Method and apparatus for testing a battery

• US 4,433,294 A
• Filed: 06/05/1981
• Issued: 02/21/1984
• Est. Priority Date: 06/05/1981
• Status: Expired due to Term

• Current Assignee: KW Powersource, Inc.
• Original Assignee: Firing Circuits, Inc.
• Inventors: Windebank, Robert W.
• Primary Examiner(s): Tokar, Michael J.
• Assistant Examiner(s): O'Shea, Kevin D.
• Application Number:
  US06/270,823
• Time in Patent Office: 991 Days
• Field of Search: 324/426, 324/429, 324/433, 324/434, 324/73 AT, 320/27, 320/32, 320/48
• US Class Current: 324/426
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/385 Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: Y10S 320/13 Fault detection
• CPC Class Codes: Y10S 320/21 State of charge of battery

Abstract

The operating condition and/or characteristics of a battery is tested by obtaining the dynamic voltage-current characteristic of the battery as a function of the charge condition thereof. A controllably varying charging current is supplied to the battery, and the voltage produced across the battery while that current is supplied is measured. The dynamic voltage-current characteristic is obtained as a function of the measured voltage and supplied current. This voltage-current characteristic is compared to predetermined voltage-current characteristics representing batteries of the type being tested in order to determine the operating condition and/or characteristics of the battery under test.

Claims

1. A method of testing an electrical storage battery of the type having a pair of output terminals, to obtain information relating to a fault condition and/or characteristics thereof, said method comprising the steps of supplying to said battery a gradually increasing charging current to increase the voltage of the battery toward and beyond the gas voltage level thereof, followed by a gradually decreasing charging current, said currents being supplied over a predetermined current-level range;

measuring said voltage produced across said pair of output terminals of said battery in response to the increasing and decreasing currents supplied thereto while said currents are being supplied;

obtaining the dynamic voltage-current characteristic loop of said battery as a function of the measured voltage and the increasing and decreasing currents supplied over said predetermined range, said dynamic voltage-current characteristic loop having a first portion produced in response to said increasing charging current and a second portion produced in response to said decreasing charging current; and

determining the operating condition, including a fault condition, and/or characteristics of said battery as a function of the obtained voltage-current characteristic loop.

2. The method of claim 1 wherein said step of determining the operating condition, including a fault condition, and/or characteristics of said battery comprises comparing the obtained voltage-current characteristic loop to a predetermined voltage-current characteristic loop representing batteries of the type being tested and known to be in desirable operating condition, said predetermined voltage-current characteristic loop being provided over the same range of ramp currents as the range of currents used to produce said obtained voltage-current characteristic loop;

and determining the operating condition and/or characteristics of said battery as a function of said comparison.

3. The method of claim 2 wherein said step of obtaining the dynamic voltage-current characteristic loop includes obtaining the open-circuit voltage produced across said pair of output terminals of said battery in response to substantially zero charging current;

and said predetermined voltage-current characteristic loop is the voltage-current characteristic loop which includes an open-circuit voltage substantially equal to the open-circuit voltage obtained for the battery under test.

4. The method of claim 2 wherein said step of obtaining the dynamic voltage-current characteristic loop further comprises determining the slope of said obtained voltage-current characteristic loop, thereby representing the charge capacity of the battery under test;

and said predetermined voltage-current characteristic loop is the voltage-current characteristic loop representing batteries having substantially the same charge capacity as that determined for said battery under test.

5. The method of claim 1 further comprising the steps of determining the slope of said dynamic voltage-current characteristic loop, thereby representing the charge capacity of the battery under test;

obtaining the open-circuit voltage produced across said output terminals of said battery in response to substantially zero charging current;

comparing the obtained open-circuit voltage to reference open-circuit voltage levels associated with batteries having substantially the same charge capacity as that determined for said battery under test; and

determining the charge condition of said battery under test as a function of said comparison.

6. The method of claim 5 further comprising the steps of sensing predetermined changes in the slope of said obtained voltage-current characteristic loop;

and determining that said battery under test is charged to its gassing condition when said predetermined changes in said slope are sensed at a preselected charge condition for said determined charge capacity of said battery under test.

7. The method of claim 6 further comprising the step of determining a fault condition in said battery under test if said predetermined changes in said slope are sensed at less than said preselected charge condition.

8. The method of claim 1 wherein said step of supplying increasing and decreasing charging currents comprises generating an increasing ramp current followed by a decreasing ramp current;

and supplying said ramp currents to said battery.

9. The method of claim 8 wherein said step of generating an increasing ramp current followed by a decreasing ramp current comprises increasing the current supplied to said battery by equal increments in successive time steps;

sensing if said current or voltage produced across said battery output terminals exceed predetermined current or voltage levels, respectively;

if said predetermined current or voltage levels are exceeded, maintaining said current at a substantially constant level for the duration equal to the time that would have been needed for said time steps to reach a predetermined number and then return to the step last attained thereby; and

decreasing the current supplied to said battery by equal increments in successive time steps until substantially zero current is supplied.

