U.S. patent application number 09/902492 was filed with the patent office on 2002-01-24 for apparatus and method for carrying out diagnostic tests on batteries and for rapidly charging batteries.
Invention is credited to Klang, James K..
Application Number | 20020008523 09/902492 |
Document ID | / |
Family ID | 22244413 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020008523 |
Kind Code |
A1 |
Klang, James K. |
January 24, 2002 |
Apparatus and method for carrying out diagnostic tests on batteries
and for rapidly charging batteries
Abstract
A method and system for performing automatic and rapid
diagnostic testing and charging of a battery. The diagnostic test
unit utilizes a charger combined with a rapidly variable load.
After inputting battery characteristics including the cranking
rating (CCA or CA) and the temperature of the battery, a diagnostic
ramp procedure is utilized to provide an instantaneous current
versus voltage analysis to determine the instantaneous cranking
value (i.e., the single crank capability at full charge) of the
battery being tested. If the instantaneous cranking value of the
battery is above a level determined acceptable, a sustained
discharge is carried out to tax the capacity of the battery. At the
end of the constant current discharge, the current is again to
determine a loaded cranking value which simulates the battery power
after multiple cranking attempts. If the loaded cranking value is
below a desired percentage of the cranking rating, then the battery
is put into charge. If a battery cannot be acceptably charged
within the time of a given number of diagnostic probes, the battery
is deemed to be a bad battery. The charging steps utilized during
the diagnostic testing, as well as any charging of batteries
determined to be good, utilizes a novel interactive stepping
procedure which allows batteries determined to be good to be
recharged in a minimum period of time without overheating the
battery.
Inventors: |
Klang, James K.; (Eagan,
MN) |
Correspondence
Address: |
Judson K. Champlin
WESTMAN CHAMPLIN & KELLY
International Center
900 South Second Avenue, Suite 1600
Minneapolis
MN
55402-3319
US
|
Family ID: |
22244413 |
Appl. No.: |
09/902492 |
Filed: |
July 10, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09902492 |
Jul 10, 2001 |
|
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|
09361487 |
Jul 26, 1999 |
|
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6259254 |
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60094308 |
Jul 27, 1998 |
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Current U.S.
Class: |
324/429 ;
320/125 |
Current CPC
Class: |
G01R 31/3842 20190101;
H02J 7/0069 20200101; H02J 7/007194 20200101; H02J 7/0071 20200101;
G01R 31/386 20190101; G01R 31/3648 20130101; G01R 31/3647
20190101 |
Class at
Publication: |
324/429 ;
320/125 |
International
Class: |
G01N 027/416; H02J
007/00 |
Claims
I claim:
1. A method of charging a battery, comprising: outputting a charge
voltage to the battery in dependence on a base voltage level;
adjusting the charging voltage in steps of predetermined magnitude
to provide first, second and third voltage levels; measuring first,
second, third and fourth currents, wherein the first current is
measured at the first voltage level, the fourth current is measured
at the third voltage level, and the second and third currents are
measured at the second voltage level at differing times;
calculating a first differential from the difference in the first
and second currents and calculating a second differential from the
difference in the third and fourth currents; comparing the first
differential to the second differential; and adjusting the base
voltage as a function of the comparison.
2. The method as recited in claim 1, wherein the first voltage
level is less than the second voltage level and the second voltage
level is less than the third voltage level.
3. The method as recited in claim 1, wherein the first voltage
level is greater than the second voltage level and second voltage
level is greater than the third voltage level.
4. The method as recited in claim 1, wherein the step of adjusting
the base voltage further comprises the step of increasing the base
voltage a selected increment amount if the first differential is
greater than the second differential.
5. The method as recited in claim 1, wherein the step of adjusting
the base voltage further comprises the step of decreasing the base
voltage a selected increment amount if the first differential is
less than the second differential.
6. The method as recited in claim 1, wherein the step of measuring
further comprises delaying the measurement of the first current for
a predetermined time increment.
7. The method as recited in claim 1, wherein the step of measuring
further comprises delaying the measurement of the second current
for a first predetermined time increment and the measurement of the
third current for a second predetermined time increment greater
than the first predetermined time increment.
8. The method as recited in claim 7, wherein the first
predetermined time increment is selected to allow the current to
become substantially stable.
9. The method as recited in claim 8, wherein the second
predetermined time increment is selected to allow the current to
become substantially stable.
10. The method as recited in claim 1, wherein the step of measuring
further comprises delaying the measurement of the fourth current
for a predetermined time increment.
11. The method as recited in claim 1, wherein the first and second
voltage levels and the second and third voltage levels generally
differ by a predetermined voltage step.
12. The method as recited in claim 11, wherein the predetermined
voltage step is selected to generate a minimal measurable current
response.
13. The method as recited in claim 1, further comprising the step
of accumulating in a moving average the result of the step of
comparing each time the step of comparing is performed.
14. The method as recited in claim 13, further comprising the step
of making the accumulated moving average relative on a zero to one
scale and using the relative, accumulated moving average multiplied
by a predetermined voltage when adjusting the charging voltage.
15. The method as recited in claim 11, wherein the first and second
voltage levels and the second and third voltage levels generally
differ by the predetermined voltage step.
16. The method as recited in claim 1, further comprising the steps
of determining if the battery is effectively charged and, if the
battery is effectively charged, conditioning the battery.
17. The method as recited in claim 16, wherein the step of
conditioning the battery comprises supplying a constant current to
the battery to generally equalize the battery cells and
substantially destratify the battery electrolyte.
18. The method as recited in claim 17, wherein the step of
determining if the battery is effectively charged comprises
determining if the charging current falls below a fraction of a
determined capacity of the battery in ampere-hours.
19. The method as recited in claim 17, wherein the step of
determining if the battery is effectively charged comprises
determining if the charging current falls below a predetermined
fraction of an estimate of the cranking power of the battery at
full charge.
20. The method as recited in claim 1, further comprising the step
of monitoring for a drop in current and, if a drop in current is
detected, stopping the charging of the battery.
21. The method as recited in claim 1, further comprising the step
of performing a diagnostic test on the battery to determine if the
battery is in a condition to be effectively charged.
22. A readable medium having processor-executable instructions for
use in charging a battery, the instructions performing the steps
comprising: outputting a charge voltage to the battery in
dependence on a base voltage level; adjusting the charging voltage
in steps of predetermined magnitude to provide first, second and
third voltage levels; measuring first, second, third and fourth
currents, wherein the first current is measured at the first
voltage level, the fourth current is measured at the third voltage
level, and the second and third currents are measured at the second
voltage level at differing times; calculating a first differential
from the difference in the first and second currents and
calculating a second differential from the difference in the third
and fourth currents; comparing the first differential to the second
differential; and adjusting the base voltage as a function of the
comparison.
23. A method of charging a battery, comprising: outputting a charge
current to the battery in dependence on a base current level;
adjusting the charging current in steps of predetermined magnitude
to provide first, second and third current levels; measuring first,
second, third and fourth voltages, wherein the first voltage is
measured at the first current level, the fourth voltage is measured
at the third current level, and the second and third voltages are
measured at the second current level at differing times;
calculating a first differential from the difference in the first
and second voltages and calculating a second differential from the
difference in the third and fourth voltages; comparing the first
differential to the second differential; and adjusting the base
current as a function of the comparison.
24. The method as recited in claim 23, wherein the step of
measuring further comprises the step of delaying each of the
measurements of the first, second, third and fourth voltages for a
respective, predetermined time increment.
25. The method as recited in claim 24, wherein the respective,
predetermined time increments for measuring the first, third and
fourth voltages are selected to allow the current to become
substantially stable.
26. A battery tester and charger system, comprising: an adjustable
power source adapted to electrically charge a battery at variable
current or voltage levels; an adjustable load adapted to
electrically discharge the battery at variable current or voltage
levels; feedback sensors adapted to generate signals indicative of
conditions within the system; a controller in communication with
the feedback sensors, the power source and the load, the controller
adapted, as a function of the signals, to engage and disengage the
power source and the load with a battery and to adjust the power
source and the load to effectively test and charge the battery.
27. The system as recited in claim 26, wherein the controller is
further adapted to stop the test and charge of the battery as a
function of the signals.
28. The system as recited in claim 26, wherein the feedback sensors
are selected from a group consisting of a charging current sensor,
a discharging current sensor, a voltage sensor, a reverse polarity
sensor, a temperature sensor, and a proximity sensor.
29. The system as recited in claim 26, wherein the controller
issues commands to the power source to output a charge voltage to
the battery in dependence on a base voltage level and to adjust the
charge voltage in steps of predetermined magnitude to provide
first, second and third voltage levels to the battery, wherein the
feedback sensors measure first, second, third and fourth currents
being supplied to the battery, the first current being measured at
the first voltage level, the fourth current being measured at the
third voltage level, and the second and third currents being
measured at the second voltage level at differing times, and
wherein the controller is further adapted to calculate a first
differential from the difference in the first and second currents
and a second differential from the difference in the third and
fourth currents, to compare the first differential to the second
differential and to command the power source to adjust the base
voltage as a function of the comparison thereby effectively
charging the battery.
30. The system as recited in claim 26, further comprising a display
and an input device in communication with the controller, the
display providing feedback to an operator of the system and the
input device receiving input from the operator to control the
operation of the system.
31. The system as recited in claim 26, further comprising a printer
for outputting information representative of the signals generated
by the sensors.
32. The system as recited in claim 30, wherein the controller
causes the battery to be automatically tested and charged in
response to the operator using the input device to initiate the
operation of the system.
33. The system as recited in claim 26, wherein the controller is
adapted to perform a diagnostic ramp procedure to provide an
instantaneous current versus voltage analysis to determine if the
controller should proceed with causing the battery to be
charged.
34. The system as recited in claim 26, further comprising a cabinet
in which is carried the adjustable power source, the rapidly
adjustable load, the feedback sensors and the controller, the
cabinet further comprising a safety chamber adapted to carry the
battery.
35. The system as recited in claim 34, wherein the safety chamber
further comprises a safety glass cover.
36. The system as recited in claim 34, wherein the safety chamber
has a proximity sensor for detecting the presence of the
battery.
37. The system as recited in claim 34, wherein the safety chamber
has a temperature sensor.
