Measuring battery degradation

• US 10,162,401 B1
• Filed: 09/29/2015
• Issued: 12/25/2018
• Est. Priority Date: 09/29/2015
• Status: Active Grant

• Current Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Original Assignee: Amazon Technologies, Inc. (Amazon.com, Inc.)
• Inventors: Brys, Wieslaw, Jones, Eric Bernard, Goloski, Richard Alan, Trenholme, Kevin John
• Primary Examiner(s): Isla, Richard
• Assistant Examiner(s): Robbins, Jerry D
• Application Number:
  US14/869,678
• Time in Patent Office: 1,183 Days
• Field of Search: 324427
• CPC Class Codes: B66F 9/063 Automatically guided
• CPC Class Codes: G01R 31/3842 combining voltage and current measurements
• CPC Class Codes: G01R 31/389 Measuring internal impedance, internal conductance or related variables
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• CPC Class Codes: G06F 1/266 Arrangements to supply power to external peripherals either directly from the computer or under computer control, e.g. supply of power through the communication port, computer controlled power-strips
• CPC Class Codes: G06F 1/3212 Monitoring battery levels, e.g. power saving mode being initiated when battery voltage goes below a certain level

Abstract

Approaches and related devices monitor the condition of a battery via voltage measurement during routine recharging instances. An approach includes supplying a charging current to the battery during each of a plurality of routine charging instances. The charging current is increased by a measured or predetermined amount during a current pulse portion of each of the routine charging instances. A resulting change in a battery voltage of the battery during the current pulse portion of each of the routine charging instances is measured. An impedance-indicative value of the battery is determined for each of the routine charging instances based on the change in the battery voltage during the current pulse portion. The impedance-indicative value is stored in a memory device for each of the routine charging instances. A condition of the battery is estimated based on one or more changes in the impedance-indicative values.

Claims

1. An inventory management system, comprising:

an inventory workspace;

a plurality of inventory holders, each of the plurality of inventory holders being configured to store one or more inventory items;

a plurality of mobile drive units, each of the plurality of mobile drive units including a respective battery powering the mobile drive unit to transport one or more of the plurality of inventory holders between locations within the inventory workspace;

a battery charging station to which each mobile drive unit of the plurality of mobile drive units can be routinely coupled to charge the respective battery of the mobile drive unit during normal operation of the mobile drive unit, the battery charging station being configured to supply a charging current to the battery during a charging period, the charging current increasing by a measured or predetermined amount during an initial current pulse portion of the charging period during which the charging current increases from a zero initial current to a target charging current and producing a resulting change in a battery voltage of the battery during the initial current pulse portion of the charging period; and

a control unit comprising a processor and a tangible memory device storing non-transitory instructions executable by processor to cause the processor to, for each of the batteries;

determine and store a first value, for each of a plurality of routine charging instances of the battery, that is indicative of an impedance of the battery and based on the resulting change in the battery voltage produced by the charging current during the initial current pulse portion of each of the routine charging instances;

receive and store a temperature value, for each of the plurality of routine charging instances of the battery, that is indicative of a temperature of the battery;

determine, for each of the plurality of routine charging instances of the battery, a set of battery impedance-indicative values, based on the first values and the temperature values, that accounts for impedance variation induced by variation in the temperature values;

store the battery impedance-indicative values for the battery in a tangible memory device for each of the plurality of routine charging instances;

estimate a condition of the battery based on changes over time in the set of battery impedance-indicative values; and

compare one or more changes in the battery impedance-indicative values for one of the batteries with one or more changes in the battery impedance-indicative values for one or more other batteries to determine that the estimated condition of the one of the batteries is indicative of the one of the batteries needing to be replaced.

2. The inventory management system of claim 1, wherein:

the charging current is measured; and

the set of battery impedance-indicative values excludes battery impedance-indicative values for routine charging instances having a charging current less than a predetermined magnitude.

3. The inventory management system of claim 1, wherein:

the charging current is measured for each of the plurality of the routine charging instances;

the first value is calculated for each of the plurality of routine charging instances based on the measured charging current and the resulting change in the battery voltage produced by the charging current;

a temperature-corrected impedance value is calculated for each of the plurality of routine charging instances based on the respective first value and the respective temperature value; and

the set of battery impedance-indicative values includes the temperature-corrected impedance values.

4. The inventory management system of claim 1, wherein the instructions are executable by the processor to cause the processor to determine that the estimated condition of the battery is indicative of the battery needing to be replaced.

5. A computer-implemented method of estimating a condition of a battery of a mobile drive unit for moving inventory holders in an inventory management system, wherein the inventory management system comprises a plurality of mobile drive units, each of the plurality of mobile drive units including a respective battery powering the mobile drive unit, the computer-implemented method comprising for each of the batteries:

supplying a charging current to the battery during each of a respective plurality of routine charging instances during normal operation of the mobile drive unit, the charging current increasing by a measured or predetermined amount during an initial current pulse portion of each of the plurality of routine charging instances;

measuring a resulting change in a battery voltage of the battery during the initial current pulse portion of each of the plurality of routine charging instances, wherein during the initial current pulse portion the charging current increases from a zero initial current to a target charging current;

determining a battery impedance-indicative value for the battery for each of the respective plurality of routine charging instances based on the change in the battery voltage during the initial current pulse portion of each of the respective plurality of routine charging instances;

storing the battery impedance-indicative values for the battery in a tangible memory device for each of the plurality of routine charging instances;

estimating a condition of the battery based on one or more changes in the battery impedance-indicative values; and

comparing one or more changes in the battery impedance-indicative values for one of the batteries with one or more changes in the battery impedance-indicative values for one or more other batteries to determine that the estimated condition of the one of the batteries is indicative of the one of the batteries needing to be replaced.

6. The computer-implemented method of claim 5, comprising:

measuring a temperature of the battery for each of the plurality of routine charging instances; and

storing the temperature of the battery in a tangible memory device for each of the plurality of routine charging instances,

wherein estimating the condition of the battery is further based on the temperature of the battery stored for each of the plurality of routine charging instances so as to account for impedance variation induced by variation in the battery temperatures.

7. The computer-implemented method of claim 6, wherein:

the charging current is measured for each of a plurality of the routine charging instances;

a temperature-corrected battery impedance value is calculated for each of the plurality of routine charging instances based on the measured charging current, the change in battery voltage, and the respective temperature value; and

the battery impedance-indicative values include the temperature-corrected battery impedance values.

8. The computer-implemented method of claim 5, wherein:

the charging current is measured; and

the battery impedance-indicative values exclude battery impedance-indicative values based on routine charging instances having a charging current less than a predetermined magnitude.

9. The computer-implemented method of claim 5, wherein the initial current pulse portion of each of the plurality of routine charging instances has a duration selected to avoid any significant increase in a temperature of the battery during the initial current pulse portion.

10. The computer-implemented method of claim 5, comprising determining that the estimated condition of the battery is indicative of the battery needing to be replaced.

11. The computer-implemented method of claim 5, wherein the initial current pulse portion has a duration of less than 3 seconds.

12. The computer-implemented method of claim 5, wherein a temperature change during the current pulse portion is less than 0.05 degrees C.

13. The computer-implemented method of claim 5, further comprising initiating each of the routine charging instances with the initial current pulse portion, and conducting a remainder of each of the routine charging instances at the target charging current.