Analysis of automotive lead-acid batteries exchange rate on the base of field data acquisition

The development of automated driven vehicles is the major challenge of the vehicle development with regard to reliable and fail operational systems. Sensor systems, controllers and software reliability concepts have already been investigated. Hence, the energy distribution system has an essential role to provide an fail operational energy distribution, while the lead-acid battery will be an important component of future energy distribution designs. Accordingly, this work provides an overview of existing reliability investigations and an analysis of 1 043 463 exchanged lead-acid batteries based on field data from vehicle workshops, vehicle and battery production data. Furthermore, a stochastic model is developed with 263 617 battery exchanges, investigating lead-acid batteries in a production period from 2009 until 2010. The found distribution provides values for failure in time (FIT), based on battery exchange. From the distribution a statistical value for a constant non ageing and an ageing related fault could be found. The failure in time value for ageing increases significantly with progressive ageing. Hence, a reliability analysis must both consider constant and ageing faults for future energy distribution systems.