38. In a battery diagnostic system, a method for performing a
diagnostic test on a battery to determine if the battery is in a
condition acceptable for recharging the battery, the method
comprising: automatically determining an instantaneous cranking
value for the battery; and if the instantaneous cranking value for
the battery is determined to be above a predetermined level,
automatically performing the further steps of: performing a
sustained discharge of the battery to generally tax the capacity of
the battery; determining a loaded cranking value for the battery
that generally simulates battery power after multiple cranking
attempts; and if the loaded cranking value for the battery is above
a desired percentage of a rated cranking value for the battery,
deeming the battery to be in good condition for charging.
39. The method as recited in claim 38, wherein the step of
automatically determining the instantaneous cranking value for the
battery further comprises using a cold cranking rating and
temperature of the battery in connection with a diagnostic ramp
procedure to perform an instantaneous current versus voltage
analysis on the battery.
40. The method as recited in claim 39, further comprising the step
of accepting from a user input device the cold cranking rating of
the battery and the temperature of the battery.
41. The method as recited in claim 39, further comprising the step
of accepting from a temperature sensor the temperature of the
battery.
42. The method as recited in claim 38, wherein the step of
determining the loaded cranking value for the battery further
comprises the step of ramping a current discharged from the battery
from a first level to a second, lower level.
43. The method as recited in claim 38, wherein the step of
determining the loaded cranking value for the battery further
comprises the step of ramping a current discharged from the battery
from a first level to a second, higher level.
44. The method as recited in claim 38, wherein the step of
performing a sustained discharge of the battery further comprises
the step of selectively placing an adjustable load in electrical
connection with the battery.
45. The method as recited in claim 38, if the loaded cranking value
is below a desired percentage of a rated cranking value for the
battery, repeating the diagnostic test over a predetermined number
of iterations.
46. The method as recited in claim 38, further comprising the step
of sensing if the battery is connected to the system, and in
response to a sensed connection, prompting a user for a
characteristic of the battery, and using the characteristic in
performing the step of automatically determining the instantaneous
cranking value for the battery.
47. The method as recited in claim 38, further comprising the step
of sensing the open circuit voltage of the battery and, if the open
circuit voltage is below a predetermined value, performing further
diagnostic tests on the battery.
48. A readable-medium having processor executable instructions for
use in performing a diagnostic test on a battery to determine if
the battery is in a condition acceptable for recharging the
battery, the instructions performing the steps comprising:
automatically determining an instantaneous cranking value for the
battery; and if the instantaneous cranking value for the battery is
determined to be above a predetermined level, automatically
performing the further steps of: performing a sustained discharge
of the battery to generally tax the capacity of the battery;
determining a loaded cranking value for the battery that generally
simulates battery power after multiple cranking attempts; and if
the loaded cranking value is above a desired percentage of a rated
cranking value for the battery, deeming the battery to be in good
condition for charging.
49. In a battery diagnostic and charging system, a method for
performing a diagnostic test on a battery to determine if the
battery is in a condition acceptable for recharging the battery,
the method comprising: automatically determining the instantaneous
cranking value for the battery; and if the instantaneous cranking
value for the battery is determined to be above a predetermined
level, automatically performing the further steps of: performing a
sustained discharge of the battery to generally tax the capacity of
the battery; determining a characteristic of the battery under
load; and if the determined battery characteristic is within a
desired percentage of a rated characteristic for the battery,
recharging the battery.
50. The method as recited in claim 49, wherein the characteristic
of the battery is a loaded cranking value for the battery that
generally simulates battery power after multiple cranking
attempts.
51. The method as recited in claim 50, wherein the step of
determining comprises determining if the loaded cranking value for
the battery is above a desired percentage of a rated cranking value
for the battery.
52. In a battery diagnostic and charging system, a method for
operating the system comprising: accepting from a user input device
a characteristic of a battery; and in response to the input of the
characteristic, automatically performing the further steps of:
determining if the battery is in a condition to be recharged; and
if the battery is in a condition to be recharged, recharging the
battery.
53. The method as recited in claim 52, wherein the characteristic
is the cold cranking rating of the battery.
54. The method as recited in claim 52, further comprising the step
of conditioning the battery after the battery has been generally
recharged.
55. In a battery diagnostic and charging system connectable to a
battery, a method for operating the system, comprising: performing
a diagnostic test on the battery; if the battery passes the
diagnostic test, charging the battery; and during the steps of
performing the diagnostic test and charging the battery, sensing if
a disconnection of the battery from the system occurs and, in
response to a sensed disconnect, automatically discontinuing the
steps of performing the diagnostic test and charging the
battery.
56. The method as recited in claim 52, further comprising the step
of testing the state of the battery while determining if the
battery is in a condition to be recharged and recharging the
battery.
57. A method for performing a diagnostic on a battery, the method
comprising: discharging the battery at a first predetermined
amperage to determine a single crank capability of the battery;
discharging the battery at a second predetermined amperage to
determine a multiple crank capability of the battery; and
determining a state of the battery using the single crank
capability and the multiple crank capability.
58. The method as recited in claim 57, wherein the second
predetermined amperage is higher than the first predetermined
amperage.
59. The method as recited in claim 57, wherein the step of
determining the state of the battery comprises deriving a
resistance activation voltage for the battery using the single
crank capability and multiple crank capability.
60. In a battery diagnostic and charging system connectable to a
battery, a method for operating the system, comprising: sensing if
a reverse connection exists between the battery and the system; if
the reverse connection is not sensed, performing a diagnostic test
on the battery; and if the battery passes the diagnostic test,
charging the battery.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
Application Ser. No. 60/094,308 filed on Jul. 27, 1998, still
pending.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of lead-acid
batteries, and, more particularly, to an apparatus and a method for
rapidly carrying out highly discriminating diagnostic tests on
lead-acid batteries and charging such batteries if appropriate.
BACKGROUND OF THE INVENTION
[0003] Over the years, the purchasing habits of customers for
starting, lighting and ignition ("SLI") batteries for automotive
and other applications has changed. In the replacement market for
SLI batteries, it has been increasingly the case that customers
purchase such batteries at mass merchandisers and that warranties,
often relatively expensive, are provided.
[0004] Accordingly, when a customer has problems starting his
vehicle and suspects that the battery has gone bad, the customer
returns the battery to the retailer or other location where the
battery was purchased, and the warranty provided with the sale
comes into play. A typical resolution is that the retailer takes
the "bad battery" back, providing a new battery.
[0005] Indeed, it seems that the battery gets the blame as the
cause for the problem regardless. Yet, it has been found that a
significant proportion of batteries perceived as bad, and thus
replaced per the warranty, are in fact lacking in charge, but
capable of being recharged so as to provide satisfactory
performance in use. The warranty cost to both the retailer or other
battery seller and to the battery manufacturer is substantial.
[0006] For this reason, mass merchandisers and other battery
sellers have turned to various types of testing devices in an
attempt to effectively distinguish between good and bad batteries.
Some battery testers which have been used carry out simple fixed
discharges to determine battery power. Such testers are a variation
of a standard load test in the industry which discharges the
battery at half its cold cranking rate for 15 seconds and then
looks for a minimum voltage adjusted for temperature to determine
whether the battery being tested is good or not. While such a
standard test is relatively simple and straightforward, this test
requires that the battery be highly charged, a condition usually
lacking in batteries that are giving problems for whatever reason
and are thus perceived as being bad. Such a standard test also
requires a large sustained discharge current which, of course,
discharges the battery significantly. Many commercial diagnostic
testing units include a fixed resistor which discharges all
batteries at a close-to-constant rate that is well below the load
test. Acceptable voltages are either fixed or relative to the
cranking rate of the battery.
[0007] Testing units can also combine charging with the discharge
test. Charging usually is done with a straight fixed voltage or
current charger from a simple transformer with a rectifying diode
which tries to force charge into the battery no matter what its
condition. Yet, charging a battery can mask defects such as shorted
cells and the like. Further, when batteries with shorted cells or
bad internal connections are charged substantially, there can be a
great deal of gassing and spewing of electrolyte which can be
dangerous.
[0008] Another type of test unit proposed and used is a unit
providing a conductance meter. Using relatively small current
probes, the internal conductance of the battery is measured. This
internal conductance is assumed to be proportional to the cranking
rate of the battery, therefore providing a relative performance
criteria. However, this type of test unit does not stress or
polarize the battery enough to determine if there is sufficient
power to sustain a discharge for more than a brief instant and
cannot accurately predict the full-charge performance when the
battery being tested is in a heavily discharged condition. Such an
analysis also provides no information about the chargeability of
the battery being tested.
[0009] Accordingly, despite the clear need for a highly
discriminating lead-acid battery diagnostic test unit, it is
believed that none of the types of test units being used satisfy
the need. The warranty problem is a major issue in the lead-acid
battery field which has simply not been solved.
[0010] Indeed, the situation is perhaps exacerbated by the
increasing role mass merchandisers play in selling SLI and other
lead-acid batteries. More particularly, the personnel responsible
for dealing with battery returns not only do not have
discriminating test units at their disposal, but are often less
than adequately trained to deal with the many issues underlying
whether a battery being returned is bad or good.
[0011] Still further, in many situations, the lack of patience of
the customer can be evident. A decision as to whether the battery
is good or bad needs to be capable of being provided in a
relatively short period of time. Additionally, if the battery is
determined to be good but in a discharged condition, then the
customer will want to have the battery recharged in as short a time
as possible.
[0012] Given the many and varied parameters that need to be
addressed to allow a highly discriminating diagnostic testing
regiment to take place and to rapidly recharge acceptable
batteries, providing a suitable diagnostic test unit which can be
safely used by the responsible personnel is a formidable task.
Accordingly, it is a primary object of the present invention to
provide a method and apparatus capable of rapidly discriminating
between good and bad lead-acid batteries. A more specific object of
this invention provides a test regiment capable of carrying out the
appropriate determination in no more than 15, and still more
preferably less than 10, minutes.
[0013] Another object lies in the provision of a diagnostic test
unit capable of testing various types of lead-acid batteries having
a variety of capacities as well as conditions while appropriately
discriminating between good and bad batteries.
[0014] Still another object of the present invention provides a
diagnostic test unit which can be operated by personnel with
limited training at most.
[0015] Yet another object of the present invention provides a
diagnostic test unit characterized by safety features which
minimize, if not eliminate, safety issues as regards both users and
as to the test units themselves.
[0016] A more specific object of this invention lies in the
provision of a diagnostic test unit which includes an interactive
charging unit capable of rapidly and reliably recharging lead-acid
batteries.
