Monitoring device for electric storage battery and configuration therefor

• US 5,159,272 A
• Filed: 07/21/1989
• Issued: 10/27/1992
• Est. Priority Date: 07/27/1988
• Status: Expired due to Fees

• Current Assignee: GNB Technologies Inc.
• Original Assignee: GNB, Inc.
• Inventors: Kump, William H., Fowler, Clarence W., Jay, Benny E., Rao, Purushothama
• Primary Examiner(s): Wieder, Kenneth A.
• Assistant Examiner(s): Regan, Maura K.
• Application Number:
  US07/383,084
• Time in Patent Office: 1,194 Days
• Field of Search: 324/429, 324/435, 324/433, 340/636, 320/48, 429/90-93
• US Class Current: 324/429
• CPC Class Codes: G01R 1/0408 Test fixtures or contact fields; Connectors or connecting adaptors; Test clips; Test sockets G01R1/067 takes precedence; mass production testing systems G01R31/59; testing of connections G01R31/66; for testing printed circuit boards G01R31/2808
• CPC Class Codes: G01R 31/006 on road vehicles, e.g. automobiles or trucks testing of ignition installations peculiar to internal combustion engines F02P17/00
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 6/505 Cells combined with indicating means for external visualization of the condition, e.g. by change of colour or of light intensity
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10S 320/21 State of charge of battery

Abstract

An electric storage battery is provided having a monitoring device for indicating the state-of-charge of the battery and particularly indicating whether a discharged battery is healthy and capable of being recharged or unhealthy and impending on a state of failure. The monitoring device achieves the foregoing by testing the open circuit voltage of the battery and determining if the voltage of the battery drops below a first preset value after application of a load and subsequently fails to rise above a second preset value after the load has been removed. Also, the monitoring device for the battery includes the capability of sensing when the battery has been placed into a system such as an engine system for an automobile and in response thereto modifying testing certain parameters. Preferably, the monitoring device is made integral with the battery case by providing a receptacle for receiving the device and a pair of connecting arms at least partially embedded in the battery container or cover.

Claims

1. In an electric storage battery having a housing comprising a plurality of walls for enclosing the electrochemical components of said battery and further having at least one pair of positive and negative battery terminals suitable for connecting said battery in an engine system, an apparatus for electrically communicating with the electrochemical components of said battery and testing the health thereof, said apparatus comprising:

a monitoring device received by a receptacle formed in one of said walls of said battery;

first means electrically associated with at least one pair of battery terminals for placing said monitoring device in electrical communication with the electrochemical components of said battery;

said monitoring device including a low charge detector for detecting a first voltage condition across said terminals and in response thereto indicating said battery is being operated in a state of low charge but remains capable of starting said engine;

said monitoring device also including a replacement detector for detecting a second voltage condition across said terminals of said battery and in response thereto indicating said battery is being operated in a state that is impending on a state of low charge which is insufficient to start said engine;

signalling means responsive to said first and second circuits for signalling the detection of said first or second voltage conditions; and

said monitoring device further including a start detector for detecting a third voltage condition following a previous detection of said second voltage condition and causing said signalling means to remove any indication of the previous detection.

2. An apparatus as set forth in claim 1 wherein said monitoring device includes a circuit for detecting the first connection of a load across said terminals and in response thereto changing said first voltage condition from a first value to a second value reflecting the battery transferring from a shelf mode to an installed mode.

3. An apparatus as set forth in claim 1 wherein said second voltage condition is the voltage across said terminals momentarily dropping below a first value when a load is placed across said terminals.

4. An apparatus as set forth in claim 3 wherein said third voltage condition is the voltage across said terminals rising above a second value greater than said first value after said load is removed from across said terminals and thereafter not falling below said first value when said load is again placed across said terminals.

5. An apparatus as set forth in claim 1 wherein said signalling means includes an alarm system having a first means responsive to said first or second voltage conditions for generating audible acoustic vibrations.

6. An apparatus as set forth in claim 5 wherein said alarm system includes a second means for sensing the running of an engine associated with said battery and in response thereto preventing the generation of said audible acoustic vibrations.

