Automatic battery analyzer including apparatus for determining presence of single bad cell

• US 4,322,685 A
• Filed: 02/29/1980
• Issued: 03/30/1982
• Est. Priority Date: 02/29/1980
• Status: Expired due to Term

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Globe-Union Inc.
• Inventors: Dougherty, Thomas J., Johnson, Richard T., Frailing, Charles E.
• Primary Examiner(s): Tokar, Michael J.
• Application Number:
  US06/126,165
• Time in Patent Office: 760 Days
• Field of Search: 324/426, 324/429, 324/433, 320/48
• US Class Current: 324/429
• CPC Class Codes: G01R 19/16542 for batteries charge condition monitoring in G01R31/36
• CPC Class Codes: G01R 31/364 Battery terminal connectors with integrated measuring arrangements
• CPC Class Codes: G01R 31/367 Software therefor, e.g. for battery testing using modelling or look-up tables
• CPC Class Codes: G01R 31/374 with means for correcting the measurement for temperature or ageing
• CPC Class Codes: G01R 31/379 for lead-acid batteries
• CPC Class Codes: G01R 31/385 Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: G01R 31/386 using test-loads
• CPC Class Codes: G01R 31/396 Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery

Abstract

There are described apparatus for detecting the presence of a defective cell in a lead-acid storage battery. The apparatus is included as a part of a larger apparatus for analyzing the condition of the battery and its suitability for further use in automobile lighting, starting, and ignition applications. The apparatus measures the terminal potential of the battery when it is subject to a constant resistance load. If that potential is found to increase more than a predetermined amount during a time interval following the application of the load, the battery is known to have at least one defective cell.

Claims

1. Apparatus for determining the acceptability of a storage battery under test and comprising:

first circuit means for coupling to the battery under test and performing a load test on said battery;

second circuit means for coupling to the battery under test and performing a voltage bounce back test on said battery;

third circuit means for coupling to the battery under test, placing a load on said battery, and testing whether the rate of change of the battery voltage exceeds a predetermined value; and

fourth circuit means coupled to said first, second, and third circuit means for controlling the sequence in which the tests of said first, second, and third circuit means are performed and providing a readout responsive to outputs of said first, second, and third circuit means.

2. The apparatus of claim 1 wherein said fourth circuit means further provides that said load test is the first of said tests to be performed on the battery under test, said voltage bounce back test is the second of said tests to be performed on the battery under test, and said battery voltage rate of change test is the third of said tests to be performed on the battery under test.

3. The apparatus of claim 2 wherein said fourth circuit means further provides a readout that the battery under test is acceptable if said load test is passed.

4. The apparatus of claim 3 wherein said fourth circuit means further prevents the occurrence of said voltage bounce back test and said battery voltage rate of change test if said load test is passed.

5. The apparatus of claim 3 wherein said fourth circuit means provides a readout that the battery under test is unacceptable if said voltage bounce back test is passed.

6. The apparatus of claim 5 wherein said fourth circuit means further prevents the occurrence of said battery voltage rate of change test if said voltage bounce back test is passed.

7. The apparatus of claim 6 wherein said fourth circuit means further provides a readout that the battery under test should be recharged and retested if said battery voltage rate of change does not exceed said predetermined value.

8. The apparatus of claim 7 wherein said fourth circuit means further provides a readout that the battery under test is unacceptable if said battery voltage rate of change exceeds said predetermined value.

9. The apparatus of claim 8 wherein said third circuit means further determines whether the battery voltage is less than a predetermined value at the end of a time period following the placing of said load on said battery.

10. The apparatus of claim 9 wherein said fourth circuit means further provides a readout that the battery under test is acceptable but should be recharged if the battery voltage exceeds said predetermined value at the end of said time period.

11. The apparatus of claim 1 wherein said third circuit means further determines whether the battery terminal voltage exceeds a second predetermined value at the end of a time period following the placing of said load on said battery.

12. The apparatus of claim 11 wherein said fourth circuit means further provides that the test performed by said first circuit means is the first of said tests to be performed on the battery under test, the test performed by said second circuit means is the second of said tests to be performed on the battery under test, and the tests performed by said third circuit means are the last of said tests to be performed on the battery under test.

13. The apparatus of claim 12 wherein said fourth circuit means further provides a readout that the battery under test should be recharged and retested if said battery terminal voltage exceeds said second predetermined value at the end of said time period.

14. The apparatus of claim 13 wherein said fourth circuit means further provides a readout that the battery under test is unacceptable if said battery terminal voltage is less than said second predetermined value at the end of said time period.

15. The apparatus of claim 1 wherein said third circuit means further determines whether the battery terminal voltage at the end of a first time period following the placing of said load on said battery and the battery terminal voltage at the end of a second time period following the removal of said load from said battery fulfill a predetermined relationship.