[0017] Other objects and advantages will become apparent from the
following detailed description.
SUMMARY OF THE INVENTION
[0018] In general, the present invention provides a straightforward
diagnostic test unit and system which automatically and rapidly
takes advantage of the known phenomenon that battery resistance can
be characterized by discharging at various rates and measuring the
resulting voltage. Thus, as is known, the current versus voltage
relationship is linear and the proportionality constant is the
resistance (or inversely the conductance) of the battery in a
discharging mode. This can also provide a derived voltage at
vanishing current which represents the polarized potential of the
battery. According to the present invention, the diagnostic test
unit utilizes a charger combined with a rapidly variable load. Each
is controlled by signals to and from a microprocessor; and,
additionally, an input display provides directions to, and derives
information from, the system operator. After inputting the battery
type (12V or 6V), the cold cranking rating ("CCA") or cranking
rating ("CA"), and providing the temperature of the battery, a
diagnostic ramp procedure is utilized to provide an instantaneous
current versus voltage analysis to determine the instantaneous CCA
(i.e., the single crank capability at full charge) of the battery
being tested. If the instantaneous CCA of the battery being tested
is above a level determined acceptable, a sustained discharge is
carried out to tax the capacity of the battery.
[0019] The amount of time held at this sustained discharge rate is
proportional to the determined instantaneous CCA of the battery and
the temperature. Small batteries with low CCA rates are discharged
a shorter time than large CCA batteries while cold batteries are
discharged for a shorter period of time than are hot batteries.
[0020] At the end of the constant current discharge, the current is
again ramped from a high level to a lower level to determine a
loaded or polarized CCA which simulates the battery power after
multiple cranking attempts. If the loaded CCA (i.e., the single
crank capability at the present state of charge of the battery) is
below a desired percentage of the rated capacity, then the battery
is put into charge. It has been found that a battery does not have
to be charged very much to respond acceptably to these ramping
probes. Indeed, if a battery cannot be acceptably charged within
the time of a given number of diagnostic probes, the battery is
deemed to be a bad battery.
[0021] In accordance with the preferred embodiment of the present
invention, the charging steps utilized during the diagnostic
testing, as well as any charging of batteries determined to be
good, utilizes a novel interactive stepping procedure which allows
batteries determined to be good to be recharged in a minimum period
of time without overheating the battery or spewing electrolyte.
[0022] Additional features and advantages of the invention will be
made apparent from the following detailed description of
illustrative embodiments which proceeds with reference to the
accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] While the appended claims set forth the features of the
present invention with particularity, the invention, together with
its objects and advantages, may be best understood from the
following detailed description taken in conjunction with the
accompanying drawings of which:
[0024] FIG. 1 is a block diagram of a battery diagnostic tester and
charging system embodying the present invention;
[0025] FIG. 2 is a block diagram of a system controller for
performing diagnostic tests and charging a battery according to the
invention;
[0026] FIG. 3 is a block diagram of DC sensors for sensing voltage
and current across the battery terminals according to the
invention;
[0027] FIG. 4 is a block diagram of a variable programmable DC
power supply/load for charging and discharging batteries according
to the invention;
[0028] FIG. 5 is a logic flow diagram illustrating the steps
involved in performing the diagnostic battery test and battery
charge procedures according to the present invention;
[0029] FIG. 6 is a logic flow diagram illustrating the steps
involved in starting up the diagnostic tester and charging
system;
[0030] FIGS. 7A and 7B are logic flow diagrams illustrating the
steps involved in performing the diagnostic procedure;
[0031] FIG. 8 is a logic flow diagram illustrating the steps
involved in performing the diagnostic ramp procedure;
[0032] FIGS. 9A and 9B are logic flow diagrams illustrating the
steps involved in performing the charge start procedure;
[0033] FIG. 10 is a logic flow diagram illustrating the steps
involved in performing the charge control procedure;
[0034] FIG. 11 is a logic flow diagram illustrating the steps
involved in charging the battery according to the interactive
stepping procedure;
[0035] FIG. 12 is a logic flow diagram illustrating the steps
involved in running the current stability reset procedure;
[0036] FIGS. 13A and 13B are logic flow diagrams illustrating the
steps involved in the check procedure;
[0037] FIGS. 14A and 14B are logic flow diagrams illustrating the
steps involved in conditioning or destratifying the cells of a
battery;
[0038] FIG. 15 is a logic flow diagram illustrating the steps
involved in monitoring the current stability during the charging
procedure;
[0039] FIG. 16 is a logic flow diagram illustrating the steps
involved in stopping the charger/discharger once a "good" battery
is tested and charged;
[0040] FIG. 17 is a logic flow diagram illustrating the steps
involved once a battery is deemed untestable;
[0041] FIG. 18 is a logic flow diagram illustrating the steps
involved in shutting down the charger/discharger if stopped by the
operator or if the conducting cables are removed;
[0042] FIG. 19 is a logic flow diagram illustrating the steps
involved in shutting off the charger/discharger if the battery
tested is a failure;
[0043] FIG. 20 is a logic flow diagram illustrating the steps
involved in shutting off the charger/discharger if a fault
occurs;
[0044] FIGS. 21A and 21B are probing profiles that illustrate the
stepped output voltage settings over time in conformance with the
interactive stepping procedure; and
[0045] FIG. 22 is a graphical representation of the diagnostic
tester and charger unit according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] The present invention is directed to a battery diagnostic
testing system and method that tests batteries under both charge
and discharge conditions yielding discriminating data relating to
the condition and usability of the batteries. The invention is
further directed to a battery charging system and method that
rapidly recharges batteries based on an interactive charging
procedure. While this invention is primarily described with respect
to the diagnostic testing and charging of lead-acid batteries,
there is no intention to limit the invention to any particular type
of battery. Rather, the invention is specifically intended to be
used with all types of batteries capable of accepting an external
charge, including, but not limited to, all types of lead-acid
batteries, nickel-cadmium batteries and other rechargeable battery
types.
[0047] Turning to the drawings and referring first to FIG. 1, a
diagnostic tester and charging system 10 according to the invention
comprises a system controller 12, a variable programmable DC power
supply and load 14, DC sensors 24, conducting cables 18 and a
battery 16. The system controller 12 is coupled to the power supply
14 and includes control circuitry for regulating the output of the
power supply 14. The power supply and load 14 are coupled in a
conventional manner to a battery 16 using conducting cables 18
which link the power supply and load 14 to the charging terminals
20, 22 of the battery 16. Depending on the amount of charge to be
conveyed, the conducting cables 18 may comprise heavy-gauge copper
wires or cabling compliant with National Electrical Code
requirements. The DC sensors, which sense current and voltage
across the battery terminals 20, 22, return the values thereof to
the system controller 12 to which they are coupled.
[0048] As shown in FIG. 2, the system controller 12 comprises a
microprocessor 26, a memory 28, and input/output (I/O) circuitry 30
connected in a conventional manner. The memory 28 is comprised of
random access memory (RAM), read-only memory (ROM) and the like.
The I/O circuitry 30 is coupled to an operator input 32 that
comprises the means to input relevant operator commands and data,
such as the rated CCA (Cold Cranking Amps) of the battery. The I/O
circuitry 30 is also coupled to a display 34 that comprises the
means to display relevant output messages, such as messages
informing the operator on the status of diagnostic testing or
charging, or messages prompting the operator to enter commands or
data. The I/O circuitry 30 is further coupled to the power supply
and load 14 and comprises the means to send commands originating in
the microprocessor 26 to the power supply and load 14 and to send
messages originating in the power supply and load 14 to the
microprocessor 26. Similarly, the I/O circuitry 30, which is
coupled to the DC sensors 24 through the use of sensing leads,
comprises the means to receive sensor data.
[0049] The preferred system controller 12 includes
analog-to-digital converters 38 therein for converting the current
and voltage measurements supplied by the DC sensors 24 to digital
values capable of being manipulated by the microprocessor 26. The
system controller 12 also includes a digital-to-analog converter 40
therein for converting a digital control signal to the proper
analog signal required by the power supply and load 14. In the
preferred embodiment, pulse width modulators (PWMs) are used in
place of digital-to-analog converters 40 to generate the command
signal. Moreover, in the preferred embodiment, the
analog-to-digital converters 38 and pulse width modulators 40 are
contained within, or on board, the microprocessor 26 along with RAM
and ROM 28. Alternatively, the analog-to-digital converters and
pulse width modulators can be separate devices contained within
either the input/output circuitry 30 (as shown) or the DC sensors
24.
[0050] One integrated circuit, a Microchip PIC17C756
microcontroller, has been identified as being particularly useful
as a component within the system controller 12, as it provides a
microprocessor, RAM, ROM, analog-to-digital converters and
timer/counter capabilities in a single chip. The PIC17C756
analog-to-digital converters allow conversion of an analog input
signal, here voltage, to a corresponding 10-bit digital number
through the use of analog voltage comparators. The PIC17C756 also
allows transmission of signals enabled through the use of on-board
pulse width modulators.
[0051] As represented in FIG. 3, the exemplary diagnostic tester
and charger is comprised of four DC sensors: a charging current
sensor 42, a discharging current sensor 44, a voltage sensor 46,
and a reverse polarity sensor 48. As illustrated, the voltage
sensor 46 is connected in a conventional manner to measure the
voltage across the terminals 20, 22 of the battery 16. The voltage
across the battery terminals is read and attenuated by a voltage
attenuator in order to match the input range of the
analog-to-digital converters 38 residing in the system controller
12. The voltage sensor 46 is selected so as to be sensitive enough
to reflect critical voltage changes with 0.01V accuracy.
[0052] The reverse polarity sensor 48, connected in a like manner
across the battery terminals 20, 22, senses negative voltage
indicating that the battery leads are connected backwards. The
reverse polarity sensor 48 is similarly connected to a voltage
attenuator which scales the voltage reading to match the input
range of the analog-to-digital converters 38.
[0053] The charging current sensor 42 and discharging current
sensor 44 are connected to measure the current across a shunt
resistor 50. Due to differences in current magnitude and
sensitivity, two current sensors may be required to measure the
charge and discharge currents. The charging current sensor 42, used
to measure current flow into the battery 16, is selected so as to
be sensitive and accurate enough to measure changes in the charging
current at the various steps of the charging procedure. (See FIG.
11). According to the invention, the charging current sensor 42
should be capable of sensing current in the range between 0 and 80
A.
