This brings back memories
One of my first professional gigs was with Johnson Controls for their Interstate and Sears’s brands doing controlled testing.
Regardless where a wet celled battery resides (and external influences such as impact or overcharging) there are 4 things fatal to any battery.
Heat- The individual battery’s tolerance varies based on design parameters but a good rule of thumb is that if it is any warmer than about 90°F under full load then there is a potential problem. A wet battery must have adequate ventilation for gassing and thermal dispersion.
Shock/vibration- this is impact and high frequency/resonance. Put a pad under it and secure it.
Electrolyte balance- they really do mean that 65/35 ratio (if you still have one using acid). Only add DI/distilled water because if the chemistry or conductivity of the fluid changes it will damage the cell.
Running undercharged- all batteries need a load/topping every once in a while.
The last thing (not listed because this is a system issue, it affects the battery) is system load and electromotive force during operation. The main reason this exists is because QS 9000 and the SAE are not under or subject to the NEC and IEEE.
(Remember an automotive engineer designed that system, not a licensed Electrical Engineer to any industrial code or standard)
Granted the voltage drop and impedance of a DC circuit given the run distances in a car is negligible in one realm, it can have an endothermic effect on a battery and greatly reduce service life.
In layman’s terms (not literally accurate but illustratively accurate for general conversation purposes and a good fundamental understanding)
A battery is a chemical storage device- you don’t actually charge a battery, you “excite” it. So during cycles you continuously “excite” it.
Understanding also that anytime you have heat- you have a loss.
So, when you pull power from a wet cell battery, it’s similar to squeezing a soaked sponge and several things happen concurrently.
The chemistry between the metals and electrolyte changes (back and forth depending on charge/discharge amounts)
Heat builds up in the fluid all the way to the poles and backs up due to resistance during flow- this extrudes chemicals and flexes the plates.
That’s the way they are designed to work so eventually even in the “perfect world” the chemistry will wear out and the plates will either develop micro fractures or the coatings on the plates will calcify and the reaction is weakened enough to kill the cell. This cannot be stopped because that’s just physics but it can be reduced drastically with a few simple tricks that every non SAE type application uses.
Battery- they make them smaller now to save space and weight (and BCI changed their metrics for ampacity). If your application allows, put the largest size battery possible and preferably a deep cycle. (Greater mass dissipates heat and handles those issues better and deep cycle batteries by design have thicker plates and greater spacing)
Ampacity- get the strongest possible (look at the reserve capacity) the bigger those numbers, the less potential it loses and reduces the effects in the charging/ discharging cycle.
Wire- There’s a lot of mystery and misunderstanding here. When you remove the skin effect and RF (which really don’t apply except in AC and signals) total resistance and ampacity is based on cross section because electrons flow on the OUTSIDE of a conductor. So, all of these SAE type connectors that flatten the wire create high resistance points. You will greatly enhance everything if you solder/braze the end solid (and if possible) use marine connections and solder the wire in with the greatest possible surface contact at the battery terminals. Obviously get the largest conductor you can fit based on physical size relative to the current load of the conductor. (See non SAE conductors crimp to the circumference, they don’t squash the wire like hitting a pipe with a hammer)
Connections- use dielectric compounds and as much surface contact as possible.
I do tons of thermography on switchgears, busses, transformers and panels- when you can actually SEE these issues, it will amaze you.
These methods and techniques although not common in the automotive industry are the standards in industry and they work well.
Hope that helps anyone wanting to experiment.