Energy based battery backup unit testing

• US 10,386,421 B2
• Filed: 09/14/2015
• Issued: 08/20/2019
• Est. Priority Date: 09/14/2015
• Status: Active Grant

• Current Assignee: Meta Platforms, Inc. (f/k/a Facebook, Inc.)
• Original Assignee: Meta Platforms, Inc. (f/k/a Facebook, Inc.)
• Inventors: Ebrahimzadeh, Soheil, Sarti, Pierluigi
• Primary Examiner(s): Isla, Richard
• Assistant Examiner(s): Torres Ruiz, Johali A
• Application Number:
  US14/853,526
• Publication Number:
  US 20170074946A1
• Time in Patent Office: 1,436 Days
• Field of Search: 324426
• CPC Class Codes: G01R 31/386 using test-loads
• CPC Class Codes: G01R 31/392 Determining battery ageing or deterioration, e.g. state of health
• CPC Class Codes: G11C 2029/5602 Interface to device under test
• CPC Class Codes: G11C 29/021 in voltage or current generators
• CPC Class Codes: G11C 29/56012 Timing aspects, clock generation, synchronisation
• CPC Class Codes: G11C 5/141 Battery and back-up supplies

Abstract

Several embodiments perform battery backup unit (BBU) degradation testing. For example, a BBU testing system can be coupled to or part of a BBU. The BBU testing system can discharge the BBU by engaging a variable load to the BBU. The BBU testing system can monitor a discharge energy consumption over time as the BBU discharges until the discharge energy consumption reaches a specified amount of energy. The BBU testing system can determine a discharge time for the discharge energy consumption to reach the specified amount of energy. The BBU testing system can then compute a degradation state of the BBU based on the discharge time.

Claims

1. A method, comprising:

discharging a battery backup unit (BBU) in a BBU degradation test by electrically coupling the BBU to a variable load;

monitoring a discharge energy consumption, in Joules or a functionally equivalent measurement unit, over time while the BBU is discharging until the discharge energy consumption reaches a specified amount of energy, wherein monitoring the discharge energy consumption comprises;

measuring electric current levels of the discharging and voltage levels across the BBU as the BBU discharges; and

integrating the electric current levels multiplied by the voltage levels over time to dynamically calculate the discharge energy consumption;

measuring a discharge time for the discharge energy consumption to reach the specified amount of energy and a closed circuit voltage across the BBU when the discharge energy consumption reaches the specified amount of energy;

electrically decoupling the BBU from the variable load when the discharge energy consumption reaches the specified amount of energy;

monitoring, after electrically decoupling the BBU from the variable load, the voltage levels across the BBU at least until the voltage levels across the BBU stabilize;

measuring, when the voltage levels across the BBU stabilize, an open circuit voltage across the BBU and a settlement time for the voltage levels across the BBU to stabilize; and

determining at least one of a degradation state or a rate of deterioration of the BBU based on one or more of the measured discharge time, the measured closed circuit voltage, the measured open circuit voltage, or the measured settlement time.

2. The method of claim 1, wherein measuring the discharge time includes starting a clock counter when the discharging begins and stopping the clock counter when the discharging ends.

3. The method of claim 1, wherein during the discharging, the variable load drains the BBU at varying rates of discharge.

4. The method of claim 3, wherein the variable load includes a computing device for which the BBU provides backup power and wherein the computing device continues to operate during the BBU degradation test.

5. The method of claim 1, wherein determining at least one of the degradation state or the rate of deterioration of the BBU includes determining that the BBU has degraded when the measured closed circuit voltage is lower than a voltage threshold.

6. The method of claim 5, wherein the voltage threshold is a minimum voltage that a DC-to-DC converter requires as an input to convert to a DC voltage that is usable by a computing device for which the BBU provides backup power.

7. The method of claim 1, wherein determining at least one of the degradation state or the rate of deterioration of the BBU includes determining that the BBU has degraded when the measured discharge time is higher than a time threshold.

8. The method of claim 7, wherein the time threshold corresponds to maximum amount of time to get a backup generator running to produce stable and sufficient power to a system load that the BBU supports.