[0054] The discharging sensor 44, used to measure current flow out
of the battery 16, is selected so as to be sensitive enough to
measure a wide range of current during the diagnostic discharge
routine. (See FIGS. 7A and 7B). According to the invention, the
discharge current sensor 44 measures current flow between 0 and 400
A. In addition, the charging and discharging current sensors are
connected to a current amplifier which scales the current reading
to match the input range of the analog-to-digital converters.
[0055] As shown in FIG. 4, the variable programmable DC power
supply and load 14 includes a DC power supply 52 and a variable
load 54. According to the invention, the power supply 14 is capable
of providing an electrical charge output at either a variable
voltage level or a variable current level (or both). The amount of
current and/or voltage supplied by the power supply 14 is
determined by the system controller 12 which sends commands to the
power supply 14. The power supply 14, therefore, includes the means
to interpret the commands which can be either in the form of
digital signals or analog signals. In the preferred embodiment,
pulse width modulators 50 are provided within the system controller
12 so that the power supply only requires the means to interpret
analog commands.
[0056] To discharge current from the battery 16, a variable load 54
is programmed to provide a variable or constant (sustained) load
between 0 to 400 A. Programmable load variance is used to determine
battery performance during diagnostic testing. The preferred
variable load 54 is comprised of a series of field effect
transistors (FETs) connected to heat sinks. Alternatively, a series
of straight resistors can be used to vary the load or one large
resistor can be used while simultaneously charging and discharging
to effectively vary the resistance or any combinations thereof.
Like the power supply 14, the variable load 54 includes the means
to interpret commands sent by the system controller 12.
[0057] During the diagnostic test or charge, the system controller
12 may control means 56 such as a relay, a switch or the like to
automatically connect the battery 16 to the circuit. For example,
the switch 56 is open while measuring the open circuit voltage of
the system. Conversely, the switch 56 is closed allowing current to
flow across a shunt resistor 50 to enable charging, discharging and
current measurements to be taken.
[0058] It can be readily appreciated that any number of equivalent
system controllers and DC power supplies/loads can be developed
from other digital and analog circuitry components to perform the
desired control functions as described in more detail below. For
example, a diagnostic tester and charger apparatus has been
implemented comprising an IBM 486SX33MHz personal computer as the
system controller 12 executing instructions originally written in
the BASIC programming language (here Quick Basic Version 4.5), to
control a switch mode power supply and load 14 via a data
acquisition/control board interface bus. A diagnostic tester and
charger apparatus has also been implemented comprising a system
with an on-board microprocessor for measuring and adjusting the
components for charging and discharging but takes commands from a
higher level processor on-board a PC computer via an RS232
interface bus.
[0059] While not necessary to the invention, it can also be readily
appreciated that it is preferable to employ dedicated circuitry as
the system controller 12 and power supply and load 14 for use in
commercial applications such as in vehicle-based battery testing
and charging systems or stand-alone battery testing and charging
devices.
[0060] According to the invention, the system controller 12
executes a software routine that performs diagnostic tests on a
lead-acid battery to determine whether the battery is "good" (e.g.,
capable of accepting a charge and delivering acceptable power).
Upon determining that the battery is good, the battery is charged
to an appropriate level in a timely manner and may be conditioned
to destratify the electrolyte and equalize the cells and
electrodes. FIGS. 5-20 illustrate the steps involved in performing
the diagnostic battery test and charge method according to the
present invention.
[0061] FIG. 5 illustrates the overall procedure used to implement
the current invention. The exemplary testing/charging procedure
begins in step 100 by connecting, in a conventional manner, the
lead-acid battery to the diagnostic unit as illustrated in FIGS.
1-4. In step 102, the start up procedure is invoked wherein proper
connection of the battery to the diagnostic unit is verified,
critical data is input by the operator via appropriate buttons and
keys, and the voltage is measured. At step 104, a preliminary
determination is made as to whether the battery is untestable by
measuring a very low voltage after the start key is pressed. An
untestable battery causes the procedure to stop at step 106 and
return to start at step 100. A testable battery proceeds to the
diagnostic procedure at step 108 wherein the cold cranking amps,
CCA, of the battery is measured through the use of current
discharge. After the diagnostic procedure which is preceded by
several charging attempts, the battery being tested may be deemed
"bad," in which case at step 110 a decision is made to proceed to
step 112 and end diagnostic testing and charging on the battery. A
"bad" battery is generally described as one which is either
defective or appears to lack adequate cranking after one or more
charging attempts.
[0062] If the battery is not judged "bad," however, at step 114 the
charger will be turned on and the battery will be charged and
checked in accordance with the rapid interactive stepping procedure
at step 116. During the charging process, in steps 118 through 130,
a status determination is repeatedly made as to the battery's
viability. At step 118, if the battery is judged "good and charged"
to an acceptable level, the method proceeds to step 120 wherein the
battery is either conditioned to destratify the electrolyte or the
charge procedure is stopped. Alternatively, at step 122, if the
battery is judged "bad," the method proceeds to the fail shutoff
procedure at step 124 and the charger/discharger is turned off. If,
however, the operator pressed stop or the cables were removed
during the charge procedure as determined in step 126, the method
proceeds in step 128 to the shutdown procedure. If none of the
above conditions is fulfilled, meaning the battery has not tested
good and is not adequately charged, the system proceeds to step 130
where the system will either continue to charge the battery in step
116 or retest the battery in step 108. In all, the system will
attempt to charge and test the battery a limited set number of
times before designating the battery as bad and incapable of
delivering adequate power.
[0063] FIGS. 6 through 20 illustrate in more detail the various
steps outlined generally in FIG. 5. The start up procedure,
illustrated in FIG. 6, begins at step 134 by resetting and
calibrating the diagnostic tester unit. During this step, all
critical variables are initialized as required by the method. For
example, a variable AH, used to indicate the capacity of a battery
in ampere-hours, is zeroed. The reset step is implemented at the
beginning of each diagnostic testing/charging routine for each
battery regardless of whether the diagnostic unit is turned off
between batteries. Upon completion of the reset and calibration
step, at step 136 a tester identification message is posted briefly
on the display and a small delay of two seconds is implemented to
allow the system to stabilize. After the short delay, at step 138
the diagnostic tester measures the battery open circuit voltage
(OCV) with a switch 56 such that the voltage sensor 46 and reverse
polarity sensor 48 read the voltage across the battery terminals
20, 22 without any load or charge.
[0064] In all, steps 138 through 150 determine whether the battery
to be tested is properly connected to the diagnostic unit. For
example, at step 140, the diagnostic unit determines if the
operator has pressed the start button. If the start button has been
pressed, at step 142, the OCV is compared to an extremely low
voltage to determine whether the battery is testable. If the
battery's OCV is less than 0.3V, the method proceeds at step 143 to
run the untestable procedure which notifies the operator that the
battery is untestable. (See FIG. 17). If the start button has not
been pressed, at step 144, the OCV is compared to a low negative
voltage to determine whether the conducting cables 18 are properly
connected to the battery 16. If the OCV is less than -0.5V, the
method proceeds at step 146 to notify the operator that the leads
are reversed. If the OCV is greater than -0.5V, at step 148, the
OCV is compared to an extremely low voltage to determine whether a
battery is connected. If the OCV is less than 0.3V, indicating that
a battery is not connected, the method proceeds at step 150 to
display a message instructing the operator to connect the
cables.
[0065] If the OCV is greater than 0.3V, indicating a properly
connected battery, the method proceeds at step 151 to determine the
type of battery that has been connected. If the OCV is less than
7.2V, at step 152, the operator is prompted to enter the battery
type. At step 153, the operator inputs the battery type, either 12V
or 6V, depending on the type connected to unit for testing. At step
154, the operator is next prompted to enter the rating mode of the
battery. As is known in the art, batteries are rated by the CCA
(Cold Cranking Amps) or CA (Cranking Amps) of the battery, where CA
is equal to approximately 1.2 times the CCA. The CCA of a battery
is the number of amperes a lead-acid battery at 0 degrees F (-17.8
degrees C) can deliver for 30 seconds while maintaining at least
1.2 volts per cell (7.2 volts for a 12 volt battery). A typical car
battery will have a CCA in the range of 350 A to 900 A. The CA of a
battery is the number of amperes a lead-acid battery at 32 degrees
F (0 degrees C) can deliver for 30 seconds and maintain at least
1.2 volts per cell (7.2 volts for a 12 volt battery). The operator
inputs the rating mode at step 155. The operator is next prompted,
at step 156, to input the battery's rated CCA or CA and at step
157, the rated CCA or CA is input into the system. If the operator
does not alter the default value of the battery rating, the
CCArated variable is set to the previously tested value or the
default value of 550 A. In the case of a CA (cranking amps) rated
battery, the default value is 650 A.
[0066] Next, at step 158, the method prompts the operator to input
the battery's temperature. As is known in the art, the temperature
of the battery is a major factor affecting the battery's cranking
power. According to the invention, a temperature probe is used to
accurately measure the battery's temperature before the diagnostic
test. The exemplary diagnostic unit is equipped with an automatic
temperature probe, such as an infrared temperature sensor or a
thermocouple in contact with the battery. In the preferred
embodiment, the temperature sensor is in the form of a temperature
gun pointed at the battery by the operator. In another preferred
embodiment, the temperature sensor is an infrared sensor mounted in
the diagnostic unit safety chamber having safety glass, as shown in
FIG. 22, and may include a proximity sensor for sensing the
presence of the battery in the chamber. Alternatively, a manual
device for measuring temperature such as a thermometer or thermal
sensor strip affixed to the battery can be used. At step 159, the
battery temperature is input into the system. If the operator does
not alter the battery temperature, the default value is set to
80.degree. F. or the previous temperature value.
[0067] Once critical battery information is input into the system,
at step 160 the operator is prompted to press start. The method
then waits at step 162 until start is pressed where upon the method
proceeds to probe the battery for a preliminary impression of
chargeability. At step 164, the voltage and current output in the
power supply are set to appropriate levels in order to create an
inrush current. Thereafter, commands are sent to close the solenoid
switch 56 to allow current flow into the battery, to turn the
charger on, and to set the start the system timer.