7. An apparatus as set forth in claim 6 wherein said second means of said alarm system includes a timer for permitting generation of said audible acoustic vibrations for a predetermined time after said second means no longer senses the running of said engine.

8. An apparatus as set forth in claim 6 wherein said first and second means of said alarm system both include a piezoelectric tone generator for alternately generating acoustic vibrations or detecting mechanical or acoustical vibrations so as to sense the running of said engine.

9. An apparatus as set forth in claim 1 wherein said first means is substantially completely embedded in one of said walls.

10. An apparatus as set forth in claim 1 wherein said monitoring device and the receptacle include means for aligning the monitoring device therein in order to ensure a correct electrical connection between the monitoring device and the electrochemical components of said battery.

11. An apparatus as set forth in claim 1 wherein said receptacle is recessed in said one wall and sized so that the top surface of said monitoring device is approximately flush with said one wall.

12. An apparatus as set forth in claim 11 wherein said monitoring device and said receptacle include means which cooperate to retain the monitoring device in the receptacle once the monitoring device is installed therein.

13. An apparatus as set forth in claim 12 wherein said retaining means includes means for permitting the monitoring device to be removed from the receptacle and subsequently reinstalled.

14. The apparatus as set forth in claim 1 wherein said first means includes at least one pair of terminal bushings at least partially embedded in said one wall with each of said bushings in electrical contact with at least one of said terminals.

15. The apparatus as set forth in claim 14 wherein each of said terminal bushings extends from at least one of said terminals to said receptacle and terminates within said receptacle so as to form a terminal which contacts a complementary terminal associated with said monitoring device and thereby communicate electrical energy and a voltage signal to said monitoring device from said battery.

16. The apparatus as set forth in claim 15 wherein each of said bushings is provided with one or more ribs circumferentially disposed on the surface thereof.

17. An apparatus for testing the health of a battery having at least one pair of positive and negative terminals connected in an engine system, the apparatus comprising:

a first detector for detecting a first voltage condition across the terminals and in response thereto indicating the battery is being operated in a state of low charge but remains capable of starting the engine;

a second detector for detecting a second voltage condition across the terminals of the battery and in response thereto indicating the battery is being operated in a state that is impending on a state of low charge which is insufficient to start the engine;

a display responsive to the first and second detectors for indicating the detection of the first and second voltage conditions; and

first means for detecting a third voltage condition following a previous detection of the second voltage condition and causing the display to remove any indication of the previous detection.

18. An apparatus as set forth in claim 17 including:

second means for detecting the first connection of a load across the terminals and in response thereto changing the first voltage condition from a first value to a second value, reflecting the battery transferring from a shelf mode to an installed mode.

19. An apparatus as set forth in claim 17 wherein the second detector includes a delay means responsive to the detection of a first voltage condition by the first detector for preventing the indication of the battery being in a state that is impending on a state of low charge insufficient to start the engine if the first voltage condition is present at the terminals for more than a predetermined time period.

20. An apparatus as set forth in claim 17 wherein the first detector includes a first circuit for detecting the falling of the voltage across said terminals below a first predetermined value.

21. An apparatus as set forth in claim 20 wherein the second detector includes a second circuit for detecting the falling of the voltage across the terminals below a second predetermined value.

22. An apparatus as set forth in claim 21 wherein the second detector includes a delay circuit responsive to the second circuit for detecting the time period the voltage across the terminals remains below the first predetermined value and inhibiting any indication by the second detector that the battery is unhealthy if the time period exceeds a predetermined value.

23. An apparatus for distinguishing between a healthy but discharged battery and an unhealthy battery impending on a state of failure, the apparatus comprising:

first voltage detection circuit for detecting a voltage of the battery falling below a first predetermined value;

second voltage detection circuit for detecting the voltage of the battery falling below a second predetermined value which is less than the first predetermined value;

a delay circuit responsive to the first voltage detection circuit for providing an indication of the rate of change of the voltage of the battery;

first means responsive to the first voltage detection circuit for indicating the battery is healthy but discharged when the voltage of the battery falls below the first predetermined value; and

second means responsive to the second voltage detection circuit and delay circuit for indicating the battery is unhealthy and impending on a state of failure if the voltage of the battery falls below the second predetermined value when the rate of change of the voltage of the battery as measured by the delay circuit is above a predetermined value.

