System for simultaneously testing a plurality of batteries for multiple operating specifications

• US 5,966,014 A
• Filed: 10/17/1997
• Issued: 10/12/1999
• Est. Priority Date: 10/17/1997
• Status: Expired due to Fees

• Current Assignee: Chaojiong Zhang
• Original Assignee: Chaojiong Zhang
• Inventors: Piwonka, Dennis, Zhang, Chaojiong
• Primary Examiner(s): Do, Diep N.
• Application Number:
  US08/953,335
• Time in Patent Office: 725 Days
• Field of Search: 324/426, 324/427, 324/433, 324/434, 324/437, 324/754, 340/636, 361/728
• US Class Current: 324/434
• CPC Class Codes: G01R 31/01 Subjecting similar articles in turn to test, e.g. "go/no-go" tests in mass production; Testing objects at points as they pass through a testing station testing of cables continuously passing the testing apparatus G01R31/59; testing dielectric strength or breakdown voltage G01R31/12
• CPC Class Codes: G01R 31/36 Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]

Abstract

This disclosure sets out a multiple battery tester having a tray loaded with a set of batteries. The tray is placed in a receptacle and end located terminals move vertically to clamp a battery. The contacts bear on the battery, establishing a current flow path. This loop connects in charge/discharge system for testing. Test routines can be varied and data is recorded over time.

Claims

1. An apparatus for testing a battery having spaced positive and negative terminals thereon, the apparatus comprising:

(a) a battery tray for holding the battery in a fixed position so that the positive and negative terminals thereof are exposed;

(b) contacts for contacting the battery including a positive terminal contact and a negative terminal contact;

(c) test signal apparatus responsive to said contacting and for testing of the battery;

(d) a clamp mechanism comprising a cam mechanism to initiate and then terminate engagement and disengagement of said contacts with the terminals of the battery; and

(e) a current flow path including said test apparatus, positive and negative contacts, and said battery wherein said current flow path is implemented by operation of said cam mechanism.

2. The apparatus of claim 1 wherein said battery tray is constructed and arranged to hold N batteries where said N batteries are all positioned with the positive and negative terminals thereof exposed for contact in like fashion, and said battery tray is removable from said clamp mechanism so that said battery tray can be loaded with N batteries and thereafter unloaded after testing and testing is conducted through said clamp mechanism.

3. The apparatus of claim 2 wherein said battery tray comprises spaced planar members with a space there between so that N batteries are held in a common orientation and are parallel thereby exposing the positive terminals in a common orientation, and also exposing the negative terminals in a common orientation, and said tray inserts into and from engagement with said clamp mechanism to form battery test circuit connections through said clamping mechanism with no wiring.

4. The apparatus of claim 3 wherein said battery tray also includes N individual current flow structural members there through for the N batteries in said battery tray to avoid wiring in the battery test circuits.

5. The apparatus of claim 4 wherein said battery tray incorporates an individual control switch for each of said N batteries and said switches are selectively operable to control connection of said N batteries into said current flow path for testing by said test apparatus and said test circuit connections are through said battery test circuits to avoid wiring.

6. The apparatus of claim 5 wherein said N switches comprise N relays, and one relay is uniquely connected to each battery of said N batteries, and said relays and batteries are controllably switched so that the batteries for testing are selectively connected in series and selectively connected in parallel by said tray and said clamp assembly to avoid wiring and circuit connections are solely through said clamp mechanism.

7. The apparatus of claim 1 wherein said positive and negative terminal contacts are aligned to move toward a battery for testing and are relatively movable away from a battery after testing.

8. The apparatus of claim 1 wherein said terminal contacts include a current terminal contact and a separate voltage terminal contact.

9. The apparatus of claim 8 wherein said separate current and voltage contacts are arranged concentrically on a common axis.

10. The apparatus of claim 7 wherein said contacts are spring biased.

11. The apparatus of claim 1 wherein said cam mechanism comprises a rotatable shaft supporting a cam thereon and said cam is positioned to move said battery tray in a direction for contacting, said contacts against the terminals of batteries in said battery tray.