[0068] In steps 166 to 170, the start up routine loops until the
inrush current exceeds a nominal value, e.g., 4 A, at which point
the diagnostic procedure is invoked at step 170 (see FIGS. 7A and
7B). If, after an adequate time, e.g., fifteen seconds, the inrush
current fails to exceed a low minimum threshold, around 0.5 A in
the preferred embodiment, the battery is deemed bad for failure to
accept a charge and the start up routine proceeds to the fail
procedure at step 176. (See FIG. 19).
[0069] As illustrated in FIG. 7A, the exemplary diagnostic
procedure begins in step 180 by informing the operator via the
display 34 that testing has begun. In step 182, the method
initializes the unit in preparation for discharge testing. More
specifically, the charger is turned off, a temperature factor used
to accurately gauge the battery's CCA is calculated, and all
cranking variables critical to the procedure are set or reset. For
example, the instantaneous CCA, CCAinst, which represents an
estimate of the cold cranking power at full charge, is set to zero.
In addition, the probe number counter is incremented to reflect the
number of diagnostic attempts made at periodic intervals, e.g.,
five minutes, to test the battery. In the preferred embodiment,
only a limited number of attempts, preferably four or less, are
made to test any particular battery before the battery is deemed
bad (see FIG. 9A, step 266). As a result, with the preferred five
minute intervals of charge, diagnosis of the battery as "good"
should occur within fifteen minutes or the battery is deemed
"bad."
[0070] After the probe number counter is incremented, the
discharger is turned on. Thereafter, in steps 184 through 196, the
adjustable load is gradually increased from zero current in
incremental amounts which effectively increases the discharge
current flow from the battery. In the preferred embodiment, at step
184, the discharge current is increased by 20 A during each pass
until the load reaches 200 A. After each increase in load, at step
186, the resultant voltage and current are measured and the
ampere-hours, AH, calculation is updated. In step 188, the current
output measured is compared to a minimum threshold value. In the
preferred embodiment, if the current output falls below 5 A, the
method proceeds at step 190 to the shutdown procedure. (See FIG.
18). Similarly, in step 192, the voltage output measured is
compared to a minimum threshold value. In the preferred embodiment,
if the voltage drops below a minimum of 7.2V, the discharge
procedure is immediately stopped at step 238 (FIG. 7B). Sustaining
a high rate of discharge at low voltages yields little information
regarding the condition of the battery and may lead to dangerous
conditions. Before proceeding to the charge routine, at step 194
the instantaneous CCA, CCAinst, is calculated and at step 208 the
CCA is set to zero. If voltage output measures above a minimum
threshold value, at step 196, the current discharge, Idischarge, is
compared to a threshold discharge current. Once the threshold
discharge current, set at 100 A in the preferred embodiment, is
reached, the diagnostic ramp procedure is invoked at step 198. (See
FIG. 8).
[0071] The diagnostic ramp procedure, as illustrated in FIG. 8,
begins at step 244 by setting/resetting the ramping variables and
setting the initial discharge current, Idischarge, to a level of
100 A. Then in steps 245 to 251, the discharge current level is
incrementally increased to reach a safe upper ramp current.
According to the invention, the battery should be taxed at a
reasonably high current value in order to produce meaningful values
of battery resistance. In the preferred embodiment, the maximum
discharge current should be near 400 A if the discharge voltage is
above a minimum level. During steps 245 to 251, the current
discharge decrement, Y, is also determined so that the discharge
ramp procedure cycles through a sufficient number of discharge
steps in order to produce an adequate number of data points for
performing regression testing.
[0072] At step 252, the discharge current and voltage are measured
across the battery terminals and the ampere-hours, AH, calculation
is updated. As the discharge process loops from step 252 to 262,
the current is rapidly decreased while the-resultant current and
voltage are measured at each level until the load reaches a base
level. According to the invention, the base level is equal to the
high current value, A1, minus four times the current discharge
decrement, Y. In the preferred embodiment, the base level is near
200 A. At step 253, if the current drops below a minimum value, the
method proceeds at step 254 to the shutdown procedure. (See FIG.
18). In the preferred embodiment, a current reading below a minimum
value of 5 A indicates cable removal or a connection interrupt.
[0073] Given an adequate current, however, at step 255 the current
and voltage measurements taken at step 252 are stored in variable
arrays and a counter, N, is incremented to track the number of
iterative measurements. During the discharge procedure, the voltage
and current are examined to verify that the battery has adequate
power. Low battery power yields only meaningless battery
measurements which are not helpful in determining the battery's
state as either good or bad. Therefore, at step 256, if the voltage
level drops below a minimum acceptable level the discharge
procedure is stopped. In the preferred embodiment, a load voltage
across the battery below 2V suspends the discharge routine until
the battery is charged. If the discharge routine is suspended, a
low value estimate of the CCA of the battery is calculated at step
258 and the process returns to the diagnostic procedure at step
268. Overall, the entire ramping discharge process generally lasts
only a fraction of a second and removes only a minimum amount of
capacity from the battery.
[0074] Once the rapid discharge is complete and a base level is
reached as indicated in step 262, the voltage and current data
measured is used to calculate regression parameters in step 264.
For example, SA and SV represent the sum of all current and voltage
measurements, respectively. Similarly, SA2 and SV2 represent the
sum of all current and voltage measurements squared, respectively.
Then, in step 266, the method uses the regression parameters to
determine the linear relation between voltage and current wherein M
represents the slope of the line in terms of negative ohms, R is
the resistance in milliohms, and VACT is a resistance activation
voltage. The resistance activation voltage is easily determined to
be the voltage at zero current predicted from the straight current
versus voltage line. A low VACT potentially indicates a short in
the battery or the battery is very discharged, whereas a high VACT
means the battery is reasonably charged.
[0075] After completion of the first discharge routine, the
diagnostic ramp procedure is exited at step 268 and the overall
diagnostic procedure resumes processing at step 200 as illustrated
in FIG. 7A. At step 200, the system determines whether a CCA has
already been calculated by comparing the CCA to zero. If a CCA has
already been calculated, as in step 258 for the reason that the
voltage dropped below a minimum set level, the process follows a
separate path ultimately charging the battery. Specifically, in
step 202 the instantaneous CCA is set to the previously calculated
CCA and the CCA is then set to zero in step 208. The system then
proceeds, as shown in FIG. 7B, to turn off the discharge unit in
step 238 prior to attempting diagnostic testing again.
[0076] If the CCA is zero in step 200, indicating that the
diagnostic ramp properly finished, at step 204 the system
calculates the instantaneous CCA, CCAinst, based on previously
calculated parameters. According to the invention,
CCAinst=(((0.00618*Battery Temperature+11.6)-(7.9+0.0043*Batte- ry
Temperature))* 1000/R)/Temperature Factor, where R is the
resistance calculated during the diagnostic ramp procedure in step
198 and Temperature Factor is a value from 1 to 3 stored in a
lookup table. If the calculated instantaneous CCA is below a
fraction, k, of the rated CCA, as in step 206, no further discharge
occurs. The method thereafter proceeds at step 208 to reset CCA to
zero and then at step 238 to turn off the discharge unit. The
battery will thereafter be charged in an attempt increase its
power. In the preferred embodiment, the tested battery should
perform at or above sixty-five percent of the rated CCA in order to
continue diagnostic testing. If the instantaneous CCA is above the
set level in step 206, a sustained discharge to tax the capacity of
the battery is performed for a period proportional to the
determined instantaneous CCA of the battery at its present
temperature. As such, batteries with a low CCA will be discharged
for a shorter period of time than those with a larger CCA.
Similarly, cold batteries will be discharged for a shorter period
of time than hot batteries.
[0077] In the preferred embodiment, the constant current discharge
is set to 200 A, or half of the CCAinst if CCAinst is less than 400
A, and the timer is started at step 210 in FIG. 7B. The procedure
then loops through steps 212 to 222, reading the resultant current,
voltage and updating the ampere-hours, AH, at step 212. In steps
214 and 218, the voltage and current are compared to minimum
threshold values during the constant current discharge period. A
current drop below 5 A indicates a connection interrupt and the
method proceeds to the shutdown procedure in step 216. (See FIG.
18). Similarly, if the voltage drops below 7.2V, the discharge
routine is stopped and the battery proceeds to turn off the
discharge unit at step 238 after setting the CCA to zero at step
200.
[0078] At the end of the constant current discharge as determined
in step 222, the cranking variables are reset at step 224 and the
diagnostic ramp procedure is invoked for the second time at step
226. As described previously and illustrated in FIG. 8, the current
is ramped from a high level to a lower level while recording the
current and voltage readings at each level. Upon returning from the
diagnostic ramp procedure, at step 228, a determination is made as
to whether the CCA was calculated. If the CCA is not equal to zero,
indicating the battery failed to complete the full ramp, a
temperature adjustment is made at step 230 and the discharge unit
is turned off at step 238.
[0079] If the CCA is equal to zero, the second ramp data is then
used to determine a loaded or polarized CCA, at step 232, which
represents the battery's actual power after multiple cranking
attempts. According to the invention,
CCA=((VACT-(7.9+0.0043*Battery Temperature))*1000/R)/Temperatu- re
Factor, where VACT is the activation voltage, R is the resistance
calculated in step 266 of FIG. 8, and Temperature Factor is a value
from 1 to 3 stored in a lookup table. In addition, 7.9 represents
an adjustment factor required to predict cold cranking at 7.2V and
0.0043 represents the resultant change in voltage from a change in
temperature. In addition to calculating the CCA in step 232, the
activation voltage, Vact1, is set to the resistance activation
voltage, VACT. At step 234, if the loaded or polarized CCA is below
a fraction, k, of the rated CCA, the discharge unit is turned off
at step 238. If, however, the loaded CCA is above a fraction of the
rated CCA, the battery power is deemed acceptable or "good" at step
236. In the preferred embodiment, the tested battery should perform
at or above sixty-five percent of the rated CCA in order to be
deemed acceptable. Thereafter, the discharge unit is turned off at
step 238 and the battery proceeds to the charge routine in step
240.
[0080] The battery charging process begins with the charge start
procedure illustrated in FIGS. 9A and 9B. Overall, the charge start
procedure initializes the system and prepares the battery to
receive a charge. During the charging process precautions are taken
to ensure the battery is capable of accepting a charge as well as
setting the charging values according to the specifics of the
battery.