24. In an electric storage battery having at least one pair of positive and negative terminals, a method of monitoring the voltage of a battery comprising the steps of:

monitoring a voltage across said terminals relative to a first predetermined reference voltage whose value is selected to reflect said battery being maintained in a shelf mode;

placing said battery into an engine system and momentarily connecting a load across said terminals in order to start said system;

detecting the voltage across said terminals dropping below a second predetermined reference voltage during the momentary connection of said load across said terminals, thereby indicating said battery is in an installed mode; and

adjusting the value of said first predetermined reference voltage in response to the detection of the terminal voltage dropping below said second predetermined reference voltage.

25. A method as set forth in claim 24 including the step of:

detecting the voltage across said terminals dropping below said adjusted value of said first predetermined reference voltage and in response thereto indicating said battery is being operated in a state of low charge but remains capable of starting said engine.

26. A method as set forth in claim 24 including the step of:

detecting the voltage across said terminals dropping below a third predetermined reference voltage during the momentary connection of said load across said terminals and indicating in response thereto said battery is being operated in a state of low charge which is impending on a state which will fail to start said engine system.

27. A method as set forth in claim 26 including the step of:

detecting the transition of said voltage across said terminals from a value greater than a fourth predetermined reference voltage to a value less than said fourth predetermined reference voltage during the momentary connection of said load across said terminals wherein said fourth predetermined reference voltage is greater than said third predetermined reference voltage, and in response thereto, removing any existing indication of said battery being operated in a state of low charge which is impending on a state which will fail to start said engine system.

28. Apparatus for testing the condition of a battery used to start an engine in a vehicle, comprising:

a first voltage detector responsive to the voltage of a battery under test and operable to measure an open circuit voltage of the battery relative to a predetermined open circuit voltage prior to engine start-up and after engine shutdown, in determination of the state of charge of the battery;

a second voltage detector responsive to the voltage of a battery under test and operable to measure the voltage of the battery under load during engine start-up in determination of an engine start-up operation;

a memory device responsive to a determination by the second voltage detector that an engine start-up operation has occurred, and monitoring the third voltage detector to record a determination that the voltage of the battery under load during engine start-up dropped below a predetermined level;

a first visual indicator responsive to the determinations made by the first and third voltage detectors, and signaling that the battery under test is in good condition based upon the first voltage detector determining that the charge of the battery under test is sufficient to maintain the predetermined open circuit voltage and upon the third voltage detector determining that the battery voltage during an engine start-up operation remained above a predetermined level;

a second visual indicator responsive to the determination made by the first voltage detector and signaling that the battery under test is in a poor state of charge based upon the first voltage detector determining that the charge of the battery under test is insufficient to maintain a predetermined open circuit voltage; and

a third visual indicator responsive to the determinations made by the second and third voltage detectors, and signaling that the battery under test is in poor health based upon the second voltage detector determining that an engine start-up operation was made and upon the third voltage detector determining that the battery voltage during the engine start-up operation dropped below a predetermined level.

29. The apparatus of claim 28 further comprising an oscillator circuit providing a driving signal to the visual indicators, and causing the indicators to flash on and off when signaling.

30. The apparatus of claim 28 further comprising:

an audible alert device responsive to the determinations made by either of the first and third voltage detectors, and signaling to a motorist that the battery under test has been determined to be in poor state of charge based upon the first voltage detector determining that the charge of the battery is insufficient to maintain a predetermined open circuit voltage or that the battery has been determined to be in poor health based upon the third voltage detector determining that the battery voltage during engine start-up dropped below a predetermined level; and

means for preventing energization of said audible alert device in response to detecting operation of said engine.

