What are the common faults of lithium batteries
Written by: GEB Engineering Team | Technical Review by: Senior Battery System Engineer | Updated: August 2026
Problems in the production process of lithium-ion batteries:
- Internal resistance of battery
If the positive and negative plates of the battery are improperly welded or the internal resistance of the rivets in contact with the pressure plate is too large, the internal resistance of the lithium-ion battery will be affected. If the pores of the separator are too small, the internal resistance of the battery will also be affected.
- Battery voltage
In the production process of lithium-ion batteries, the positive electrode will be mixed with impurities, and the crystallization of the negative electrode will reduce the voltage of the lithium-ion battery. The incomplete formation of the SEI film during the formation process can also make the voltage of the Li-ion battery too low.
Problems during the use of lithium-ion batteries:
- Unable to charge and discharge
Lithium-ion batteries cannot be charged while being charged, and cannot be discharged normally when in use. There may be the following reasons.
The failure of the protection plate protection or the failure of the protection plate and the external short circuit between the lithium-ion battery and the appliance may cause the lithium-ion battery to not charge effectively.
The voltage of the lithium-ion battery is lower than the protection voltage of the protection board or the controller, and the damage of the protection board or the controller will make the lithium-ion battery unable to discharge normally during use. The same result occurs when the line is disconnected.
- Abnormal temperature
If the lithium-ion battery has abnormal temperature during charging or discharging, such as excessive temperature, there may be a slight short circuit inside the lithium-ion battery.
- Suddenly stop working
When the lithium-ion battery suddenly stops working during use, it is very likely that the lithium-ion battery has been discharged. When the minimum voltage of the protection board or the controller is reached, the self-protection function of the lithium-ion battery is turned on, resulting in a power outage.
If the excessive working current for a long time exceeds the designed protection current of the protection board or the continuous current of the controller, the protection board or the controller will stop working, causing the lithium-ion battery to suddenly stop working.
Custom LiPo & Lithium Battery Manufacturer – GEB
General Electronics Battery (GEB) is a lithium battery manufacturer serving international B2B customers with over 15 years of industry experience. We specialize in high-performance OEM/ODM custom battery packs for agricultural drones, FPV UAVs, industrial robots, e-bikes, and commercial energy systems.
| Evaluation Factor | Engineering Specification | Verification Method | Red Flags to Watch |
|---|---|---|---|
| Cell Sourcing & Lot Quality | Grade-A tier-1 brand or verified source cell | Original factory lot inspection sheet & OCV scan | Unverified reclaimed or mixed-lot B-grade cells |
| Cell Matching Tolerances | ΔV ≤ 5mV, ΔAC IR ≤ 2mΩ (@1kHz), ΔCap ≤ 1% | Automated sorting data before pack assembly | No screening data; directly spot-welded upon arrival |
| BMS Protection & Hardware | Overcharge, overdischarge, overcurrent, thermal cutoff | Active bench load testing & NTC calibration | Generic boards without custom threshold specifications |
| Welding & Structural Safety | Pure nickel strip, pull strength ≥ 5.0 kgf, UL94-V0 | Destructive pull-force testing & micro-section | Nickel-plated steel strips or fragile hand soldering |
| Aging & Quality Audit | 100% full charge-discharge cycle & capacity log | Automated aging cabinet logs with Pack SN | Zero aging cycle; packed immediately after welding |
Written by: GEB Engineering Team | Technical Review by: Senior Quality Diagnostics Lead | Updated: August 2026
Direct Answer: The most common operational faults in industrial lithium batteries stem from four root causes: ① Premature voltage cutoff: caused by cell capacity imbalance or elevated internal resistance in one series cell; ② No output voltage: triggered by BMS low-voltage sleep protection, blown fuse, or loose balance lead; ③ Physical pouch swelling: generated by gas evolution from electrolyte decomposition during high-temperature overdischarge; and ④ Rapid self-discharge: caused by internal separator micro-contaminants.
- Tailored Engineering: Custom voltage (1S–24S+), high capacity, ultra-high discharge rates (up to 150C burst), and integrated smart BMS.
- Documentation topics may include UL, CE, UN 38.3, MSDS, RoHS and ISO 9001; applicability depends on model, configuration and market.
- Fast Prototyping: Rapid sample delivery in 7–10 business days for commercial testing.
Related Technical Engineering Guides: Battery Technology Improvement, New Energy Vehicle Sales Booming | New Open Structure Lithium Battery Material Enables Ultra-Fast Charging
Frequently Asked Questions
Why is LiFePO4 chemistry preferred for commercial and residential energy storage?
LiFePO4 (lithium iron phosphate) features exceptional thermal stability with thermal runaway thresholds exceeding 270°C, zero oxygen release during puncture, and superior calendar life delivering over 3,500 to 6,000 cycles at 80% Depth of Discharge (DoD).
Can different capacity or aged LiFePO4 cells be mixed in series/parallel strings?
No. Mixing cells with differing capacities or internal resistance creates voltage imbalances, leading to premature BMS low-voltage cutoffs and localized cell degradation. All series cells must be factory-graded and strictly matched within 1% capacity and IR variance.
What active balancing specifications are recommended for large LiFePO4 battery modules?
For modules exceeding 100Ah capacity, an active balancing circuit with 1.0A to 2.0A transfer current is recommended over passive bleed balancing. This prevents cell drift during the steep voltage knee at the end of the charging curve.
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