Battery health reporting fails independent validation across manufacturers

Abstract

Battery state-of-health (SOH) reported by on-board battery management systems (BMS) is the primary metric available to electric vehicle (EV) owners and regulators, yet no study has validated its reliability across manufacturers against independent measurements. Here we show, through an epidemiological study of 1,114 EVs spanning five manufacturers and 375 days, that battery health reporting is fundamentally unreliable: real capacity differences of 12-25% exist within every model, but BMS SOH fails to track them, with correlations ranging from \r{ho} = 0.10 (non-significant) to \r{ho} = 0.62 only under restrictive filtering, while 384 vehicles do not expose SOH at all. A manufacturer-independent electrochemical marker achieves 74-89% degradation classification accuracy across all platforms without requiring BMS data, and a controlled laboratory validation on cells identical to those in the fleet confirms that partial-voltage-window charge measurements track reference capacity with \r{ho} > 0.80 across all 60 voltage windows (p < 0.001). These findings reveal a structural information asymmetry with direct implications for the EU Battery Regulation's 2027 SOH transparency mandate, California's Advanced Clean Cars (ACC) II durability requirements, warranty enforcement, used-vehicle valuation, right-to-repair legislation, and second-life battery markets.