Maximize your battery life, protect against common mistakes and also mitigate costs by discovering exactly how to select the ideal battery for your device eextremely time.

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Did you know that batteries, also via practically identical specifications, may have actually unequal life and performance? It’s true. Choosing the right version for your mechanism can suppose the distinction between long project life, low maintenance and high performance — or frustrating downtime and also at an early stage faiattract.

All batteries are made in a different way. Some manufacturers use heavier grids and also more lead, robotic assembly and automated high quality control, and also exhaustive performance trial and error. Other manufacturers make batteries utilizing hands-on assembly and outdated materials that have the right to weaken performance. Low-price batteries seem prefer a barget, but they often call for more maintenance, fail previously and expense even more in the lengthy run.

By asking the best questions, you’ll be able to determine differences in design, products, production and quality control to select the best battery for you.

Understand Different Battery TypesThe first action is to choose the ideal form. Lead-acid batteries are created specific applications, and also some aren’t a good fit for renewable power (RE) systems. Automotive and commercial starter batteries deliver brief bursts of power and stay at complete charge most of the time, making them unsuited for such applications. Uninterruptable power supply (UPS) batteries are designed to carry out backup electrical energy during power outeras however will certainly not tolerate continuous discharge and also charge cycles.

Deep-cycle batteries deliver power for a long time, even multiple days, because they’re designed for continuous discharge and also charge cycles. The distinction between deep-cycle and also RE-particular batteries is that RE batteries’ standard design accounts for the particular demands of renewable power applications.

Flooded batteries are the most typically supplied batteries in RE and grid-backup systems, bereason they’re affordable, simple to keep, long-lasting and reliable. Valve-regulated lead–acid (VRLA) batteries, such as absorbent glass mat (AGM) and gel, are maintenance-free yet commonly more expensive. Whatever kind of battery you pick, recognize which materials, construction techniques and also high quality manage systems translate right into affordable, dependable power for your system.


Acid recirculation devices use computerized vacuums to circulate acid via batteries, reducing warm for much longer life. Photograph courtesy of Crvery own Battery Manufacturing

Materials And Manufacturing MatterA battery produces electric current via a reaction that converts its stored chemical energy into electric energy. This process starts in the lead itself. Many manufacturers in the North American battery market usage recycled lead, so the performance and also lifeexpectations distinctions between lead in the batteries come from the amount of lead, additive formulation, lead-oxide production methods and also top quality controls employed by producers.

Metal grids that hold lead paste make power storage possible. Thicker, heavier plates withstand corrosion longer and also host even more lead for chemical reactions, so they increase battery life. But raw lead prices have skyrocketed because 2006, and also since lead comprises 60 to 80% of a battery’s price, there’s press to reduced corners to offset raw material price hikes.

Manufacturers that understand also the prominence of quality still develop a remarkable product. They do not try to cut prices with cutting back on essential materials favor lead, but by boosting manufacturing effectiveness and also making use of of energetic lead materials. Eventually, even more lead and also advanced production conserve customers money bereason they don’t need to rearea their batteries as regularly.

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Even grid manufacturing approaches impact life. Some manufacturers use increased metal and stamped grid manufacturing because they’re much faster, but these approaches embed impurities and porosity into grid wires. In comparison, grids created by gravity spreading contain no impurities and near-zero porosity. Gravity-actors plates extfinish life and improve relicapability.

Active lead material is applied to plates in a process called pasting, and also dozens of variables in paste mixing considerably impact battery performance. In conventional units, these variables are changed by hand also and also paste is just as good as its operator. Computerized paste mixing alleviates these difficulties by instantly adjusting variables.

Once grids are pasted, they’re cured (dried in specialized “curing ovens” at a certain temperature and also humidity) to bond active lead materials to the grid for much better performance and also longer life. Look for batteries constructed via plates all set in curing ovens, which optimize vital variables such as temperature and also humidity at eexceptionally stage of the curing cycle to encertain all plates deliver optimal capacity and organization life.

After curing, battery plates are stacked in groups and also linked by fusing the plates together with a lead strap that creates a parallel circuit between the plates. Many type of carriers still usage strap-assembly procedures that originated in the first fifty percent of the 20th century because they’re economical. Workers manually affix lead lugs to a strap and also burn them together one-by-one making use of a torch and also lead stick or by manually pouring molten lead approximately a jig. Manually welded straps have weaker link points.

Other service providers usage cast-on-strap (COS) assembly units that fuse battery plates together all at once at the optimal temperature. Because COS enables for 4,000 adjustments versus just 40 for hand also welding, it ensures continual, low electrical-resistance welds that strengthen connections, withstand cracking and boost battery life. Robotic COS assembly additionally prevent faiattract settings that are common through manually-assembled batteries, such as “lead run-down” between plates, and also allow for features that mitigate corrosion, boost current and also minimize maintenance expenses.


Robots pack plates in this computer-managed manufacturing mechanism, for enhanced precision and also lifeexpectancy. Photo courtesy of Crvery own Battery Manufacturing

Properly integrating the COS process have the right to be expensive and time-consuming. Make certain your battery manufacturer has actually had time to refine its COS system. If a company advertises using COS, make sure to ask if it produces 100% of its offerings utilizing COS production.

Following assembly, batteries are charged for the initially time in a procedure called development that converts lead sulfate and ensures maximum capacity. Some carriers “rate up” development utilizing better curleas, which cut manufacturing time at the price of active (usable) material and lifespan. In comparison, reduced present over a much longer time always results in longer life.

Recognize QualityQuality manage must be built right into all steras of production to improve product quality and also consistency. In even more progressed plants, this contains machine experimentation for brief circuits, together with computerized welding and warmth sealing. Some battery companies also use vision units (photo capturing and also advanced software application that automatically check parts) to spot defects human beings have the right to miss out on.


Battery manufacturers need to monitor eincredibly phase of production through a mix of trained employees and also computer units. Picture courtesy of Crvery own Battery Manufacturing


An on-site lab tests batteries to encertain performance and also consistency. Picture courtesy of Crown Battery Manufacturing

When you understand what to look for — and what to protect against — in a renewable energy battery, it’s a lot easier to uncover the finest model for your requirements. To compare manufacturing approaches and materials and obtain a far better idea of which batteries will certainly perdevelop much better and last longer, visit your RE battery manufacturer’s webwebsite or speak to the manufacturer or your distributor.

John Connell is the vice president of Crvery own Battery’s SLI Products Group. Crown Battery manufactures all batteries at its Fremont, Ohio plant.