12. The apparatus of claim 11 wherein said cam and cam shaft are rotatable between first and second positions wherein said first position permits said tray to be inserted and removed to an operative position with respect to said cam shaft, and wherein said second position moves said tray supporting said batteries into said contacts.

13. The apparatus of claim 12 wherein said tray mounts in a spaced relationship separated from said contacts, and said tray is retracted from the mounted position for loading or unloading batteries therein.

14. The apparatus of claim 11 wherein said cam mechanism comprises said rotatable cam and shaft below said tray;

and said tray is an elongate rectangular frame sliding to a position between said positive and negative terminal contacts so that test circuits for said batteries are connected in N current flow paths with no wiring.

15. The apparatus of claim 14 wherein replicated positive terminal contacts are spaced from replicated negative terminal contacts, there being N each positive and negative terminal contacts for testing N batteries.

16. The apparatus of claim 15 wherein said positive terminal contacts define a plane and said negative terminal contacts define a spaced and parallel plane and said two planes are spaced apart to receive said tray therebetween to form N current flow paths having structurally rigid conductors.

17. The apparatus of claim 15 wherein said tray holds N batteries and supports said batteries aligned so that said batteries are aligned for simultaneous movement into operative connection to said contacts.

18. The apparatus of claim 17 wherein said batteries each are held with parallel axes and said axes are coincident with said contacts.

19. The apparatus of claim 17 including dedicated and isolated, structurally rigid current flow members supported by said tray to complete isolated current flow paths through said tray for each of said batteries.

20. A battery testing apparatus comprising:

(a) a battery tray for holding an upstanding battery;

(b) a battery tray receptacle for holding said battery tray;

(c) first and second battery terminal contacts located in said battery receptacle so that said battery tray, after positioning within said battery tray receptacle, positions the upstanding battery in aligned relationship with the terminal contacts;

(d) a tray transport for moving said battery tray in said receptacle so that said battery tray moves the upstanding battery to the terminal contacts and thereby connects said upstanding battery in current conducting communication with a battery test circuit; and

(e) said tray transport moves the upstanding battery to end current conducting communication with the battery test circuit.

21. The apparatus of claim 20 wherein said battery tray is constructed and arranged to hold N batteries where said N batteries are all positioned with the positive and negative terminals thereof exposed for contact in like fashion, and said battery tray is removable so that said battery tray can be loaded with N batteries and can be unloaded of N batteries after testing.

22. The apparatus of claim 21 wherein said battery tray comprises spaced structurally rigid members with a space there between so that batteries are held in a common orientation and are parallel thereby exposing the positive terminals in a common orientation, and also exposing the negative terminals in a common orientation.

23. The apparatus of claim 22 wherein said battery tray also includes N individual current flow structural members there through for the N batteries in said battery tray.

24. The apparatus of claim 23 wherein said battery tray incorporates an individual control switch for each of said N batteries and said switches are selectively operable to control connection of said N batteries into said current flow path for testing by said battery test circuit comprising a current measuring apparatus.

25. The apparatus of claim 24 wherein said switches comprise N relays, and one relay is uniquely connected to each battery, and said relays and batteries are controllably switched so that the batteries are selectively connected in series and selectively connected in parallel.

26. The apparatus of claim 20 wherein said positive and negative terminal contacts are aligned to move toward a battery for testing and are relatively movable away from a battery after testing.

27. The apparatus of claim 26 wherein said terminal contacts include a current terminal contact and a separate voltage terminal contact.

28. The apparatus of claim 27 wherein said separate current and voltage contacts are arranged concentrically on a common axis.

29. The apparatus of claim 28 wherein said contacts are spring biased.

30. The apparatus of claim 20 wherein said tray transport comprises a cam mechanism having a rotatable shaft supporting a cam thereon and said cam is positioned to move said battery tray in a direction for contacting said battery terminal contacts against the terminals of batteries in said battery tray.

31. The apparatus of claim 30 wherein said cam and cam shaft are rotatable between first and second positions wherein said first position permits said battery tray to be inserted and removed to an operative position with respect to said cam shaft, and wherein said second position moves said tray supporting said batteries into said battery terminal contacts.

