Apparatus and method for carrying out diagnostic tests on batteries and for rapidly charging batteries
First Claim
1. A method of charging a battery, comprising:
- outputting a charge voltage to the battery in dependence on a base voltage level;
adjusting the charging voltage in steps of predetermined magnitude to provide first, second and third voltage levels;
measuring first, second, third and fourth currents, wherein the first current is measured at the first voltage level, the fourth current is measured at the third voltage level, and the second and third currents are measured at the second voltage level at differing times;
calculating a first differential from the difference in the first and second currents and calculating a second differential from the difference in the third and fourth currents;
comparing the first differential to the second differential; and
adjusting the base voltage as a function of the comparison.
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Abstract
A method and system for performing automatic and rapid diagnostic testing and charging of a battery. The diagnostic test unit utilizes a charger combined with a rapidly variable load. After inputting battery characteristics including the cranking rating (CCA or CA) and the temperature of the battery, a diagnostic ramp procedure is utilized to provide an instantaneous current versus voltage analysis to determine the instantaneous cranking value (i.e., the single crank capability at full charge) of the battery being tested. If the instantaneous cranking value of the battery is above a level determined acceptable, a sustained discharge is carried out to tax the capacity of the battery.
At the end of the constant current discharge, the current is again to determine a loaded cranking value which simulates the battery power after multiple cranking attempts. If the loaded cranking value is below a desired percentage of the cranking rating, then the battery is put into charge. If a battery cannot be acceptably charged within the time of a given number of diagnostic probes, the battery is deemed to be a bad battery. The charging steps utilized during the diagnostic testing, as well as any charging of batteries determined to be good, utilizes a novel interactive stepping procedure which allows batteries determined to be good to be recharged in a minimum period of time without overheating the battery.
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Citations
40 Claims
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1. A method of charging a battery, comprising:
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outputting a charge voltage to the battery in dependence on a base voltage level;
adjusting the charging voltage in steps of predetermined magnitude to provide first, second and third voltage levels;
measuring first, second, third and fourth currents, wherein the first current is measured at the first voltage level, the fourth current is measured at the third voltage level, and the second and third currents are measured at the second voltage level at differing times;
calculating a first differential from the difference in the first and second currents and calculating a second differential from the difference in the third and fourth currents;
comparing the first differential to the second differential; and
adjusting the base voltage as a function of the comparison. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A readable medium having processor-executable instructions for use in charging a battery, the instructions performing the steps comprising:
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outputting a charge voltage to the battery in dependence on a base voltage level;
adjusting the charging voltage in steps of predetermined magnitude to provide first, second and third voltage levels;
measuring first, second, third and fourth currents, wherein the first current is measured at the first voltage level, the fourth current is measured at the third voltage level, and the second and third currents are measured at the second voltage level at differing times;
calculating a first differential from the difference in the first and second currents and calculating a second differential from the difference in the third and fourth currents;
comparing the first differential to the second differential; and
adjusting the base voltage as a function of the comparison.
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23. A method of charging a battery, comprising:
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outputting a charge current to the battery in dependence on a base current level;
adjusting the charging current in steps of predetermined magnitude to provide first, second and third current levels;
measuring first, second, third and fourth voltages, wherein the first voltage is measured at the first current level, the fourth voltage is measured at the third current level, and the second and third voltages are measured at the second current level at differing times;
calculating a first differential from the difference in the first and second voltages and calculating a second differential from the difference in the third and fourth voltages;
comparing the first differential to the second differential; and
adjusting the base current as a function of the comparison. - View Dependent Claims (24, 25)
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26. A battery tester and charger system, comprising:
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an adjustable power source adapted to electrically charge a battery at variable current or voltage levels;
an adjustable load adapted to electrically discharge the battery at variable current or voltage levels;
feedback sensors adapted to generate signals indicative of conditions within the system;
a controller in communication with the feedback sensors, the power source and the load, the controller adapted, as a function of the signals, to engage and disengage the power source and the load with a battery and to adjust the power source and the load to effectively test and charge the battery. - View Dependent Claims (27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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38. In a battery diagnostic and charging system connectable to a battery, a method for operating the system, comprising:
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performing a diagnostic test on the battery;
if the battery passes the diagnostic test, charging the battery; and
during the steps of performing the diagnostic test and charging the battery, sensing if a disconnection of the battery from the system occurs and, in response to a sensed disconnect, automatically discontinuing the steps of performing the diagnostic test and charging the battery. - View Dependent Claims (39)
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40. In a battery diagnostic and charging system connectable to a battery, a method for operating the system, comprising:
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sensing if a reverse connection exists between the battery and the system;
if the reverse connection is not sensed, performing a diagnostic test on the battery; and
if the battery passes the diagnostic test, charging the battery.
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Specification