Although batteries’ internal resistance would ideally be zero, internal resistance exists due to a variety of factors. Internal resistance increases as a battery degrades. On battery cell production lines, defective cells are detected by comparing the internal resistance of tested cells to that of known-good reference cells.
Internal resistance testing is carried out at each process after battery cells are filled with electrolyte and their assembly completed (charge/discharge testing, aging testing, shipping inspections, etc.). There are two methods for measuring internal resistance: the AC method (AC-IR) and the DC method (DC-IR).
Battery cells used in vehicles typically have an internal resistance less than 1 mΩ.) When measuring low resistance levels of 1 Ω or less, internal resistance is measured using the 4-terminal method. Resistance can be measured using either the 4-terminal method or the 2-terminal method.
AC resistance meters apply a constant-current AC signal to the battery. They then detect the minuscule voltage generated by the current and calculate the resistance value. Note that DC resistance meters cannot measure batteries, which have non-zero voltage or electromotive force. Measurement method varies depending on the equipment configuration.
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