[0081] The charge start procedure begins at step 272 by performing
an initial reading of the battery's current and voltage across the
battery terminals 20, 22 and starting a timer. Next, the system
loops through steps 274 to 278 until the voltage across the
terminals stabilizes or a set time elapses as indicated by the
timer. In the preferred embodiment, at step 274, the most recent
voltage reading is stored as Vk and new current and voltage
readings are measured at step 276 after a short delay, around 1
second. Then, at step 278 a comparison of the two most recent
voltage readings, V and Vk, is made and fluctuations within the
accuracy range of the system, 0.01V, indicate the voltage is
stabilized allowing the method to proceed to step 280. For
fluctuations greater than 0.01V, an elapsed time greater than
twenty seconds also causes the method to proceed to step 280.
[0082] At step 280, the open circuit voltage, Vopen, and shutoff
voltage, Vshutoff, are set to the last voltage reading taken at
step 276. If the open circuit voltage is extremely low, less than
0.3V, as determined in step 282, the method proceeds to the fail
routine at step 284. At this point in the charging process, an
extremely low open circuit voltage indicates the battery has an
extremely high resistance and is incapable of being charged or
discharged, thus, requiring shut down of the charge process. If an
adequate open circuit voltage is measured, however, at step 286,
the method determines whether the battery previously tested "good"
during the diagnostic routine. If the battery did not previously
test good, at step 288, the method checks the probe number to
identify the number of times the charging routine has previously
been initiated. If the probe counter is equal to one, indicating
that the charging routine has not previously been initiated, the
process cautiously continues with the charge start procedure at
step 302. If, however, the probe counter is greater than one,
indicating that the charging process was previously run, six
separate inquiries are made in series in steps 290 to 300, to
determine if the charging process should continue or proceed in
step 301 to the fail routine as a result of a bad battery.
[0083] For example, in step 290, the method proceeds to the fail
routine if the probe counter reveals that charging has been
attempted more than a set number of times. In the preferred
embodiment, the system is limited to no more than four attempts at
probing and three attempts at charging, lasting up to fifteen
minutes. In step 292, the previous charging current, PREVAMP, is
compared to an adequate charging current. If the previous charging
current is too low, less than 15 A, indicating that the battery is
not charging at an acceptable rate, the method proceeds to the fail
routine. In steps 294 to 298, other criteria are used to determine
if the battery should continue charging. If the battery fails any
of these tests, the system will either proceed in step 301 to the
fail routine as a result of a bad battery or proceed to step 300.
In step 300, a comparison of the calculated CCA and rated CCA is
made so that with each probe the acceptable performance, f(probe),
gradually changes thus taking into consideration numerous charging
attempts when determining the state of the battery. If the battery
does not pass the test in step 300, the method proceeds to the fail
procedure in step 301.
[0084] Referring back to step 286, if the battery previously tested
"good" during the diagnostic routine or passed the tests in step
290 to 300, then the method proceeds to step 302 wherein the charge
timer is started. Thereafter, in step 304, illustrated in FIG. 9B,
all critical charging variables are reset. For example, the first
and second differential variables are reset to zero, all step
current values are reset to zero, and the charger current setting
is set to a nominal amount to allow the battery to accept an
adequate charge.
[0085] At step 306, the charger voltage setting, Vset, is set to a
voltage greater than the previously measured open circuit voltage.
In the preferred embodiment, the charger voltage is set to 3.5V
greater than the open circuit voltage if the battery was not
previously determined to be good, and 2V greater than the open
circuit voltage if the battery was previously determined to be
good. Also, at step 306, the maximum charging current is set to the
highest level acceptable, 70 A in the preferred embodiment.
However, at step 308, when the open circuit voltage is then
compared to a value empirically determined to be low for typical
batteries, if the open circuit voltage is below that value, less
than 10.5V in the preferred embodiment, the system proceeds
cautiously in the event the battery is shorted and at step 310 sets
the charger voltage and maximum charging current to values less
than optimal. Thereafter, the charging current is set to the
maximum charging current and a charge setup timer is started at
step 312.
[0086] In steps 314 through 320, a minimal delay is used to allow
the voltage and current to stabilize. At step 314, voltage and
current measurements are taken and the battery's capacity in
ampere-hours is updated. In step 316, a current reading below a
minimum threshold value, around 0.3 A, indicates a connection
interrupt and the method proceeds to the shutdown procedure at step
318. Otherwise, after a delay of thirty seconds at step 320, the
method proceeds to step 322.
[0087] In step 322, the charger voltage setting, Vset, is adjusted
based on the stabilized voltage and current readings taken at step
314, the cable resistance and an anticipated rise in voltage. In
addition, the charger current setting, Iset, is increased by 5 A to
allow latitude for current excursions in the stepping procedure.
(See FIG. 11). Once the charger voltage and current are properly
set, the system proceeds to the charge control procedure at step
324.
[0088] Overall, the charge control procedure, illustrated in FIG.
10, monitors and controls the interactive charging of the battery
such that the charge process is maintained within certain effective
and safe parameters. According to the invention, the procedure
loops from step 328 to 362 until either it is stopped by conditions
placed in the loop which dictate the disposition of the battery, or
the charge time exceeds the maximum charge time allowed, or the
capacity of the battery measured in ampere-hours exceeds the
maximum charging ampere-hours allowed.
[0089] Beginning with step 328, the average charging current is
saved as PREVAMP for future comparisons. Next, in step 330 the
current, voltage and time are read followed by an update of the
average charging current and battery capacity, AH, in step 332.
Also, in step 332, the maximum charging current is determined and
an estimate of the remaining charge time is calculated. Step 334 is
a precautionary step which looks for a sudden drop or low value in
current, as in the case of removed cables or a faulty connection.
In that situation, the potential for unsafe conditions due to
arcing is high and therefore, the method proceeds in step 335 to
the shutdown procedure in which the charger is immediately shut
off. If the current is adequate, in step 336 the average charging
current, Aave, is compared to the maximum measured charging current
MAXA. If the average charging current is greater than the
previously measured maximum charging current, then at step 337 the
maximum measured charging current is reset.
[0090] In steps 338 to 348, the charge control procedure determines
the condition of the battery during the charging process. More
particularly, in step 338, if the battery is deemed good and
charged, the method informs the operator via the display 34 that
the battery is good and it is acceptable to press stop in step 340.
In step 342, if the battery is deemed good, but not adequately
charged, the method informs the operator in step 344 that the
battery is good and to wait for a complete charge. In step 346, if
the battery is neither deemed good nor charged, the method informs
the operator in step 348 that the battery is charging and to wait
for a diagnostic retest to determine the status of the battery.
[0091] In step 350, a comparison of the voltage measured at step
330 to the maximum allowable charging voltage, Vmax, is made. If
the voltage is too high, the charger voltage setting is reduced
minimally in step 356 followed by a short time delay. Repeated
small decrements of the charging voltage will result in a drop in
the current after a brief period of time. The method then bypasses
the stepping procedure at step 358 and proceeds to the check
procedure at step 360. (See FIGS. 13A and 13B). If the voltage in
step 350 is not too high, then in step 352, a comparison of the
average current as calculated in step 332 to the sum of the maximum
charging current allowable and the absolute differential current of
the first charging step, explained below, is made.
[0092] If the average current is greater than the sum, the method
proceeds in step 354 to the current stability reset procedure. As
illustrated in FIG. 12, the current stability reset procedure
operates to reset various current stability factors when maximum
current is achieved so that a determination of current stability is
bypassed. Beginning at step 434, the method first assures that the
voltage is not falling at maximum current. If the voltage is
falling, the method proceeds at step 440 to return to the calling
procedure. If the voltage is rising, at step 436 the stability
factors are reset to zero. At step 438, the shutoff voltage
comparator is saved for future use and at step 440, the method
returns to the calling procedure. After completion of the current
stability reset procedure, the charger voltage setting is reduced
with a small time delay at step 356, the stepping procedure is
bypassed and the check procedure is invoked at step 360. (See FIGS.
13A and 13B).
[0093] Referring back to step 352, if the average current is less
than the sum of the maximum charging current allowable and the
differential current of the first charging step, the method
proceeds to the stepping procedure at step 358. According to the
invention, once a battery is deemed acceptable for charging, the
system proceeds in a step-wise manner to charge the battery as
illustrated in FIG. 11. Overall, charging the battery is
accomplished by first charging the battery at a voltage dependent
on the base charging level, and then adjusting the base charging
voltage level in a direction that provides a more optimal charge
acceptance. The goal of charger method is to provide the maximum
charge while minimizing to the greatest extent possible gassing of
the battery. An exemplary step routine for charging a battery is
disclosed in U.S. Pat. No. 5,589,757 assigned to the same assignee
as that of the present application. The '757 method for
step-charging batteries disclosed may be used in combination with
the apparatus and method disclosed in the present invention.
[0094] In addition, a novel interactive stepping routine,
illustrated in FIGS. 11 and 21, may be used to adjust the charging
output to the battery in a direction of a more optimal charge
acceptance. Overall, the stepping procedure requires that the
charging output to the battery be adjusted so that the steps form
two pairs of charging levels, where A1 and A2 constitute one pair
and A3 and A4 constitute a second pair. According to a primary
aspect of the invention, three separate probing voltage steps are
coupled with a relaxation period to allow for the four separate
current measurements, A1, A2, A3, and A4.
[0095] As shown in FIG. 11, steps 368 to 396, and FIG. 21, a
current A1 is measured after a short delay TD1. The voltage is then
increased, step one, and after a short delay TD2, the second
current A2 is measured. The voltage output is then held constant
for a relaxation period, TD3, to allow the current to stabilize.
Thereafter, the third current, A3, is measured and the voltage is
increased for a second time, step two. Finally, after a short
delay, TD4, the current measurement, A4, is read and the voltage
level is reset to its original amount. According to the invention,
step increases or decreases in voltage are chosen to gather
information about the battery during the charging process. In the
preferred embodiment, the step one and step two voltage changes are
set to the same value, +/-0.0425V, and the reset voltage change is
set to two times the step one/step two voltage change (i.e.,
+/-0.085V) for 12V batteries. For 6V batteries, the step one/step
two voltage changes are preferably +/-0.02125V and the reset
voltage change is +/-0.0425. In addition, time delays TD1, TD2,
TD3, and TD4 are set to 250 ms, 150 ms, 300 ms, and 125 ms
respectively.