9. The method of claim 8, wherein the specified amount of energy corresponds to an amount of energy required to sustain a maximum usage by the system load for the maximum amount of time.

10. The method of claim 1, wherein determining the rate of deterioration of the BBU is based on a comparison of metrics determined across multiple BBU degradation tests.

11. The method of claim 10, wherein determining the rate of deterioration of the BBU comprises computing an internal resistance of the BBU based on the specified amount of energy, the measured closed circuit voltage, the measured open circuit voltage, and the measured settlement time.

12. The method of claim 10, wherein determining the degradation state of the BBU is based on at least one of the measured closed circuit voltage or the measured discharge time.

13. The method of claim 1, wherein the variable load both does not have predefined discharge parameters and does not produce a constant discharge rate.

14. A battery backup unit (BBU) test system, comprising:

a controller configured to initiate a BBU degradation test by engaging a variable load to discharge the BBU;

a current meter configured to measure electric current levels of the BBU; and

a voltage meter configured to measure voltage levels across the BBU;

wherein the controller is configured to;

monitor a discharge energy consumption, in Joules or a functionally equivalent measurement unit, over time as the BBU is discharged until the discharge energy consumption reaches a specified amount of energy, wherein monitoring the discharge energy consumption comprises;

measuring the electric current levels of the discharging and the voltage levels across the BBU as the BBU discharges; and

integrating the electric current levels multiplied by the voltage levels over time to dynamically calculate the discharge energy consumption;

measure a discharge time for the discharge energy consumption to reach the specified amount of energy and a closed circuit voltage across the BBU when the discharge energy consumption reaches the specified amount of energy;

electrically decouple the BBU from the variable load when the discharge energy consumption reaches the specified amount of energy;

monitor, after electrically decoupling the BBU from the variable load, the voltage levels across the BBU at least until the voltage levels across the BBU stabilize;

measure, when the voltage levels across the BBU stabilize, an open circuit voltage across the BBU and a settlement time for the voltage levels across the BBU to stabilize; and

determine at least one of a degradation state or a rate of deterioration of the BBU based on one or more of the measured discharge time, the measured closed circuit voltage, the measured open circuit voltage, or the measured settlement time.

15. The BBU test system of claim 14, wherein the controller is configured to determine the degradation state based on at least one of the measured closed circuit voltage or the measured discharge time.

16. The BBU test system of claim 14, wherein the controller is configured to determine the rate of deterioration based on at least one of the measured open circuit voltage or the measured settlement time.

17. The BBU test system of claim 16, further comprising a data storage memory, wherein the controller is configured to store at least one of the measured open circuit voltage or the measured settlement time in the data storage memory for a subsequent comparison.

18. A backup power system for one or more computer servers, comprising:

a battery backup unit (BBU);

a server rack as a power consumer that relies on the BBU for backup power;

a load switch to engage or disengage the server rack from the BBU; and

a BBU testing system configured to;

monitor a discharge energy consumption, in Joules or a functionally equivalent measurement unit, over time as the BBU is discharging via the load switch until the discharge energy consumption reaches a specified amount of energy, wherein monitoring the discharge energy consumption comprises;

measuring electric current levels of the discharging and voltage levels across the BBU as the BBU discharges; and

integrating the electric current levels multiplied by the voltage levels over time to dynamically calculate the discharge energy consumption;

measure a discharge time for the discharge energy consumption to reach the specified amount of energy and a closed circuit voltage across the BBU when the discharge energy consumption reaches the specified amount of energy;

electrically decouple the BBU via the load switch when the discharge energy consumption reaches the specified amount of energy;

monitor, after electrically decoupling the BBU via the load switch, the voltage levels across the BBU at least until the voltage levels across the BBU stabilize;

measure, when the voltage levels across the BBU stabilize, an open circuit voltage across the BBU and a settlement time for the voltage levels across the BBU to stabilize; and

determine at least one of a degradation state or a rate of deterioration of the BBU based on one or more of the measured discharge time, the measured closed circuit voltage, the measured open circuit voltage, or the measured settlement time.