Electronic battery testing device and method for testing batteries

• US 6,037,778 A
• Filed: 11/05/1997
• Issued: 03/14/2000
• Est. Priority Date: 11/05/1997
• Status: Expired due to Term

• Current Assignee: SPX Corporation
• Original Assignee: Stat Engineering Company, LLC
• Inventors: Makhija, Surender K
• Primary Examiner(s): Do, Diep N.
• Application Number:
  US08/964,489
• Time in Patent Office: 860 Days
• Field of Search: 324/426, 324/427, 324/429, 324/433, 340/636, 320/134, 320/136
• US Class Current: 324/433
• 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
• CPC Class Codes: G01R 31/389 Measuring internal impedance, internal conductance or related variables

Abstract

An electronic battery testing device and a method for testing batteries are provided. Device applies a small first fixed load and measures the voltage at the end of the first fixed load and then applies a medium second fixed load and measures the voltage at the end of the second fixed load. The device then analyzes the condition of the battery based on these voltage values. A method is also provided involving: (a) applying a first small fixed load to a battery, (b) measuring the voltage at the end of the first small fixed load, (c) applying a second medium fixed load to the battery, (d) measuring the voltage of the battery at the end of the second medium fixed load, and (e) analyzing the condition of the battery based on the voltage values. Preferably the method also involves evaluating the recovery voltage wave form after the second medium load. The device and method allowed for evaluation of deeply discharged batteries without the need to charge the batteries and also allows for the test equipment to be in hand held form.

Claims

1. A method for evaluating the condition of a direct current energy storage unit, said method comprising:

(a) applying a first load to said unit for a first time period,

(b) measuring a first voltage of said unit at the end of said first time period,

(c) applying a second load to said unit for a second time period, said second load being greater than said first load,

(d) measuring a second voltage of said unit at the end of said second time period,

(e) analyzing the condition of said unit based on the voltage drop between said first voltage and said second voltage, and

(f) monitoring a recovery voltage of the unit for a predetermined time period after removing the second load.

2. The method of claim 1 wherein said first load is between 0.5 and 1.4 amps and is applied for a first time period of between three seconds and seven seconds, said second load being between 6.0 and 8.0 amps and being applied for a second time period of between one second and four seconds.

3. The method of claim 1 wherein said step of monitoring the recovery voltage of the unit for a predetermined time period includes the step of measuring the recovery voltage of the unit for at least three seconds after removing the second load.

4. The method of claim 3 wherein said method comprises analyzing the recovery voltage to determine the condition of the battery.

5. The method of claim 4 wherein said recovery voltage is analyzed to determine the capacitive action of the battery.

6. The method of claim 1 wherein said analyzing comprises utilizing the first voltage to determine the state of charge of the battery.

7. The method of claim 1 wherein said analyzing comprises comparing a voltage drop from the first voltage to the second voltage to determine the condition of the battery.

8. The method of claim 1 wherein said analyzing comprises comparing a first voltage drop between an open circuit voltage and the first voltage to a second voltage drop between the first voltage to the second voltage.

9. The method of claim 8 wherein said analyzing comprises determining whether the first voltage drop is larger than the second voltage drop.

10. The method of claim 8 wherein said unit is an automotive battery having a designed full voltage of about 12 volts, said analyzing comprising determining whether the first voltage drop is greater than the second voltage drop, and determining whether the second voltage is larger than 4.0 volts.

11. A method for evaluating the condition of a battery having a state of charge, said method comprising:

applying a first load to the battery for a first time period;

measuring a first voltage of the battery at the end of said first time period;

applying a second load to the battery for a second time period, said second load being greater than said first load;

measuring a second voltage of the battery at the end of the second time period;

monitoring a recovery voltage of the battery for a predetermined time period after removing the second load, including measuring a first recovery voltage after a first recovery time period, measuring a second recovery voltage after a second recovery time period; and

determining the condition of the battery using the first voltage or the second voltage, and monitoring the recovery voltage, including determining whether the battery is defective irrespective of the battery state of charge including the steps of determining a capacitive recovery factor, defining a capacitive recovery factor threshold, and comparing the capacitive recovery factor to the capacitive recovery factor threshold.

12. The method of claim 11, wherein the capacitive recovery factor threshold is 0.25.

13. The method of claim 11, wherein the step of determining a capacitive recovery factor includes determining the ratio of the second recovery voltage minus the first recovery voltage to the second recovery voltage minus the second voltage.

14. The method of claim 11, further comprising the step of defining the second recovery time period as being at least ten times greater than the first recovery time period.

15. The method of claim 11, further comprising the step of defining the first recovery time period as less than ten milliseconds and defining the second recovery time period as more then 2 seconds.

16. The method of claim 11, further comprising the step of defining the second time period as less than the first time period.

17. The method of claim 11, wherein the second load is more than 4 times greater than the first load.

18. The method of claim 11, further comprising the steps of determining an open circuit voltage, and determining a condition of the battery based on whether the open circuit voltage minus the first voltage is greater than the first voltage minus the second voltage.

19. The method of claim 18, wherein the step of determining a second condition includes the steps of defining a threshold voltage and comparing the second voltage to the threshold voltage.

20. An electronic device for determining whether a battery is defective, the device comprising:

means for applying a first load to the battery for a first time period;

means for measuring a first voltage of the battery at the end of said first time period;

means for applying a second load to the battery for a second time period, said second load being greater than said first load;

means for measuring a second voltage of the battery for a second time period;

means for monitoring a recovery voltage of the battery for a predetermined time period after removing the second load, including means for measuring a first recovery voltage after a first recovery time period, means for measuring a second recovery voltage after a second recovery time period, wherein the second recovery time period is greater than the first recovery time period; and

means for determining the condition of the battery using the first voltage or the second voltage, and means for monitoring the recovery voltage, including means for determining whether the battery is defective irrespective of the battery state of charge including means for determining a capacitive recovery factor, means for defining a capacitive recovery factor threshold, and means for comparing the capacitive recovery factor to the capacitive recovery factor threshold.

21. The device of claim 20, wherein the capacitive recovery factor threshold is 0.25.

22. The method of claim 20, wherein the means for determining a capacitive recovery factor includes means for determining the ratio of the second recovery voltage minus the first recovery voltage to the second recovery voltage minus the second voltage.

23. The method of claim 20, further wherein the second recovery time period is at least ten times greater than the first recovery time period.

24. The method of claim 20, further wherein the first recovery time period as less than ten milliseconds and defining the second recovery time period as more then 2 seconds.

25. The method of claim 20, further wherein the second time period as less than the first time period.

26. The method of claim 20, wherein the second load is more than 4 times greater than the first load.