The 12-volt battery issues in your fleet could be a silent productivity killer, even if you run EVs. Usually, no one notices battery problems until it’s too late.
If you want your fleet to run like clockwork, you should check your batteries regularly. You need to know exactly when to act, or risk being caught out by unexpected failures.
But how do you test battery health? This blog breaks it down and takes you through a systematic approach that keeps your fleet’s wheels turning and your business running smoothly.
Fleet battery testing basics
There’s more than one way to test a battery’s health. Each method provides different insights into the condition of your batteries, and choosing the right one depends on the type of vehicles in your fleet and the specific requirements for your fleet management.
Conductance testing
Conductance testing is a quick and straightforward option. It works by measuring the battery’s ability to conduct current. This method is highly efficient for checking a battery’s condition without fully loading the system. If you have a large fleet, handheld conductance testers are ideal for a quick check-up on the go.
It’s not perfect for all scenarios, though. While it’s a solid ‘all-rounder’ test, it sometimes misses more minor issues or problems that only show up under load. Conductance testing is best for identifying batteries that are still functioning but starting to show early signs of wear. It’s ideal for fleet managers who want to do regular checks without a heavy investment in equipment.
Carbon pile load testing
Carbon pile load testing simulates the actual load a battery would experience under real-world conditions. This gives you a better idea of how the battery behaves under stress, which is crucial for older vehicles or those that carry heavy loads.
While conductance testing is quick and easy, carbon pile load testing provides more accuracy when you need a thorough test. However, it requires more equipment, and it’s more time-consuming than conductance testing. It’s especially useful in commercial fleets that rely on vehicles subject to high demand, such as delivery trucks or long-haul rigs.
One additional note for fleet managers: when using load testers, remember that the battery temperature affects results. Cold weather reduces performance, while excessive heat stresses the battery. Always account for these variables in your diagnostic routine.
Resting voltage measurement
Resting voltage measurement involves checking the battery’s voltage after it has been at rest for several hours. It’s a good test for detecting obvious faults, such as a severely discharged or failing battery, but it doesn’t give you insight into how the battery will perform under load.
Still, it’s worth keeping in your diagnostic toolbox. When combined with other methods, resting voltage can help you spot the most obvious problems quickly. For fleet managers working with multiple types of batteries (such as lead-acid, AGM or lithium-ion), this test might give you a first indication of whether the battery needs more advanced analysis.
How often should you test your fleet’s batteries?
There’s no universal answer to this. It depends on several factors, such as the type of vehicles you’re managing, how often they’re used and how old the batteries are. Cars, trucks or buses operating regularly and under heavy loads will need more frequent testing than those used less or carrying lighter loads.
For example, a delivery truck running all day, every day might need a test every couple of months. On the other hand, a vehicle that only runs a few times a week might be good for a check-up every six months. If you record past battery failures, you’ll start to spot patterns and adjust your testing schedule accordingly. Have a battery that failed unexpectedly last winter? It might need more frequent testing during the cold months.
Choosing the right fleet battery testing equipment
When it comes to battery testing equipment, you get what you pay for. If you have the space and budget, workshop systems can provide detailed battery checks with minimal effort from your end. These systems often come with advanced diagnostics for detecting deeper issues, including cell imbalances or other internal faults, which are not as easily spotted with simpler tools.
Telematics systems are another great choice if you want to monitor your fleet remotely. These systems track battery health in real time, providing fleet managers with data on battery voltage, temperature, charge cycles, and even predictive failure alerts.
However, not everyone needs top-tier equipment. If you’re running a small garage with just a few vehicles, a handheld tester will do the trick. Just be sure to pick one that fits your fleet’s needs. At the very least, you want something that can measure conductance, voltage and perhaps even temperature to give you a more accurate picture of your battery health.
Interpreting results and scheduling replacements
It’s not enough to just test your batteries. You need to understand what the results mean. You should establish baseline measurements for each vehicle in your fleet. This will allow you to track changes in battery health over time and give you insight into subtle performance drops that might not be immediately noticeable.
As you collect more data, patterns will start to emerge. For example, certain vehicles might consistently degrade their batteries faster than others. This could be due to factors such as heavy use, constant starting/stopping, a particular brand or model of battery that has lower longevity, or issues with the vehicle’s charging system.
If you catch these trends early, you have time to replace or maintain failing batteries before they cause any trouble.
Battery health data also helps with budgeting. If you know that certain batteries are nearing the end of their life, you can start setting aside funds for replacements, avoiding nasty surprises down the road. It also helps you plan your maintenance schedule better, so you’re not caught off guard during busy periods.
Building a predictive maintenance system
As we’ve mentioned throughout this article so far, you’ll want to keep track of all the data you collect. It’s incredible what this information can yield for you. Keeping accurate records of battery tests, failures and replacements will help you build a predictive maintenance system unique to your organisation. Over time, you’ll build a valuable dataset to help you predict when issues might arise and make informed decisions about which vehicles need attention.
Having this data at your fingertips makes managing a fleet much easier. It also provides a clear audit trail for any regulatory checks or inspections. That’s exactly what our cloud-based ROBIS battery management platform does. When used in conjunction with compatible products like the EXP-1000 FHD tester, ROBIS provides you with all the data you need to stay organised and keep everything running smoothly. Whether you use handheld testers or invest in full-scale workshop systems, systematic battery health monitoring is an investment in your fleet’s reliability and long-term success. If you’re ready to take the next step, visit Rotronics to find the right tools and services for your fleet today.