31. The apparatus of claim 30 wherein the audible alert device includes:

a piezoelectric tone generator element;

an oscillator generating a driving signal for the piezoelectric device;

a circuit interposed between the piezoelectric device and the oscillator to couple the driving signal of the oscillator to the piezoelectric device; and

a control circuit providing a control to the circuit that applies the oscillator driving signal to the piezoelectric element, and controlling activation of the piezoelectric element based upon the determinations made by the first and third voltage detectors.

32. The apparatus of claim 31 wherein the control circuit includes a timing circuit for timing out a predetermined period of time for the piezoelectric element to be activated to produce an audible alert.

33. The apparatus of claim 31 wherein the means for preventing energization includes:

the piezoelectric element being responsive to an engine running in the vehicle and generating a voltage signal indicative thereof, said piezoelectric element acting as a capacitive coupling element and passing generator ripple and noise; and

an engine detector responsive to the voltage signal generated by the piezoelectric element and operable to determine whether the vehicle engine is running or stopped, and an output signal of the engine detector being provided as an input to the control circuit to prevent activation of the piezoelectric element when the engine is determined to be running.

34. The apparatus of claim 33 wherein the control circuit includes a timing circuit producing control signals to activate the piezoelectric element for a predetermined period of time to produce an audible alert signal in response to an output signal of the engine detector indicating that the vehicle engine has stopped running.

35. The apparatus of claim 30 further comprising:

a housing carrying the voltage detectors, the visual indicators and the audible alert device;

terminal means carried by the housing for making electrical connection to a battery under test; and

;

connection means for coupling the terminal means to the voltage detectors so as to provide the voltage of the battery under test to the voltage detectors.

36. The apparatus of claim 35 wherein the housing is adapted for integral mounting with the case of the battery under test.

37. The apparatus of claim 28 further comprising:

a voltage divider network providing to the voltage detectors a plurality of voltage levels derived from the voltage level of the battery under test, one of the voltage levels being applied as a first input signal to a respective one of the voltage detectors;

a voltage regulator coupled to the battery under test and providing a common reference voltage level to each of the voltage detectors as a second input; and

the voltage divider network voltages being scaled so that the voltage level applied to respective voltage detector as a first input decreases below the voltage set by the voltage regulator as a second input when the terminal voltage of the battery drops to a specified voltage for the determination being made by that respective voltage detector.

38. Apparatus for testing the condition of an automotive battery used to start an engine in a vehicle, comprising:

a first voltage detector responsive to the voltage of a battery under test and operable to measure an open circuit voltage of the battery prior to engine start-up and after engine shutdown in determination of the state of charge of the battery;

a second voltage detector responsive to the voltage of a battery under test and operable to measure the voltage of the battery under load during engine start-up in determination of an engine start-up operation;

a third detector responsive to the voltage of a battery under test and operable to measure the voltage of the battery under load during engine start-up in determination of whether the battery voltage during an engine start-up operation has dropped below a predetermined level;

a first visual indicator responsive to the determinations made by the first and third voltage detectors, and signaling that the battery under test is in good condition based upon the first voltage detector determining that the charge of the battery under test is sufficient to maintain a predetermined open circuit voltage and upon the third voltage detector determining that the battery voltage during an engine start-up operation remained above a predetermined level;

a second visual indicator responsive to the determination made by the first voltage detector and signaling that the battery under test is in a poor state of charge based upon the first voltage detector determining that the charge of the battery under test is insufficient to maintain a predetermined open circuit voltage;

a third visual indicator responsive to the determinations made by the second and third voltage detectors, and signaling that the battery under test is in poor health based upon the second voltage detector determining that an engine start-up operation was made and upon the third voltage detector determining that the battery voltage during the engine start-up operation dropped below a predetermined level; and

a memory device coupled voltage detector and to the second voltage detector establishing a first mode of operation wherein the first voltage detector measures open circuit voltage with respect to a first voltage detection level until an engine start-up operation occurs, whereupon a second mode of operation is established wherein the first voltage detector measures open circuit voltage with respect to a second, lower voltage detection level.

39. The apparatus of claim 38 further comprising an input terminal connected tot he memory device and adapted to receive an externally applied signal to reset the memory device to the first mode of operation.