[0096] Once the four probing currents are measured, in step 398,
three differential calculations are made. First, a lower
differential, DA1, using the first pair of charging levels, A2 and
A1, is calculated where DA1 is equal to A2 minus A1. Similarly, an
upper differential, DA2, is calculated where DA2 is equal to A4
minus A3. Lastly, a second differential, D2A, using the first
differentials, DA1 and DA2, is calculated where D2A is equal to DA1
minus DA2. Overall, the second differential current, D2A, is used
to adjust the charging voltage direction. The D2A differences in
current are accumulated in a moving average so that spurious
individual readings do not dominate the system. Furthermore, the
average is made relative on a zero to one scale and multiplied by
the voltage step increment to adjust the battery voltage. Ideally,
the system adjusts the charging voltage until little or no voltage
change is required to maintain an optimal charging level.
[0097] At step 400, the differential values are first evaluated to
determine if the calculations yielded values within a normal range
expected. If the values prove to be too large, the method skips
ahead to step 414 using previously calculated differential values.
If the values are within a normal range, steps 402 to 410 limit the
range and direction of the stepping voltage adjustment referred to
as the "stepfraction." In the preferred embodiment, changes in the
current measured by the second differential are limited to
increments of 0.1 or -0.1 so that only fractional corrections are
made. The fractional corrections represent the rate of adjustment
and the speed at which changes are made to the voltage in order to
charge at an optimal rate. The determination to increment or
decrement the voltage is made in steps 402 to 408. That is, second
differential values greater than 0.1 result in a 0.1 step change at
step 404. Second differential values less than -0.1 result in a
-0.1 step change at step 408. As a result, second differential
values greater than or equal to -0.1 and less than or equal to 0.1
result in no changes to the D2A value previously calculated.
[0098] Thereafter in step 410, a weighted average is calculated to
smooth the step changes and the stepfraction is normalized between
zero and one. A stepfraction or change in voltage of one means a
high rate of change is required, whereas a stepfraction of zero
represents a zero rate of adjustment indicating that the battery is
being charged at an optimal rate. Prior to adjusting the charger
voltage setting, a comparison of several charging currents is made
in step 412 in order to determine if any further current
adjustments are required to maintain current levels at a maximum
without large fluctuation. Specifically, the absolute value of the
difference between the average charging current and maximum
charging current allowed is compared to the absolute value of the
first differential, DA1. If the current is below the maximum level,
at step 414 a determination is made whether to increment or
decrement the charger voltage setting, Vset, by a factor of the
stepfraction in steps 416 and 418. However, if the current is at or
near the maximum, at step 420 the current stability reset procedure
is invoked, as described above, to prevent shutdown at the maximum
flat current. Then, at step 422 the stepfraction is interpolated so
that a change in the charger voltage setting results in the maximum
current for stability. At step 424, a determination is made whether
the average charging current is greater than the maximum charging
current. If greater, the charger voltage setting, Vset, is reduced
in step 418 and if less, the voltage is increased in step 426.
After a current and time reading, an AH update, and a final time
delay, TD5, at step 428, the system returns to the charge control
procedure at step 430. In the preferred embodiment, time delay TD5
is set to 200 ms.
[0099] Referring back to step 358 in FIG. 10, after completion of
the stepping procedure the check procedure is invoked at step 360.
Overall, the check procedure, illustrated in FIGS. 13A and 13B, is
used to determine when a battery is charged or in need of a retest,
or to identify defective batteries. The check procedure begins at
step 444 by first determining whether to measure current stability.
A check of the charging stability is made periodically in order to
ensure an abnormal current rise is not occurring. In the preferred
embodiment, a timer is used to enable a current stability check
every two minutes.
[0100] If the timer does not indicate a stability check is
necessary, the method proceeds at step 460 to determine if the
average charging current, Aave, is below a rate sufficient to
condition and charge the battery. If the average charging current
is below the threshold level, a final check of the battery's status
is evaluated in steps 450 through 458. At step 450, batteries which
are "not good," that is, shorted or low powered, are identified. If
the battery is non-responsive as indicated by various voltage
readings so as to be considered not good, the system proceeds to
the fail procedure in step 452. (See FIG. 19). If the battery is
responsive and behaving normally, at step 454 a determination is
made as to whether the battery requires conditioning. If the
battery is sulfated or requires conditioning or destratification,
the method proceeds to the conditioning procedure at step 456. (See
FIGS. 14A and 14B). If conditioning is not required, the method
proceeds at step 458 to the good/stop procedure. (See FIG. 16).
[0101] Referring back to step 460, if the average charging current
is not sufficiently high, a check of the time is made at step 461
to verify a delay of 90 seconds. If the time delay is less than 90
seconds, the system proceeds to step 466 in FIG. 13B (see below).
If a delay of 90 seconds has elapsed, at step 462 various voltage,
current and timing variables are evaluated to determine if the
battery is defective (e.g., either shorted or not charging
adequately). If the battery is defective, at step 464 the fail
procedure is invoked. Otherwise, at step 466 in FIG. 13B the method
determines whether the battery has previously been deemed charged.
That is, whether the flag which signals the battery is adequately
charged has been set to true in which case the method returns at
step 468 to the charge control procedure. If the flag has not been
set to true, at step 470 the method evaluates the condition of the
battery to determine if the battery is in fact adequately charged.
If the battery meets the test as illustrated in step 470, the
charged flag is set to true at step 472.
[0102] Next, at step 474 the checking procedure determines whether
the battery has previously been deemed "good." If the battery is
good as indicated by a flag, the checking procedure returns to the
charge control procedure in step 468. If the battery has not yet
been deemed good, the checking procedure at step 476 determines for
the second time whether the battery is charged. This condition will
arise only if the battery met the test of step 470 and the charged
flag was set to true in step 472. In that case, at step 482 the
checking procedure determines if any significant charge has been
applied to the battery so as to justify a retest. In the preferred
embodiment, if the amount of charge since the end of the last
charge period is extremely low, less than 0.5 AH, the system
proceeds to the fail routine at step 484. However, if the charge
increase is above the minimum threshold, the system proceeds to the
diagnostic procedure for a retest in step 486. After the diagnostic
procedure, another determination is made as to whether the charged
battery is "good." At this point, if the battery has not been
deemed good, the system proceeds to the fail procedure in step 484.
If the battery is good, the system proceeds to the charge procedure
in step 492 and thereafter returns to the charge control procedure
in step 468 to complete the charging process.
[0103] Referring back to step 476, if the battery is neither good
nor charged, at step 478 the method determines whether enough time
has elapsed to warrant another diagnostic run at step 480 or
whether the system should return to the charge control procedure at
step 490. In the preferred embodiment, diagnostic probes are run
every five minutes followed by the charge procedure. Therefore, if
five minutes have elapsed since the last probe, the diagnostic
procedure is invoked at step 480. Otherwise, the method returns to
the charge control procedure at step 490.
[0104] Returning to step 444 in FIG. 13A, if the stability timer
indicates a check in current stability is required, the system
proceeds at step 446 to the current stability check procedure.
Overall, the current stability check procedure, as illustrated in
FIG. 15, evaluates the charged capacity of the battery on a
periodic basis to monitor the average charging current of the
battery. In the preferred embodiment, the current stability
procedure is invoked every two minutes during charging. Beginning
at step 549, the stability timer is restarted. At step 550, if the
starting ampere-hours value, AHold, is equal to zero, which
indicates a first reading of AH, the system saves the current AH
measurement at step 552 and returns to the check procedure at step
566. If AHold is not equal to zero, the previously calculated
average charging current is saved as AMPold and a new average
charging current is calculated at step 554. In the preferred
embodiment, this calculation occurs every three minutes. Next, at
step 556, if AMPold is equal to zero, which indicates a second
reading is complete, the system similarly returns at step 566 to
the check procedure. If AMPold is not equal to zero, the system
proceeds at step 558 to calculate the differential current drop,
DC. Thereafter, at step 560, the differential current, DC, is
compared to the minimum allowed current drop, DELA, to determine if
the differential current is falling normally. If the current is
falling properly as determined in step 560, the current rising flag
remains at its default setting of false. If the current is rising,
the current rising flag is set to true at step 564.
[0105] After the flag is set, at step 566 the method returns to the
check procedure and resumes processing at step 448 in FIG. 13A. At
step 448, if the current rising flag is false, indicating a normal
current drop such that the current is falling a fraction of an
ampere, the method continues with the checking procedure at step
460. A current rising flag set to true, however, indicates a
potential for thermal runaway and results in a final check of the
battery's disposition in steps 450 through 458 as described
above.
[0106] According to the invention, after completion of the check
procedure, a battery which is good and charged may proceed to the
condition procedure. In the preferred embodiment, the operator is
given the choice to either disconnect the battery once it is deemed
good and charged or leave it attached for conditioning. If the
battery is left unattended, however, the battery will automatically
be conditioned by default. Overall, the conditioning procedure
equalizes the cells and electrodes within the cells of the battery
which may have unequal discharge levels or uneven electrolyte
concentrations due to stratification. Conditioning is recommended
in order to increase performance and life expectancy of the
battery.
[0107] As illustrated in FIG. 14A, the conditioning procedure
begins at step 496 by informing the operator via the display 34
that the battery is good and giving the operator the option to stop
the conditioning process. In steps 498 through 510, an evaluation
of various previously measured charging parameters determines the
level at which to set the maximum charging current, Imax. At a
minimum, the maximum charging current will be set to 2 A.
Thereafter, in step 512, various conditioning parameters are set at
limiting levels and conditioning is begun. For example, the charger
current is set to the maximum charging current allowed, the charger
voltage is set to the maximum charging voltage allowed, and a
voltage comparator, V1, is initialized at zero. In addition, at
step 512 a timer, TIMEVCHECK, used to track periodic tests of
voltage stability, is initiated at zero. According to the
invention, the goal of the conditioning process is to charge until
there is a stable voltage, that is, to bring the voltage
comparator, V1, equal to the battery voltage, V, within the
accuracy of the system.
[0108] After the conditioning parameters are set, current voltage
and current measurements are taken and the battery capacity, AH, is
updated at step 514. At step 516 in FIG. 14B, the average voltage
during conditioning, Vave, is set to the previous voltage
calculation, V, followed by another voltage and current measurement
and AH update at step 518. At step 520, if the current measurement
is very low, less than 0.3 A, indicating that the cables were
removed, the conditioning procedure is stopped and the method
proceeds directly to the shutdown procedure at step 522. However,
if the current is adequate, a new voltage, V, is then calculated at
step 524 based on the average voltage during conditioning, Vave,
and the last voltage measurement, V. This averaging process
smoothes the measurements to ensure consistent values.
