Method of testing an electric storage battery by determining a bounce-back voltage after a load has been removed

• US 5,773,977 A
• Filed: 04/18/1996
• Issued: 06/30/1998
• Est. Priority Date: 04/18/1996
• Status: Expired due to Fees

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Dougherty, Thomas J.
• Primary Examiner(s): Oda, Christine K.
• Application Number:
  US08/634,650
• Time in Patent Office: 803 Days
• Field of Search: 324/426, 324/427, 324/429, 324/430, 324/433, 324/434, 364/483, 320/48, 340/636
• US Class Current: 324/429
• 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 31/379 for lead-acid batteries
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: G01R 31/386 using test-loads

Abstract

A battery tester and associated method for determining if one or more cells in a storage battery are capable of storing sufficient charge prior to charging the battery. A predetermined load is applied to the battery for a predetermined period of time, and then the bounce back voltage of the battery is measured immediately after the load is removed. If the bounce back voltage of the battery is within a predetermined range after a predetermined time after the load is removed, then one or more cell in the battery is bad and the battery can be rejected prior to being charged.

Claims

1. A method of testing a battery to determine if one or more individual cells of the battery are bad by connecting the battery to a control circuit including a predetermined load and a switching means for controlling the connection of said load to the battery, said method comprising the steps of:

connecting said predetermined load to the battery for a first predetermined period of time;

disconnecting said predetermined load from the battery after said first predetermined period of time;

monitoring the voltage of the battery after said load has been removed; and

determining if one or more cells of the battery are bad based on said monitored battery voltage, wherein the step of determining if one or more cells of the battery are bad includes determining the battery voltage level a second predetermined period of time after the predetermined load is disconnected from the battery and comparing the determined battery voltage level to a predetermined battery voltage level so that if the determined battery voltage level is below the predetermined battery voltage level, then at least one of the cells is bad.

2. The method according to claim 1 wherein the step of connecting said predetermined load results in a current draw from the battery of between approximately 2 amps and approximately 2000 amps.

3. The method according to claim 1 wherein said first predetermined period of time is within the range of approximately 10 seconds to approximately 15 seconds.

4. The method according to claim 1 wherein the battery is a 12-volt battery and the step of determining if one or more cells are bad includes the steps of determining that one cell is bad if the voltage of the battery is about 10.1 volts about two seconds after the load is removed and is about 10.7 volts about ten seconds after the load is removed.

5. The method according to claim 1 wherein the battery is a 12-volt battery and the step of determining if one or more cells are bad includes the steps of determining that two of the cells are bad if the voltage of the battery is about 8.05 volts about two seconds after the load is removed and is about 8.6 volts about ten seconds after the load is removed.

6. The method according to claim 1 wherein the battery is a 12-volt leadacid battery including six cells.

7. The method according to claim 1 wherein the step of connecting a predetermined load to the battery includes connecting a resistor in parallel with the battery.

8. The method according to claim 1 further comprising the step of charging the battery if the step of determining if one or more cells are bad determines that no cells are bad.

9. The method according to claim 1 wherein the step of determining if one or more cells of the battery are bad includes the step of determining a slope of battery voltage with respect to time after the load is disconnected.

10. The method according to claim 1 further comprising the preliminary steps of measuring the battery voltage and charging the battery for a third predetermined period of time prior to the step of connecting a predetermined load to the battery if the measured battery voltage is below a predetermined value.

11. The method according to claim 10 wherein the step of charging the battery includes the step of charging the battery for about a five-minute time period.

12. A system for testing a battery to determine if one or more individual battery cells of the battery are bad, said system comprising:

a predetermined load; and

a control circuit including monitoring means for monitoring the voltage of the battery and switch means for controlling the connection of the load to the battery, said switch means electrically connecting the load to the battery for a first predetermined period of time and then disconnecting the load from the battery, and said monitoring means monitoring the voltage of the battery after the load is disconnected to determine if the one or more cells are bad, said monitoring means determining that the one or more cells are bad if the battery voltage is below a predetermined battery voltage a second predetermined period of time after the predetermined load is disconnected by comparing the monitored battery voltage at the second predetermined period of time to the predetermined battery voltage.

13. The system according to claim 12 wherein the predetermined load results in a current draw from the battery of between approximately 2 amps and approximately 2000 amps.

14. The system according to claim 12 wherein said first predetermined period of time is within the range of approximately 10 seconds to approximately 15 seconds.

15. The system according to claim 14 wherein the battery is a 12-volt battery and one cell is bad if the voltage of the battery is about 10.1 volts about two seconds after the load is disconnected and is about 10.7 volts about ten seconds after the load is disconnected.

16. The system according to claim 14 wherein the battery is a 12-volt battery and two of the cells are bad if the voltage of the battery is about 8.05 volts about two seconds after the load is disconnected and is about 8.6 volts about ten seconds after the load is disconnected.

17. The system according to claim 12 wherein the battery is a 12-volt leadacid battery including six cells.

18. The system according to claim 12 wherein the load is a resistor.

19. The system according to claim 12 wherein said control circuit further comprises a charging device, said charging device charging the battery if the system determines that no cells are bad.

20. A system according to claim 19 wherein the charging device charges the battery prior to the switching means electrically connecting the load to the battery if the battery voltage is below a predetermined level.

21. A method of testing a battery to determine if one or more individual battery cells of the battery are bad by connecting the battery to a control circuit including a switching circuit for controlling the connection of a predetermined load to the battery and a charging circuit for charging the battery, said method comprising the steps of:

providing a battery to be tested, said battery including a plurality of battery cells electrically connected together in a series configuration;

determining whether the voltage of the battery is above a predetermined level;

charging the battery for a first predetermined period of time if the voltage of the battery is below said predetermined level;

connecting said predetermined load to the battery, said load resulting in a current draw from the battery of between approximately 2 amps and approximately 2000 amps;

disconnecting the load from the battery a second predetermined period of time after the load is connected to the battery;

monitoring the voltage of the battery after the load has been disconnected;

determining if one or more of the plurality of battery cells of the battery are bad based on the monitored battery voltage, said step of determining if one or more of the plurality of battery cells are bad includes determining the battery voltage level a third predetermined time after the load is disconnected from the battery and comparing the determined battery voltage level to a predetermined battery voltage level so that if the determined battery voltage level is below the predetermined battery voltage level, then at least one of the cells is bad; and

charging the battery if it is determined that no cells are bad.

22. The method according to claim 21 wherein said first predetermined period of time comprises approximately five minutes.

23. The method according to claim 21 wherein the battery is a 12-volt leadacid battery including 6 cells.

24. The method according to claim 23 wherein the battery is a 12-volt battery and the step of determining if the one or more cells are bad includes the steps of determining that one cell is bad if the battery voltage is about 10.1 volts about 2 seconds after the load is disconnected and is about 10.7 volts about 10 seconds after the load is disconnected.

25. The method according to claim 21 wherein the step of determining if one or more cells of the battery are bad includes the step of determining a slope of battery voltage with respect to time after the load is disconnected.

26. A method of testing a battery to determine if one or more individual cells of the battery are bad by connecting the battery to a control circuit including a predetermined load and a switching means for controlling the connection of said load to the battery, said method comprising the steps of:

connecting said predetermined load to the battery for a first predetermined period of time;

disconnecting said predetermined load from the battery after said first predetermined period of time;

monitoring the voltage of the battery after said load has been removed; and

determining if one or more cells of the battery are bad based on said monitored battery voltage, wherein the step of determining if one or more cells of the battery are bad includes the step of determining a slope of the battery voltage with respect to time after the load is disconnected.