV, EMI filter, and PFC based on power level.
  • Main contactor and front-panel emergency stop.
  • Battery presence and reverse-polarity check before closing the circuit.

2. Power conversion

  • Synchronous buck or buck-boost for 12V and 24V CC/CV charging.
  • Superimposed pulse stage for controlled desulfation.
  • Kelvin shunt, differential ADC, and firmware-independent hardware current limiting.

3. Ultrasonic/action module

  • Resonant or half-bridge driver with swept frequency.
  • Transducer coupled to the enclosure, bath, or insertion tool.
  • Recirculation pump output and titanium-rod relays on premium versions.

4. Control and data

  • Real-time MCU with locked profiles by battery type.
  • HMI, local memory, CSV/PDF export, and batch/service history.
  • Decision algorithms: ESR, temperature delta, absorbed current, voltage stability.
Suggested operating sequence
A. Pre-check

Voltage identification, visual inspection, temperature, leak check, terminal state, and rejection for severe anomalies.

B. Fingerprint

Measure voltage, ESR, pulse response, leakage current, and initial classification.

C. Treatment

Pulsed charging, modulated ultrasound, thermal rest windows, and gentle recirculation when compatible.

D. Stabilisation

Rest window, CC/CV restart, limited equalization, and new reading of internal indicators.

E. Verdict

Recoverable / partial / reject report with measured justification and cycle data storage.

For a serious prototype, the key safeguards are hardware, not cosmetics: independent thermal cutoff, autonomous current limit, reverse-polarity detection, workspace ventilation, acid-compatible materials, and a fixture that prevents uncontrolled rod insertion.
R&D dossier

Test plan, validation criteria, and risk matrix.

This section frames the pre-project phase: which tests to launch, what evidence to produce, and which risks to reduce before committing to industrialization, certification, or overly aggressive commercial claims.

Recommended test campaign

  • Sample several battery families: flooded, AGM, GEL, VRLA, with different capacities and ages.
  • Measure before/after: voltage, ESR, recovered capacity, max temperature, absorbed current, and charge retention.
  • Run A/B tests: charge only, charge + pulses, charge + pulses + ultrasonics, charge + full treatment.
  • Test repeatability over multiple cycles and across several batteries of the same model.
  • Document rejection cases to avoid overtreating structurally lost batteries.

Minimum success criteria

  • Measured and repeatable improvement in internal resistance on a significant share of the sample set.
  • Observable gain in capacity or charge retention after stabilization.
  • No dangerous overheating, no leaks, and no enclosure deformation during the cycle.
  • Robust automatic decision between recoverable, partially recoverable, and reject categories.
  • Full traceability of cycle parameters for technical support and future compliance needs.

DOE and sweep parameters

  • Ultrasonic frequency, amplitude, duty cycle, and exposure duration.
  • Level, waveform, and cadence of desulfation pulses.
  • Duration of rest / charge / stabilization phases.
  • Titanium-rod geometry, insertion depth, and functional spacing.
  • Recirculation flow rate, chemical compatibility, and real benefit against stratification.

Pre-project deliverables

  • Comparative test report with raw data and synthesis by battery family.
  • Frozen block diagram, V1 electronic architecture, and qualified BOM.
  • Risk matrix with mitigation plans and go/no-go thresholds.
  • Operator specification: procedure, safety, checklist, and maintenance.
  • Economic evaluation: recovery cost per battery and ratio versus replacement.
Technical risk matrix
Risk Level Impact Mitigation
Insufficient ultrasonic effectiveness High No product differentiation despite higher complexity Run a DOE campaign on mechanical coupling, frequency, amplitude, and A/B comparison without ultrasound.
Battery degradation or stress High Safety risk, field rejection, product liability Hard-stop thermal thresholds, injected-energy limits, and rejection criteria before treatment.
Poorly reproducible titanium-rod behavior High Inconsistent results and fragile operator protocol Mechanical fixture, controlled insertion depth, and use limited to explicitly compatible formats.
Pump with no net benefit Medium BOM and maintenance complexity without measurable gain Validate recirculation separately and keep it for a premium version only if gains are proven.
EMI / measurement noise Medium Unstable algorithms and false diagnostics Ground separation, shielding, filtering, isolation, and disciplined multi-board architecture.
Final cost too high Medium Product hard to sell versus battery replacement Modularize the offer: premium bench, workshop station, and lighter service version.
Insufficient documentation and data Low Harder to convince partners, customers, and compliance bodies Native logging, standardized test protocol, and systematic exports from V1 onward.
The real go/no-go threshold is not occasional battery recovery. You must demonstrate repeatable, safe improvement that is economically defensible and robust enough for workshop operation without relying on a lab expert every cycle.
Advanced electronic architecture

Board-by-board breakdown and recommended components.

The goal is to turn the platform into a realistically developable architecture. Functions are split across clear boards, with controlled interfaces, identified thermal constraints, and coherent component families from prototype to pre-series.

