MODULAR HEAVY LOAD BATTERY TEST SYSTEM

• US 20090237086A1
• Filed: 03/24/2008
• Published: 09/24/2009
• Est. Priority Date: 03/24/2008
• Status: Active Grant

• Current Assignee: Bosch Automotive Service Solutions LLC (SPX Corporation)
• Original Assignee: SPX Corporation
• Inventors: ANDELFINGER, Richard
• Granted Patent: US 9,304,170 B2
• Time in Patent Office: Days
• US Class Current: 324/431
• CPC Class Codes: G01R 1/04 Housings; Supporting members; Arrangements of terminals
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/386 using test-loads

Abstract

A modular heavy load battery test system is provided. The system includes a heavy load module and a battery tester. The heavy load module includes a housing, first and second lengths of high-resistivity, large-gauge wire arranged on respective upper and lower surfaces of a heat-resistant support plate, a switch and at least one cooling fan. The battery tester includes a housing, a microcontroller and a set of battery charging wires. The microcontroller selects the configuration of the first and second wires and provides the control signal to the heavy load module, while the switch selectively connects the first and second wires to the battery tester based upon the control signal.

Claims

1. A modular heavy load battery test system, comprising:

a heavy load module, including;

a housing having a control signal connector and a high-current connector;

a heat-resistant support plate disposed within the housing;

a first length of high-resistivity, large-gauge wire arranged on an upper surface of the plate;

a second length of high-resistivity, large-gauge wire arranged on a lower surface of the plate;

a switch, coupled to the first and second wires, the control signal connector and the high-current connector, to selectively connect the first and second wires to the high-current connector based upon a control signal received over the control signal connector; and

at least one fan, coupled to the high current connector and disposed within the housing, to cool the first and second wires; and

a battery tester, including;

a housing, having a high-current connector and a control signal connector, adapted to receive the heavy load module;

a microcontroller, coupled to the control connector, to provide the control signal to the heavy load module switch; and

a set of battery wires, coupled to the high-current connector, to connect the battery tester to a battery under test.

2. The battery test system of claim 1, wherein the switch selectively connects only the first wire, only the second wire, the first and second wires in series, or the first and second wires in parallel, to the high current connector.

3. The battery test system of claim 1, wherein the heavy load module further comprises a temperature sensor, mounted on the support plate, coupled to the control signal connector.

4. The battery test system of claim 1, wherein the heavy load module further comprises a fan switching element, coupled to the control signal connector, that connects at least two fans to the high-current connector based upon a fan control signal received from the battery tester microcontroller.

5. The battery test system of claim 1, wherein the heavy load module further comprises a memory device, coupled to the control signal connector, to store at least one of configuration data, calibration data and temperature data from a temperature sensor mounted on the support plate.

6. The battery test system of claim 1, wherein the battery tester housing is adapted to receive at least two heavy load modules.

7. A heavy load module for a battery test system, comprising:

a housing having a control signal connector and a high-current connector;

a heat-resistant support plate disposed within the housing;

a first length of high-resistivity, large-gauge wire arranged on an upper surface of the plate;

a second length of high-resistivity, large-gauge wire arranged on a lower surface of the plate;

a switch, coupled to the first and second wires, the control signal connector and the high-current connector, to selectively connect the first and second wires to the high-current connector based upon a control signal received over the control signal connector; and

at least one fan, coupled to the high current connector and disposed within the housing, to cool the first and second wires.

8. The heavy load module of claim 7, wherein the switch selectively connects only the first wire, only the second wire, the first and second wires in series, or the first and second wires in parallel, to the high current connector.

9. The heavy load module of claim 7, wherein the heavy load module provides a configuration signal over the control signal connector.

10. The heavy load module of claim 7, further comprising a temperature sensor mounted on the support plate and coupled to the control signal connector.

11. The heavy load module of claim 7, further comprising a fan switching element coupled to the control signal connector and at least two fans.

12. The heavy load module of claim 11, wherein the fan switching element connects the fans to the high-current connector based upon a fan control signal received over the control signal connector.

13. The heavy load module of claim 11, wherein the plurality of fans includes four, 6 volt fans, and the fan switching element is adapted to connect the fans to the high-current connector based upon the voltage of the test battery.

14. The heavy load module of claim 13, wherein the fan switching element connects the fans to the high-current connector in a parallel configuration for a 6 volt test battery, in a series-parallel configuration for a 12 volt test battery, and in a series configuration for a 24 volt test battery.

15. The heavy load module of claim 7, further comprising a memory device, coupled to the control signal connector, to store at least one of configuration data, calibration data and temperature data from a temperature sensor mounted on the support plate.

16. The heavy load module of claim 7, wherein the first and second wires are made from FeCrAl Alloy 919, have a wire gauge of approximately 0, have a nominal resistance of approximately 0.15 ohms, and dissipate approximately 80 A of current from a 12 volt DC source.

17. A method for testing a battery using a heavy load, comprising:

selecting a heavy load module based upon a capacity of a battery under test, the heavy load module including a housing enclosing a configurable load and a switch to couple the configurable load to a battery analyzer;

connecting the heavy load module to the battery analyzer;

connecting the battery analyzer to the battery under test;

selecting a load configuration;

setting the load configuration; and

testing the battery.

18. The method of claim 17, further comprising cooling the configurable load using a plurality of fans disposed within the housing, wherein the configurable load includes first and second lengths of high-resistivity, large-gauge wire coupled to the switch and respectively arranged on upper and lower surfaces of a heat-resistant plate.

19. The method of claim 18, wherein setting the configuration of the load includes connecting only the first wire to the battery analyzer, connecting only the second wire to the battery analyzer, connecting the first and second wires to the battery analyzer in series, or connecting the first and second wires to the battery analyzer in parallel. pg,18

20. A modular heavy load battery test system, comprising:

a heavy load module, including;

a housing enclosing a configurable load;

means for setting the configuration of the load; and

means for cooling the load; and

a battery tester, including;

a housing adapted to receive the heavy load module;

means for selecting the configuration of the load; and

means for connecting the load to a battery under test.