Causes of Battery Failure
Each battery has a limited lifespan. Certain conditions, however, might significantly reduce the life lifetime of the battery, causing early failure.Â
The variables listed below are among the most typical causes of battery failure.
Considering the important function that batteries perform & will continue to play in our daily lives, a full understanding of these aspects will allow engineers & technicians involved in battery care to minimize the occurrence of some of these causes, hence extending battery life.
The characteristics listed below primarily apply to VRLA (Valve Regulated Lead Acid) batteries, which have nearly totally replaced traditional lead acid batteries with refillable liquid sulfuric acid electrolytes.
VRLA batteries are designed to be maintenance-free, and the hydrogen emitted is recombined internally in order that the electrolyte (essentially a paste) does not need to be replaced over the battery’s life.
Additionally, a valve is installed to release any additional pressure that may accumulate if the battery fails.
A significant disadvantage of VRLA batteries is their limited service life, which was achieved at the expense of minimum maintenance.
Top 10 causes of Battery Failures are:
1). Elevated Temperatures
2). Repeated Cycling
3). Overcharging
4). Undercharging
5). Over Discharge
6). Vibration
7). DC Ripple Current
8). Improper Storage
9). Misapplications
10). Internal Resistance Increase
1). Elevated Temperatures
The manufacturer specifies the anticipated battery life for batteries put in an environment at (or) near the 25°C (77°F) reference temperature. Above this temperature, the battery’s life is diminished.
Cause: The primary aging mechanism is rapid corrosion of positive plates, grid structure, & strap, that increases exponentially with temperature.
Effect: High temperatures shorten the battery life. An increase of 8.3°C (15°F) can shorten the life of a lead-acid battery by 50% or more.
Solution: Ventilate the battery to prevent overheating. Use heat-resistant batteries built for high temperatures to improve battery performance. Cleaning battery terminals & checking electrolyte levels reduces internal resistance, improving battery performance and durability.
2). Repeated Cycling
Cause: Cycling from completely charged to fully discharged and back may result in the loss of the active materials from the positive plates.
Effect: This decreases the battery’s capacity and usable life.
Solution: To extend battery life, utilize an appropriate charge controller, minimize deep discharges, keep the temperature optimal, and select batteries built for deep cycle applications.
3). Overcharging
Overcharging by battery charging system results in excessive gassing and high internal temperatures.
Cause: Too much gassing can result in the loss of active material from the plates.
Effect: Excessive heat may additionally oxidize the positive plate material, making the plates to become distorted.
Solution: To avoid overcharging, utilize an automatic charger with a voltage regulator, do not leave the battery attached after a complete charge, and regularly check the voltage level.
4). Undercharging
A defective charging system will not keep the battery fully charged.
Cause: Severe undercharging causes sulfate on the plates to harden and become tough to remove using normal charging.
Effect: Undercharged batteries may fail to provide the necessary power for their application.
Solution: To avoid undercharging, use the correct charging voltage, a suitable charger, avoid deep discharges, & perform regular maintenance.
5). Over Discharge
Cause: Over discharge causes hydration. Hydration occurs when a lead-acid battery is over discharged and not recharged immediately. Hydration occurs when lead and lead compounds from the plates dissolve in water of the discharged cell, forming lead hydrate that is deposited on the separators.
Effect: When the cell is recharged, several internal short circuits form across the positive & negative plates. Once hydration is detected, the cell is permanently ruined. VRLA cells’ containers are opaque, therefore hydration is not visible.
Solution: To prolong battery life, employ a Battery Management System (BMS) to monitor voltage levels & prevent deep discharge. Set low-voltage cut-off restrictions, charge the battery on a regular basis, and do not leave it entirely depleted. Proper maintenance & controlled discharge cycles increase battery life.
6). Vibration
Mounting a battery in a secure manner is required.
Cause: The connection can become loose, the case can shatter, and the interior components can be damaged by vibrations.
Effect: Excessive vibration can shorten battery life by producing internal damage, loosening connections, & increased wear on battery components. This leads to inferior performance, decreased capacity, and a shorter lifespan.
Solution: To avoid this, secure the batteries firmly with vibration-dampening mounts, verify connections on a regular basis, and utilize shock-absorbing materials to reduce vibration effect.
7). DC Ripple Current
Excessive DC ripple current may contribute to battery deterioration.
Cause: VRLA batteries are very susceptible to ripple current because it causes cell heating.
Effect: It accelerates the destruction of cells that are at risk of thermal runaway.
Solution: To reduce DC ripple current and increase battery life, utilize high-quality capacitors to filter out ripple, ensure correct rectifier smoothing, and use low-ripple power supply. Furthermore, keeping a consistent charging voltage and employing active ripple reduction circuits helps reduce ripple effects, reducing battery overheating & degradation.
8). Improper Storage
Cause: Storing wet cells for longer than the manufacturer’s recommended period causes sulfation.
Effect: It reduces cell capacity and longevity.
Solution: To avoid this, store batteries in a cool, dry environment with a consistent temperature, avoid overcharging (or) deep draining, and maintain them partially charged (40-60%) for long-term storage.
9). Misapplications
Most of the time, batteries are developed for a particular application.
Cause: There is a possibility that the battery will fail to perform up to its life (or) performance requirements if it was not built for the application
Effect: Misapplications such as overcharging, deep draining, and inappropriate usage can degrade battery life and performance.
Solution: To avoid this, use suitable chargers, avoid full discharges, maintain an optimal temperature, & follow manufacturer specifications.
10). Internal Resistance Increase
Internal resistance, measured in milliohms, is a battery’s protector, and the simple formula is as follows: the lower the internal resistance, the less constriction the battery experiences when supplying the required power.
Cause: A battery with low internal resistance will give high power on demand, whereas high internal resistance causes the battery to heat up and drop in voltage, reducing runtime. Though sulfation and grid corrosion are the most common causes of increased internal resistance in lead-acid batteries, severely cold weather can also cause an increase.
Effect: This can cause slower charging, lower power output, and more energy loss.
Solution: To remedy this, inspect the battery terminals on a regular basis, clean the connections, avoid deep discharges, & ensure correct charging cycles. Replace old batteries or use high-quality batteries to reduce internal resistance difficulties.