Board A: power and charging

  • Isolated AC-DC input or external DC bus depending on station/cart version.
  • Synchronous 12V/24V buck stage with hardware current limiting.
  • Kelvin shunt + differential measurement for charge current and pulses.
  • Heat dissipation on heavy copper planes, thermal vias, and NTC sensor on MOSFETs.
LM5176 INA240 BSC / OptiMOS Littelfuse TVS

Board B: real-time control

  • Main MCU for battery profiles, machine state, logging, and communications.
  • External watchdog, supervised brownout behavior, and service bootloader.
  • Internal CAN or RS-485 bus recommended for multi-board architectures.
  • Non-volatile memory for recipes, logs, and calibration.
STM32G474 ESP32-S3 MCP2562 AT24 / FRAM

Board C: ultrasound and actuators

  • Dedicated half-bridge or resonant driver for selected piezo/transducer hardware.
  • Separate outputs for pump, ventilation, titanium-rod relays, and optional valves.
  • Current and temperature measurement for the acoustic module.
  • Shielding and separated routing to avoid noise on analog measurements.
UCC27531 Infineon gate driver Murata piezo MOSFET 80V

Board D: acquisition and safety

  • Battery voltage, enclosure temperature, heatsink temperature, ambient, and optional pressure/gas measurement.
  • Interlock inputs: cover, clamp, tool presence, emergency stop, leak.
  • Hardware comparators for critical thresholds independent of the MCU.
  • Galvanic isolation recommended between power and sensitive I/O.
ADS1115 / ADS131M AMC1311 TMP235 Comparateurs TLV

Board E: HMI and service

  • TFT/OLED screen, encoder, physical buttons, status indicators, and buzzer.
  • USB service port, report export, and firmware updates.
  • Technician mode separated from operator mode to limit configuration drift.
  • Optional Wi-Fi or Ethernet for connected workshop versions.
Nextion / TFT SPI USB-C service ESP module

Board F: backplane and harness

  • Power distribution, grounds, Kelvin returns, and communication bus.
  • Strict separation of power, logic, and ultrasonic paths.
  • Locked, mechanically keyed connectors for workshop maintenance.
  • Factory test points for calibration and end-of-line validation.
TE Connectivity Amphenol Custom harness

Recommended choices for prototype V1

A coherent base would use an STM32G4 for real-time control, an INA240-class measurement front end, a TI or Analog Devices buck/buck-boost converter, 80V Infineon MOSFETs, and AMC1311-class isolation or equivalent on sensitive paths. This yields a serious platform without overloading the architecture.

Areas that require experimental development

The transducer + mechanical-coupling pair, titanium-rod geometry, chemistry-specific pulse limits, and the true value of a micro-pump all need testing. These factors determine whether the concept becomes a repeatable product.

Board-to-board integration
Interface Signal / power Best practice
Board A to B Current/voltage telemetry, fault flags, PWM enable Reinforced isolation or filtering, controlled ground reference, hardware watchdog on enable.
Board B to C Ultrasound frequency command, relays, pump, ventilation Protected outputs, separate drivers, and status feedback from each actuator.
Board D to B Temperatures, interlocks, gas, diagnostic sensors Route critical faults to hard-stop paths outside firmware.
Board E to B UI, logs, service, updates Separate production, service, and operator modes; log every recipe change.
Backplane Power distribution, communication, test points Keyed connectors, replaceable harness, and easy access for after-sales support and factory validation.
Preliminary BOM

Materials list for prototype and pre-series builds.

This BOM is a working baseline for a prototype bench. Costs are indicative in Canadian dollars for a low-volume batch and must be recalculated for final integration.