[0109] Next, according to the invention, evaluation of the
conditioning process occurs at fixed intervals. In the preferred
embodiment, the voltage stability is evaluated every ten minutes as
determined by the timer, TIMEVCHECK, at step 526. If the timer
indicates that ten minutes have elapsed, at step 532 the voltage at
the beginning and ending time periods are compared. If the voltage
is constant or decreasing over time, that is, V1 is greater than or
equal to V, the system proceeds to the good/stop procedure at step
546 since the conditioning process is complete. If the voltage is
rising, indicating charging is not complete, the timer is restarted
and the comparison voltage, V1, is reset to V at step 536.
[0110] Referring back to step 526, if less than ten minutes have
elapsed, the method looks for low voltage readings at steps 528 and
538. At step 528, a voltage less than 12.5V is indicative of a
shorted battery and thus, the method proceeds to the fail procedure
at step 530. At step 538, a voltage less than 13.4V requires that
the charger current setting be incremented by 0.1 A, with an upper
limit of 10 A, in order to raise the voltage so that conditioning
can effectively proceed.
[0111] Finally, at step 544 the battery's capacity, AH, is compared
to the maximum charging AH allowed, AHmax. If the capacity is less
than the maximum allowed, the system loops back to step 516. Once
the capacity exceeds the maximum, the system proceeds at step 546
to the good/stop procedure.
[0112] FIGS. 16 through 20 illustrate the steps taken to inform the
operator as to the disposition of the battery as determined by the
diagnostic tester and charger method. The figures further
illustrate the types of messages and prompting implemented during
the various shut down and precautionary routines. The good/stop
procedure, illustrated in FIG. 16, is implemented at various points
in the overall diagnostic testing and charging procedure after the
battery is fully charged and tests "good" (see FIG. 13, step 458).
The good/stop procedure begins at step 570 by turning off the
charge/discharge unit. Next, at step 572 the operator is informed
via the display device 34 that testing is complete followed by a
computer generated tone at step 574. In the preferred embodiment,
the testing complete message is displayed on the first line of the
display device.
[0113] In steps 576 through 588, the method loops until the battery
cables are removed and the operator presses a key. More
particularly, at step 576, after a short delay, 1 second, a message
informing the operator that the battery tested "good" is displayed
followed by another 1 second delay. Then, a message displaying the
determined cranking value is displayed, also followed by a 1 second
delay. The voltage is then read at step 577 and evaluated at step
578. If the voltage measured is greater than a threshold voltage,
indicating that a battery is present, the operator is instructed to
remove the cables at step 582. In the preferred embodiment, a
voltage greater than 2V is used as the threshold voltage.
Alternatively, if the voltage is less than 2V, the operator is
instructed to "press any key" at step 586.
[0114] In the preferred embodiment, the remove cables message or
the press any key message is displayed on the second line of the
display device such that the message alternates being displayed
every half second with the good battery message displayed in step
576. Therefore, until the cables are removed and a key press is
registered at step 588, the method loops back to step 576 and
continues to display the results of the previous test. In the
preferred embodiment, the operator will disconnect the cables from
the battery and press a key to start a new test on a different
battery. Thus, once a key is pressed, the method proceeds to the
start up procedure at step 590 in FIG. 6 to begin testing
again.
[0115] The untestable procedure, illustrated in FIG. 17, occurs
when the open circuit voltage registers a very low voltage, less
than 0.3V, and the operator presses the start key. (See FIG. 6,
step 143). The untestable procedure begins at step 594 by
confirming that the charge/discharge unit is turned off. Next, at
step 596 the operator is informed via the display device 34 that
the battery is untestable/bad. At step 598, the operator is
instructed to press any key. In the preferred embodiment, the
untestable/bad message or the press any key message is displayed
until a key press is registered at step 600. Once a key is pressed,
the display is erased and the method proceeds to the start up
procedure at step 602. (See FIG. 6).
[0116] The shutdown procedure, illustrated in FIG. 18, is interrupt
driven so that when the operator selects stop via the input device
the diagnostic or charging process ceases and is shutdown properly.
Similarly, if the conducting cables 18 are disconnected during the
diagnostic or charging procedure, an interrupt is generated and the
shutdown procedure is invoked immediately to minimize arcing and
prevent potential sparking if the cables are reconnected. The
shutdown procedure begins at step 618 by shutting off the
charge/discharge unit. At step 619, the system determines under
what condition the system was shut down. If the operator pressed
the stop button, at step 620 a message indicating that diagnostic
testing and charging was stopped by the operator is displayed
followed by a computer generated tone to alert the operator at step
622. If the shut down was initiated by the removal of the cables,
at step 621 a message indicating that that cables were removed is
displayed followed by a computer generated tone at step 622. In the
preferred embodiment, these messages are displayed on the first
line of the display device.
[0117] Thereafter, in steps 624 through 640, the operator is
informed as to the status of the battery. In the preferred
embodiment, an evaluation of two flags determines which message is
displayed to the operator. After a short delay of 1 second at step
624, the flag settings are evaluated. If the good and charged flags
are true, the operator is informed that the battery is good at step
628 followed by a 1 second delay and a message displaying the
determined cranking value, CCA. If the good flag is true, but the
charged flag is false, the operator is informed that the battery is
good but has a low charge at step 632 followed by a 1 second delay
and a message displaying the determined cranking value, CCA.
Finally, if none of the conditions are met, at step 638 the
operator is informed that the test is incomplete. In the preferred
embodiment, the message describing the battery's disposition is
displayed on the second line of the display device. Posting of the
proper message is followed by a short delay of 1 second at step
640.
[0118] Thereafter, at step 641, the voltage is measured and
evaluated at step 642. If the voltage measured is greater than a
threshold voltage, the operator is instructed to remove the cables
at step 646 followed periodically by a computer generated tone at
step 648. In the preferred embodiment, a voltage greater than 2V is
used as the threshold voltage. If the voltage is less than 2V, the
operator is instructed to press any key at step 650.
[0119] In the preferred embodiment, the remove cables message or
the press any key message is displayed on the second line of the
display device such that the message alternates being displayed
every half second with the battery's disposition message displayed
in step 628 or 632. Therefore, until a key press is registered at
step 652, the method loops back to step 624. Once a key is pressed,
the display is erased and the method proceeds to the start up
procedure at step 654. (See FIG. 6).
[0120] The fail procedure, illustrated in FIG. 19, may be
implemented at various points in the overall diagnostic testing and
charging procedure after the battery is deemed "bad," that is,
defective or lacking adequate cranking after one or more charging
attempts (see FIG. 9A, step 301). The fail procedure begins at step
658, by turning off the charge/discharge unit. Next, at step 660
the operator is informed via the display device 34 that the battery
is "bad" followed by a computer generated tone at step 662. In the
preferred embodiment, the bad battery message is displayed on the
first line of the display device.
[0121] Next, the fail procedure loops through a display process
from step 664 to step 676 waiting for the operator to remove the
cables and press any key. In step 664, a short delay, 1 second, is
followed by a message informing the operator to replace or adjust
the battery followed by another 1 second delay. Then, a message
displaying the determined cranking value is displayed, also
followed by a 1 second delay. In the preferred embodiment, these
messages are displayed on the second line of the display device.
The voltage is then measured at step 665 and evaluated at step 666.
If the voltage measured is greater than a threshold voltage, the
operator is instructed to remove the cables at step 670 followed
periodically by a computer generated tone at step 672. In the
preferred embodiment a voltage greater than 2 is used as the
threshold voltage. If the voltage is less than 2V, the operator is
instructed to press any key at step 674.
[0122] In the preferred embodiment, the remove cables message or
the press any key message is displayed on the second line of the
display device such that the message alternates, being displayed
every half second with the replace/adjust battery message displayed
in step 664. Therefore, until a key press is registered at step
676, the method loops back to step 664. Once a key is pressed, the
display is erased and the method proceeds to the start up procedure
at step 678. (See FIG. 6).
[0123] Like the shutdown procedure, the fault shutdown procedure,
illustrated in FIG. 20, is interrupt driven. That is, if a fault
occurs in the diagnostic unit, the fault generates an interrupt. In
particular, faults are generated by overheating or component
failure. The fault shutdown procedure is invoked at the beginning
of the discharge procedure if the current falls below an acceptable
minimum level indicating a faulty current while at the same time
the battery voltage is acceptable. The fault shutdown procedure is
also invoked at the beginning of the charge procedure if the
current falls below an acceptable minimum level while at the same
time the battery voltage is unacceptable. When a fault occurs in
the unit, the operator should analyze the fault and determine the
source of the problem before initiating a retest.
[0124] The fault shutdown procedure begins at step 682 by turning
off the charge/discharge unit. Next, at step 684 the operator is
informed via the display device 34 that a fault shutoff has
occurred followed by a computer generated tone at step 685. The
fault shutdown procedure then determines if the diagnostic unit
requires servicing in step 686 to step 690 because of charge of
discharge failure.
[0125] If servicing is not required, a short delay 1 second at step
691 is followed by a unit temperature reading at step 692. If the
temperature is deemed high at step 693, for safety purposes a
voltage comparison at step 694 determines whether the operator is
prompted to "remove cables" or simply "wait for reset" of the unit.
If, however, the unit temperature is not deemed high the method
proceeds to the start up procedure at step 701. (See FIG. 6).
[0126] As can be seen from the foregoing, a method and system have
been provided for testing and charging a battery wherein the
microprocessor based diagnostic test unit utilizes a charger
combined with a rapidly variable load to safely and efficiently
test, charge and condition batteries of various sizes and types.
The disclosed diagnostic unit is capable of adequately stressing
the battery to accurately determine if there is sufficient power to
sustain a discharge for more than a brief instant. The diagnostic
unit is also capable of accurately predicting the chargeability and
full-charge performance of the battery in addition to providing
safe, rapid and reliable recharge of the battery.
[0127] In view of the many possible embodiments to which the
principles of this invention may be applied, it should be
recognized that the embodiment described herein with respect to the
drawing figures is meant to be illustrative only and should not be
taken as limiting the scope of invention. For example, those of
skill in the art will recognize that the elements of the
illustrated embodiment shown in software may be implemented in
hardware and vice versa or that the illustrated embodiment can be
modified in arrangement and detail without departing from the
spirit of the invention. Therefore, the invention as described
herein contemplates all such embodiments as may come within the
scope of the following claims and equivalents thereof.
* * * * *