32. The apparatus of claim 31 wherein said tray mounts in a spaced relationship separated from said battery terminal contacts, and said tray is retracted from the operative position for loading or unloading batteries therein.

33. The apparatus of claim 30 wherein said tray transport comprises said rotatable cam and shaft below said battery tray;

and said battery tray is an elongate rectangular frame sliding to said battery tray receptacle in a position between said positive and negative terminal contacts.

34. The apparatus of claim 33 wherein replicated positive terminal contacts are spaced from replicated negative terminal contacts, there being N each positive and negative terminal contacts for testing N batteries.

35. The apparatus of claim 34 wherein said positive terminal contacts define a plane and said negative terminal contacts define a spaced and parallel plane and said two planes are spaced apart to receive said battery tray there between.

36. The apparatus of claim 35 wherein said battery tray holds N batteries and supports said batteries aligned so that said batteries are aligned for simultaneous movement into operative connection to said terminal contacts.

37. The apparatus of claim 36 wherein said N batteries each are held with parallel axes and said axes are coincident with said terminal contacts.

38. The apparatus of claim 36 including dedicated and isolated, structurally rigid current flow members supported by said battery tray to complete isolated current flow paths through said battery tray for each of said N batteries.

39. The apparatus of claim 38 including a separate load resistor for each battery.

40. A method of measuring battery performance comprising the steps of:

(a) connecting a power supply to a battery for testing said battery'"'"'s capacity to receive and hold a charge, wherein

(i) said power supply is connected with a probe comprising a first spring loaded contact and a second spring loaded contact, and

(ii) said first and said second contacts move independently;

(b) forming for the battery a test current having a;

(a) selected amplitude;

(2) selected duration; and

(3) selected polarity;

(c) directing the test current through a current measuring circuit;

(d) operating the current measuring circuit to form a time dependent measurement of current flow through the battery to determine said battery'"'"'s capacity to receive and to hold a charge;

(e) disconnecting the battery after testing and then connecting a second battery for testing and repeating steps (b), (c) and (d).

41. A battery testing apparatus comprising:

(a) a battery supporting tray for holding plural batteries to be tested;

(b) a contact assembly into which said tray is fitted and to enable electrical contact with batteries supported by said tray;

(c) a battery test circuit within said contact assembly wherein said circuit connects to a battery and current flows from said battery through said circuit for testing operating specifications of said battery;

(d) a set of battery specific contacts in said contact assembly for connecting to said battery and positioned to electrically engage and thereafter disengage a battery in said tray to enable current flow in said battery test circuit;

(e) wherein said battery specific contacts comprise first and second motion actuated contacts moving into and out of contact with said battery so that said battery test circuit is enabled.

42. The apparatus of claim 41 wherein said battery supporting tray comprises at least first and second spaced planar members separated by a specified distance so that plural batteries are held thereby, and further including battery tray supported current conductors which comprise a portion of said battery test circuit.

43. The apparatus of claim 41 wherein said contact assembly comprises spaced upper and lower contacts for contact with a battery being tested and thereby supported in said battery supporting tray, and said upper and lower contacts are connected to define said battery testing circuit and said battery testing circuit comprises rigid current conductors defining a current flow path between said upper and lower contacts.

44. The apparatus of claim 41 wherein said set of battery specific contacts comprises at least a pair of concentric contacts wherein one is deployed centrally of the other and both move independently so that they can extend for contact with a battery terminal, and one of the two contacts provides a separate voltage signal path and the other of said two contacts provides a separate flow path.

45. A battery test system comprising:

(a) first and second battery test probes having concentric, sliding and independently spring loaded contacts deployed for mating contact against a battery to test the battery for battery performance;

(b) a battery test circuit connecting through said first and second battery test probes to a battery for testing;

(c) a structurally rigid component cooperating with said first and second battery test probes to position said first and second battery test probe for releasable contact against said battery for testing; and

(d) a battery test component comprising a battery measuring device and connected by said test circuit to the battery for testing the battery and forming an indication of battery performance.

46. The battery test system of claim 45 further comprising:

(a) a test battery mount; and

(b) a structurally fixed and supported current conductor electrically communicated with one of said battery test probes and extending to the other of said battery test probes to define a completed circuit to enable charging or discharging current through the battery being tested on said battery mount.