Technical BOM
Item Function Target specification Est. CAD
Main MCU Control, profiles, measurement, logging Industrial STM32/ESP32 depending on required connectivity 12 to 28
Power board CC/CV charging and desulfation pulses MOSFET, driver, shunt, buck/buck-boost, snubbers 55 to 140
Ultrasonic transducer Acoustic agitation and deposit breakup 20-40 kHz module to validate, secure mechanical coupling 35 to 120
Titanium rods Active internal interface on accessible batteries Grade 2 or 5 titanium, chemical insulators, mechanical guide 18 to 65
Sensors Temperature, current, voltage, safety NTC/PT100, Hall or shunt, precision ADC 20 to 70
Optional pump Electrolyte mixing / recirculation Acid-chemistry compatibility, low and controlled flow rate 45 to 160
HMI Display, buttons, operator diagnostics TFT or OLED display + encoder/buttons 22 to 85
Enclosure Protection, ergonomics, isolation ABS/PC or painted metal, suitable IP level, directed ventilation 40 to 180
Connectivity Clamps, harnesses, terminal blocks, fuses 12V/24V-rated section, flexible workshop cables 25 to 95
Safety Emergency stop, interlocks, alarms Relays, buzzer, status indicator, cover detection 18 to 70
Industrial BOM oriented toward suppliers
Subsystem Supplier families References or sourcing paths Industrialization note
MCU / logic STMicroelectronics Espressif Microchip STM32G4, ESP32-S3, dsPIC depending on real-time control and connectivity needs Plan one core family to limit firmware variants and supply-chain complexity.
Power Infineon TI onsemi 60-100V MOSFETs, half-bridge drivers, INA for current/voltage measurement Choose packages that are easy to source in Canada and with thermal pads suited to locally assembled PCBs.
Ultrasound Murata PI Ceramic OEM integrators Piezo transducers and resonant assemblies to validate experimentally Mechanical coupling matters more than datasheet values alone; plan a DOE campaign.
Pump / fluidics KNF Verder Cole-Parmer Micro-pumps or low-flow chemical pumps, PTFE/PVDF tubing The fluid path must be replaceable and isolated from the electronics compartment.
Connectivity / safety TE Connectivity Amphenol Littelfuse Locking connectors, fuses, breakers, E-stop Use parts already familiar to Quebec industrial integrators.
Local manufacturing Quebec EMS Local machining Local sheet metal Assembled PCBs, mechanical fixtures, enclosure, harnesses, and test bench Structure DFM, test plans, and alternate BOMs from the start.
The right industrial approach is to define qualified component families rather than locking the product to a single reference. In Canada, supply-chain robustness and certification readiness matter as much as unit BOM cost.
Quebec / Canada production

Develop locally with validation, certification, and traceability.

If the product is aimed at the Canadian market, value comes as much from engineering quality as from compliance. Supply chain, operator safety, and proof of performance must be structured early.

Industrial roadmap

  • Alpha prototype: principle validation on flooded laboratory batteries.
  • Beta prototype: workshop chassis, HMI, safety, 12V/24V profiles, and logging.
  • QC pilot: outsourced PCB, enclosure, harness, and test benches in Quebec.
  • Canada pre-series: reliability hardening, service docs, operator fixtures, and after-sales support.

Compliance planning

  • CSA/UL assessment based on final category: charger, service equipment, or workshop machine.
  • Electromagnetic compatibility and conducted/radiated emissions for the Canadian market.
  • WHMIS, safety data sheets, acid handling procedures, and ventilation.
  • Waste-management process for unrecoverable batteries with licensed recyclers.

Target local supply

  • Assemble electronic boards in Quebec for faster iteration and quality control.
  • Machine fixtures, electrode holders, and mechanical parts through local workshops.
  • Thermoformed, injected, or bent-metal enclosures depending on station/cart version.
  • Dual-source strategy for transducers, pumps, power supplies, and cabling.

Market differentiation

  • Before/after reports for garages and fleets instead of unmeasured promises.
  • Secure workshop mode for genuinely compatible serviceable batteries.
  • Modular platform: mobile version, bench version, and 24V industrial version.
  • Eco-responsible positioning: extend useful life before replacement and recycling.
Important context

What must be stated clearly about the product.

A credible page does not sell miracles. It explains limits, risks, validation methods, and usage boundaries. This is especially important for a lead-acid-related product.

Does the system work on all batteries?

The recommended positioning is "broad lead-acid compatibility." Treatment modes differ between flooded, AGM, GEL, and VRLA batteries. Internal access is not universal.

Why titanium?

Titanium is attractive for corrosion resistance and stability. Real electrochemistry, geometry, allowable currents, and process durability must still be validated.

Why add ultrasound?

It can improve local agitation and help weaken some deposits, but effectiveness depends strongly on coupling, frequency, amplitude, and battery type.

Is the pump mandatory?

No. It becomes relevant mainly for certain reconditionable batteries where electrolyte stratification penalizes results. It must remain low-flow and chemically compatible.

What is the real commercial advantage?

Reduce premature replacements, provide quantified diagnostics, and give garages/fleets a sorting and recovery tool rather than a device making vague promises.

What evidence must be produced?

Recovered capacity, internal-resistance change, retention after multiple cycles, absence of overheating, absence of leaks, repeatability across models, and recovery cost per battery.

Evidence layer

Validation priorities for industrial credibility.

Lead-acid regeneration claims must be supported by repeatable datasets. The strongest signals are measured capacity recovery, internal-resistance evolution, thermal safety margins, and retention after controlled cycling.

What evidence should show

  • Capacity gain against baseline under standardized charge/discharge protocols.
  • ESR reduction with confidence intervals, not single-point values.
  • No abnormal gas generation, leakage, or thermal excursions during treatment.
  • Retention after repeated cycles and rest periods (not only immediate post-treatment gains).

Main risk domains

  • Overgeneralization across flooded, AGM, GEL, and VRLA chemistries.
  • Acid handling and ventilation constraints in workshop operation.
  • Mechanical/electrochemical stress from aggressive pulse settings.
  • Operator variability without strict SOPs and calibrated diagnostics.
Sources

Reference standards and technical sources.

Selected sources used to frame electrochemical diagnostics, safety, and workshop-grade validation methodology.

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