10. The method of claim 9 further comprising the steps of incrementing first counter means with each incremental increase in said current supplied to said battery;

loading second counter means with the count reached by said first counter means when said predetermined current or voltage levels are exceeded;

successively incrementing said second counter means from the loaded count thereof until a predetermined count is reached, and thereafter successively decrementing said second counter means until the count thereof is equal to the count of said first counter means; and

then decrementing said first counter means with each incremental decrease in said current supplied to said battery.

11. The method of claim 10, further comprising the steps of decrementing said current supplied to said battery and decrementing said first counter means, after said second counter means is loaded with the count reached by said first counter means, such that said predetermined current and voltage levels are not exceeded.

12. A method of testing an electrical storage battery of the type having a pair of output terminals to obtain information relating to the charge condition, fault condition and operating characteristics thereof, said method comprising the steps of supplying a gradually increasing ramp charging current followed by a gradually decreasing ramp charging current to said battery;

measuring the voltage produced across said pair of output terminals of said battery in response to the ramp currents supplied thereto while said currents are being supplied;

comparing the measured voltage to predetermined standard voltages representing batteries of the type being tested and known to be in desirable operating condition; and

determining the charge condition, fault condition and operating characteristics of the battery under test as a function of said comparison.

13. The method of claim 12, further comprising the step of storing digital data representing operating conditions and/or characteristics correlated with said predetermined standard voltages;

and wherein said step of comparing the measured voltage to said predetermined standard voltages comprises converting said measured voltage to corresponding digital representations thereof, and comparing said converted digital representations to said stored data to determine the operating condition and/or characteristics of said battery under test.

14. The method of claim 12 wherein said step of determining the operating condition and/or characteristics as a function of said comparison comprises sensing relatively abrupt changes in said measured voltage, and providing an indication of a battery fault if said abrupt change occurs at a measured voltage that is less than a predetermined one of said standard voltages.

15. A method of testing an electrical storage battery of the type having a pair of output terminals, to obtain information relating to a fault condition of said battery, said method comprising the steps of supplying a gradually increasing charging current followed by a gradually decreasing charging current to said battery;

measuring the voltage produced across said pair of output terminals of said battery in response to the charging currents supplied thereto while said charging currents are being supplied;

comparing the measured voltage to predetermined voltages representing predetermined fault conditions in batteries of the type being tested; and

determining the existence of a fault condition in the battery under test as a function of said comparison.

16. The method of claim 15 further comprising the step of storing digital data representing said predetermined voltages associated with respective levels of charging current;

and wherein said step of comparing comprises converting said measured voltage to digital representations thereof, and comparing each converted digital representation produced in response to a corresponding level of said charging current to the stored digital data associated with that level of charging current.

17. A method of testing an electrical storage battery of the type having a pair of output terminals, to obtain information relating to the operating characteristics thereof, said method comprising the steps of storing standard voltage level data representing respective battery charge levels;

storing voltage-current characteristic loop data corresponding to curves of the relationship between changes in battery voltage as current supplied to the battery varies, said voltage-current characteristic data representing respective battery charge capacities;

supplying a controllably varying charging current to said battery;

measuring the voltage produced across said battery output terminals in response to the current supplied thereto while said current is being supplied;

obtaining the dynamic voltage-current characteristic loop of said battery as a function of the measured voltage;

comparing said obtained voltage-current characteristic loop to the stored voltage-current characteristic loop data;

comparing the voltage measured when said charging current is substantially zero to said stored standard voltage level data; and

indicating the charge capacity and charge level of the battery under test as a function of said comparisons.

18. Apparatus for testing a battery comprising energizing means coupled to said battery to supply energy thereto;

sensing means coupled to said battery to sense voltage thereacross and current thereto; and

control means coupled to said energizing means and to said sensing means for supplying a gradually increasing level of energy followed by a gradually decreasing level of energy to said battery and responsive to at least one of the sensed voltage and current to obtain the dynamic voltage-current characteristic loop of said battery, said dynamic voltage-current characteristic loop having a first portion produced in response to said increasing level of energy and a second portion produced in response to said decreasing level of energy, said control means being operative to determine the charge condition of said battery as a function of said dynamic voltage-current characteristic loop.

19. The apparatus of claim 18 wherein said energizing means comprises means for supplying current to said battery, and said control means controls said energizing means to supply an increasing charging current followed by a decreasing charging current to said battery.

20. The apparatus of claim 19 wherein said control means is responsive to said sensed voltage to obtain said dynamic voltage-current characteristic loop of said battery as a function of said sensed voltage and said supplied increasing and decreasing charging currents.

21. The apparatus of claim 20 wherein said means for supplying current to said battery comprises current ramp generating means, responsive to said control means, for generating a current ramp which increases with respect to time followed by a current ramp which decreases with respect to time.

22. The apparatus of claim 18 wherein said control means comprises programmed data processing means for determing said dynamic voltage-current characteristic loop of said battery as a function of the voltage sensed by said sensing means and the increasing and decreasing levels of energy supplied by said energizing means, and for determining the charge condition of said battery as a function of said voltage sensed by said sensing means when no energy is supplied to said battery.