40. An apparatus for testing the condition of a battery used to start an engine in a vehicle, comprising:

means for comparing the magnitude of the battery voltage to a preselected discharge value and delivering a recharge battery signal in response to the preselected discharge value being greater than the magnitude of the battery voltage;

means for comparing the magnitude of the battery voltage to a preselected failure value and delivering a failed battery signal in response to the preselected failure value being greater than the magnitude of the battery voltage;

means for comparing the magnitude of the battery voltage to a preselected start-up value and, in response to the start-up value being greater than the magnitude of the battery voltage, delivering a start-up signal indicative of the engine being started, said preselected failure value being less than the preselected start-up value;

memory means for receiving the failed battery signal, storing the failed battery signal, and delivering the signal stored therein;

means for clearing the signal stored in the memory means in response to receiving the start-up signal, to permit a recheck of the battery during each engine start-up irrespective of the battery having failed a previous start-up test; and

means for producing a first and second perceptible signal in response to respectively receiving the recharge battery signal and the stored memory means signal.

41. An apparatus, as set forth in claim 40, including means for detecting the instantaneous operation of the vehicle engine and thereupon delivering an engine operating signal, and wherein the perceptible signal producing means includes means for generating an audible alert signal in response to receiving the failed battery signal and in the absence of the engine operating signal, to permit the audible alert signal to be generated only when the engine has ceased operating.

42. An apparatus, as set forth in claim 40, including means for establishing the preselected discharge value to be a first preselected magnitude during the period of time prior to the first occurrence of the start-up signal and a second preselected magnitude during the period of time subsequent to receiving the first occurrence of the start-up signal.

43. An apparatus, as set forth in claim 40, wherein the memory means includes a logical memory device having a data input connected to a logically high source of voltage, a clock input adapted to receive the start-up signal, and a data output.

44. An apparatus, as set forth in claim 43, wherein the clearning means includes the logical memory device having a reset input adapted to receive the failed battery signal.

45. An apparatus for testing the condition of a battery used to start an engine in a vehicle, comprising:

means for comparing the magnitude of the battery voltage to a preselected value and delivering a check battery signal in response to the preselected value being greater than the magnitude of the battery voltage;

means for detecting the instantaneous operation of the vehicle engine and delivering an engine operating signal in response to detecting operation thereof; and

means for generating an audible alert signal in response to receiving the check battery signal and in the absence of the operating signal whereby the audible alert signal is generated only when the engine has ceased operating.

46. An apparatus, as set forth in claim 45, wherein the engine operation detecting means includes:

a piezoelectric element adapted for generating a signal having a magnitude correlative to the level of noise produced by the engine; and

means for comparing the magnitude of the piezoelectric signal to a preselected value and delivering the operating signal when the piezoelectric signal is greater than the preselected value.

47. An apparatus, as set forth in claim 46, wherein the audible alert signal generating means includes:

an oscillator adapted for generating a driving signal for said piezoelectric element to cause an audible tone to be produced from the piezoelectric element; and

a logic circuit connected between the oscillator and the piezoelectric element, the logic circuit controlling delivery of the driving signal to the piezoelectric element in response to receiving the check battery signal and in the absence of the operating signal.

48. An apparatus, as set forth in claim 47, wherein the logic circuit includes:

an oscillator;

a counter having a clock signal input connected to the oscillator, a reset input adapted to reset the counter to an initial value in response to the absence of the check battery signal and the presence of the engine operating signal, and an output adapted to provide a first control signal when the counter has received a preselected number of input clock signals from the oscillator; and

a logic gate having an input adapted to receive the driving signal, an enable input adapted to receive the driving signal, an enable input connected to the counter output and adapted to receive the first control signal, and an output connected to the piezoelectric element.

49. An apparatus, as set forth is claim 48, wherein said logic gate includes a second enable input, said counter includes a second output adapted to produce a second control signal when the counter has received a preselected number of input clock signals after producing the first control signal, and said second counter output is connected to the second enable input, said second control signal being adapted to disable said logic gate from delivering the driving signal to the piezoelectric element to permit the piezoelectric element to produce an audible alert signal for only a preselected duration of timed after the engine has ceased operating.