47. The battery test system of claim 46 further comprising:

(a) a PCB with a conductor thereon;

(b) a conductive structurally rigid post connected to a conductor on said PCB;

(c) a second PCB spaced from said first PCB and having a conductor thereon and connected to said post; and

(d) wherein said first and second battery test probes are respectively mounted on said first and second PCBs.

48. A battery test system comprising:

(a) first and second battery test probes having contacts deployed for mating contact against a battery to test the battery for battery performance;

(b) a battery test circuit connecting through said first and second battery test probes to a battery for testing;

(c) a structurally rigid test component cooperating with said first and said second battery test probes to position said first and second battery test probe for releasable contact against said battery for testing; and

(d) wherein said battery test circuit is comprised solely of structurally rigid conductors connected to said first and second test probes and a measuring instrument.

49. The battery test system of claim 48 wherein said probes are relatively variable in spacing to bias said probe contacts at a spacing to enable movement into a clamping position in contact with a pair of battery terminals for testing said battery for battery performance.

50. The battery test system of claim 49 wherein said probes include at least one moveable contact.

51. The battery test system of claim 48 wherein said first and second battery test probes are:

(a) concentrically deployed around a common axis;

(b) independently axially movable;

(c) resiliently mounted;

(d) sized to conduct different current levels.

52. The battery test system of claim 51 wherein said first and second test probes are contacted against a common battery terminal and each of said probes connects to a separate structurally rigid test circuit component;

and said test circuit measures current and voltage separately through said first and second probes.

53. A battery test probe assembly comprising:

(a) a base socket mounted on a PCB;

(b) a first socket leg extending from one end of said base socket;

(c) a second socket leg at the same end of said base socket and

(i) electrically insulated from said first socket leg, and

(ii) axially positioned within said first socket leg;

(d) wherein said socket legs are constructed and arranged to

(i) electrically extend through said PCB,

(ii) each connects to a PCB conductive pad on said PCB, and

(iii) each forms a signal path from said socket legs to each said conductive pad on said PCB; and

(e) a probe assembly positioned positioned concentrically within said socket and contacting said first and said second socket legs to provide electrical connection to said socket legs to form signal paths to said conductive pads on said PCB, wherein

(i) said probe comprises two concentric members, and

(ii) each said concentric member is independently spring loaded.

54. The probe assembly of claim 53 wherein said concentric members of said probe assembly further comprise first and second separate electrical connections through said first and second socket legs to first and second conductive pads on said PCB and said first and second conductive pads define separate, electrically independent connections.

55. The probe assembly of claim 54 wherein said base socket has an elongate, upstanding, sleeve constructed to removably receive said probe assembly.

56. The probe assembly of claim 55 wherein said base socket has a circular lower end having said first leg thereon, and attached stakes to enable said stakes to extend through a matching set of holes in said PCB, and said stakes are conductive metal to enable electrical connection.

57. The apparatus of claim 53 wherein said first socket leg is an elongate current carrying metal member connected to said first conductive pad;

and

said second socket leg is centered within said first socket leg and extends below said socket and connects to a second and separate conductive pad.

58. The apparatus of claim 53 wherein said probe assembly includes:

(a) a movable conductive tip;

(b) an elongate shaft for said tip;

(c) a spring moving said tip to extended position; and

(d) wherein said tip and shaft form an electrically conductive signal pathway for a voltage measurement.

59. The apparatus of claim 53 wherein said probe assembly inserts into and electrically connects through said base socket to each said leg to there by define a test signal pathway.

60. The apparatus of claim 59 including a bias spring pushing said probe assembly to an extended signal measuring position.

61. The apparatus of claim 60 wherein said bias spring acts against a movable signal measuring tip.

62. The apparatus of claim 53 wherein:

(a) said first leg includes at least two parallel legs connected to said base socket and extending through said PCB to a common conductive pad;

(b) said second leg is formed in a hole through said PCB centered with respect to said base socket and extends through said PCB to a separate conductive pad; and

(c) said first and second legs differ in size to provide different current conductive paths.