23. The apparatus of claim 22 wherein said data processing means is programmed to detect a fault condition in said battery as a function of said voltage sensed by said sensing means.

24. The apparatus of claim 23 wherein said data processing means includes memory means for storing voltage data representing predetermined fault conditions associated with respective current levels;

and said data processing means is programmed to compare the voltage at different battery current levels, as sensed by said sensing means, to said stored voltage data, and to indicate the existence of a fault condition in response to said comparison.

25. Apparatus for testing a battery comprising energizing means coupled to said battery to selectively supply current and voltage thereto;

sensing means coupled to said battery to sense voltage thereacross; and

data processing means programmed to control said energizing means to supply a gradually increasing current followed by a gradually decreasing current to said battery and to determine the charge condition of said battery as a function of the sensed voltage.

26. The apparatus of claim 25 wherein said data processing means is programmed to derive data representing a dynamic voltage-current characteristic loop as a function of the voltage sensed across said battery and the current supplied to said battery.

27. The apparatus of claim 26 wherein said data processing means is programmed to determine the slope of the derived dynamic voltage-current characteristic loop.

28. The apparatus of claim 27 wherein said data processing means is programmed to detect abrupt changes in the slope of the derived dynamic voltage-current characteristic loop and to provide an indication of a battery fault if said abrupt change in slope is detected at a sensed battery voltage that is less than a predetermined voltage level.

29. The apparatus of claim 28 wherein said predetermined voltage level in the gas-voltage level of said battery.

30. The apparatus of claim 27 wherein said data processing means includes memory means for storing data representing battery charge capacities correlated with different dynamic voltage-current characteristic loop slopes;

and said data processing means is programmed to compare said determined slope with said stored data to obtain an indication of the charge capacity of said battery.

31. The apparatus of claim 30 wherein said memory means further stores data representing different charge levels, as a function of battery voltage, associated with each battery charge capacity;

and said data processing means is programmed to compare the voltage sensed across said battery when the current supplied thereto is substantially equal to zero with said data representing different charge levels to obtain an indication of the charge level of said battery.

32. Apparatus for testing a battery comprising energizing means coupled to said battery to selectively supply current and voltage thereto;

sensing means coupled to said battery to sense voltage thereacross; and

data processing means including memory means for storing charge capacity data representing charge capacities of different batteries, gas voltage data representing the gas voltage levels of said batteries, charge level data representing the charge levels of said batteries as a function of the battery voltage thereof, and fault data representing predetermined battery fault conditions as a function of battery voltage;

said data processing means being programmed to control said energizing means to supply a test current having gradually increasing and decreasing portions and to obtain a dynamic voltage-current characteristic as a function of said supplied current and the voltage across said battery sensed by said sensing means while said current is supplied;

said data processing means being further programmed to determine the number of cells included in said battery as a function of said sensed voltage when said current is substantially zero;

said data processing means being further programmed to determine the slope of said dynamic voltage-current characteristic and to derive the charge capacity of said battery as a function of the determined number of cells and determined slope;

said data processing means being further programmed to compare said sensed voltage when said current is substantially zero to said stored charge level data to derive the charge level of said battery; and

said data processing means being further programmed to compare said obtained dynamic voltage-current characteristic to said fault data to indicate the presence of a battery fault condition.

33. A method of testing an electrical storage battery of the type having a pair of output terminals, to obtain information relating to a fault condition of said battery, said method comprising the steps of supplying a gradually increasing charging current followed by a gradually decreasing charging current to said battery;

measuring the voltage produced across said pair of output terminals of said battery in response to the charging currents supplied thereto while said charging currents are being supplied;

deriving the dynamic voltage-current characteristic of said battery as a function of the measured voltage and the supplied current;

comparing the measured voltage to a predetermined gas voltage level;

detecting a discontinuity in the slope of said dynamic voltage-current characteristic when said measured voltage is less than said predetermined gas voltage level; and

determining the existence of a fault condition in the battery under test if a discontinuity n said slope of said dynamic voltage-current characteristic is detected when said measured voltage is less than said predetermined gas voltage level.

34. Apparatus for testing a battery comprising energizing means coupled to said battery to supply energy thereto;

sensing means coupled to said battery to sense voltage thereacross and current thereto; and

control means coupled to said energizing means and to said sensing means for supplying an increasing level of energy followed by a gradually decreasing level of energy to said battery and responsive to said sensed voltage and supplied current to obtain the dynamic voltage-current characteristic of said battery, said control means comprising programmed data processing means for determining said dynamic voltage-current characteristic, for comparing said sensed voltage to a predetermined gas voltage level, for detecting a discontinuity in the slope of said determined dynamic voltage-current characteristic when said sensed voltage is less than said predetermined gas voltage level, and for indicating a fault condition if said discontinuity in slope is detected when said sensed voltage is less than said predetermined gas voltage level.