50. An apparatus, as set forth in claim 45, including timing means for inhibiting said audible alert signal following a preselected duration of time after the audible alert signal is first generated.

51. An apparatus for testing the condition of a battery used to start an engine in a vehicle, comprising:

means for comparing the magnitude of the battery voltage to a preselected value and delivering a check battery signal in response to the preselected value being greater than the magnitude of the battery voltage;

means for comparing the magnitude of the battery voltage to a preselected start-up value and delivering a start-up signal indicative of the engine being started if the start-up value is greater than the magnitude of the battery voltage;

means for establishing the preselected value to be a first preselected magnitude during the period of time prior to the first occurrence of the start-up signal and a second preselected magnitude during the period of time subsequent to receiving the first occurrence of the start-up signal; and

means for producing a perceptible signal in response to receiving the check battery signal.

52. An apparatus, as set forth in claim 51, wherein the first preselected magnitude is greater than the second preselected magnitude.

53. An apparatus, as set forth in claim 52, wherein the establishing means includes:

a voltage divider network having at least three resistors connected in series with said battery, and a control resistor having a first end thereof connected intermediate the first and second resistors so as to be electrically closest to the positive terminal of the battery;

a logical memory device having a set input and an output, said output being connected to the second end of said control resistor;

a voltage regulator connected to the battery; and

said start-up comparing means includes a comparator having a non-inverting input connected intermediate the second and third resistors, an inverting input connected to the voltage regulator, and an output connected to the set input of the logical memory device to permit a drop in the battery voltage below the voltage regulator voltage level to set the logical memory device output and bias the control resistor out of the voltage divider network.

54. An apparatus, as set forth in claim 51, including means for detecting the instantaneous operation of the vehicle engine and thereupon delivering an engine operating signal, and wherein the perceptible signal producing means includes means for generating an audible alert signal in response to receiving the check battery signal and in the absence of the operating signal, to cause the audible alert signal to be generated only when the engine has ceased operating.

55. An apparatus, as set forth in claim 51 including:

means for comparing the magnitude of the battery voltage to a preselected failure value and delivering a failed battery signal when the preselected failure value being greater than the magnitude of the battery voltage;

memory means for receiving the failed battery signal, storing the failed battery signal, and delivering the signal stored therein; and

means for clearing the signal stored in the memory means in response to receiving the start-up signal to permit the battery to be rechecked during each engine start-up irrespective of the battery having failed during a previous start-up test.

56. An apparatus for testing the condition of a battery used to start an engine in a vehicle, comprising:

means for comparing the magnitude of the battery voltage to a preselected discharge value and delivering a recharge signal in response to the preselected discharge value being greater than the magnitude of the battery voltage;

means for comparing the magnitude of the battery voltage to a preselected start-up value and delivering a start-up signal indicative of the engine being started in response to the start-up value being greater than the magnitude of the battery voltage;

means for establishing the preselected discharge value to be a first preselected magnitude during the period of time prior to the first occurrence of the start-up signal and a second preselected magnitude during the period of time subsequent to receiving the first occurrence of the start-up signal;

means for comparing the magnitude of the battery voltage to a preselected failure value and delivering a failed battery signal in response to the preselected failure value being greater than the magnitude of the battery voltage, said preselected failure value being less than the preselected start-up value;

memory means for receiving the failed battery signal, storing the failed battery signal, and delivering the signal stored therein;

means for clearing the signal stored in the memory means in response to receiving the start-up signal whereby the battery is rechecked during each engine start-up irrespective of the battery having failed a previous start-up test;

means for producing a first and second perceptible signal in response to respectively receiving the recharge signal and the memory means signal;

means for detecting the instantaneous operation of the vehicle engine and delivering an operating signal in response to detecting operation thereof; and

means for generating an audible alert signal in response to receiving the memory means signal and in the absence of the operating signal whereby the audible alert signal is generated only when the engine has ceased operating.