16. The apparatus of claim 15 wherein said fourth circuit means further provides that the test performed by said first circuit means is the first of said tests to be performed on the battery under test, the test performed by said second circuit means is the second of said tests to be performed on the battery under test, and the tests performed by said third circuit means are the last of said tests to be performed on the battery under test.

17. The apparatus of claim 16 wherein said fourth circuit means further provides readouts that either the battery under test is unacceptable or should be recharged and retested dependent upon whether said predetermined relationship is fulfilled.

18. The apparatus of claim 1 further including fifth circuit means for indicating that the battery under test is thought to be fully charged and said fourth circuit means further provides that only the tests of said first and second circuit means are performed when the battery under test is thought to be fully charged.

19. The apparatus of claim 18 wherein said fourth circuit means further provides that said load test is the first of said tests to be performed on the battery under test and said voltage bounce back test is the last of said tests to be performed on the battery under test when the battery under test is thought to be fully charged and provides a readout that the battery under test is acceptable if said load test is passed, that the battery under test is unacceptable if said load test is failed, and said voltage bounce back test is passed, and that the battery under test should again be recharged and retested if said load test is failed and said voltage bounce back test is failed.

20. The method of determining the acceptability of an electrical storage battery comprising:

the first step of performing an electrical load test on said battery;

the second step of performing a voltage bounce back test on said battery;

the third step of performing a test responsive to the rate of change of the battery voltage while the battery is under a load; and

the fourth step of determining from the results of said first, second, and third steps the acceptability of said battery.

21. The method of determining the acceptability of an electrical storage battery comprising:

the first step of placing a load on said battery, determining whether the battery terminal voltage is above a first predetermined level after a first predetermined period of time, and removing said load from said battery;

the second step of determining whether the battery terminal voltage is above a second predetermined level after a second predetermined period of time following the removal of said load from said battery;

the third step of determining whether the rate of change of the battery voltage while the battery is under load is above a third predetermined value; and

the fourth step of determining from the results of said first, second, and third steps whether said battery is acceptable.

22. The method of claim 21 wherein said first, second, and third steps are performed in the order recited.

23. The method of claim 22 wherein said fourth step further comprises the steps of:

generating an indication that the battery under test is acceptable when the battery terminal voltage is above said first predetermined level after said first period of time;

generating an indication that the battery under test is unacceptable when the battery terminal voltage is below said first predetermined level after said first period of time and above said second predetermined level after said second period of time; and

generating an indication that the battery under test is either unacceptable or should be recharged and retested in response to the results of said third step when the battery terminal voltage is below said first predetermined level after said first period of time and below said second predetermined level after said second period of time.

24. The method of claim 23 wherein said last recited step further generates an indication that the battery under test is unacceptable if the change of the battery voltage while the battery is under load is above said third predetermined value and generates an indication that the battery under test should be recharged and retested if the rate of change of the battery voltage while the battery is under load is below said third predetermined value.

25. The method of claim 23 further comprising the step of determining whether the open circuit terminal voltage of said battery is below a fourth predetermined value prior to said first step and generating an indication that the battery under test is unacceptable if said open circuit terminal voltage is below said fourth predetermined value.

26. Apparatus for determining the acceptability of a storage battery under test and comprising:

first circuit means for coupling to the battery under test and performing a load test on said battery;

second circuit means for coupling to the battery under test and performing a voltage bounce back test on said battery;

third circuit means for coupling to the battery under test, placing a load on said battery, and testing whether the battery voltage increase is greater than a predetermined amount during a time period; and

fourth circuit means coupled to said first, second, and third circuit means for controlling the sequence in which the tests of said first, second, and third circuit means are performed and providing a readout responsive to outputs of said first, second, and third circuit means.

27. The apparatus of claim 26 wherein said fourth circuit means further provides that the test performed by said first circuit means is the first of said tests to be performed on the battery under test, the test performed by said second circuit means is the second of said tests to be performed on the battery under test, and the test performed by said third circuit means is the third of said tests to be performed on the battery under test.

28. The apparatus of claim 27 wherein said fourth circuit means further provides a readout that the battery under test is acceptable if said load test is passed.

29. The apparatus of claim 28 wherein said fourth circuit means further prevents the occurrence of said voltage bounce back test and the test performed by said third circuit means if said load test is passed.

30. The apparatus of claim 29 wherein said fourth circuit means provides a readout that the battery under test is unacceptable if said voltage bounce back test is passed.

31. The apparatus of claim 30 wherein said fourth circuit means further prevents the occurrence of the test performed by said third circuit means if said voltage bounce back test is passed.

32. The apparatus of claim 31 wherein said fourth circuit means further provides a readout that the battery under test should be recharged and retested if said battery voltage increases less than said predetermined amount during said time period.

33. The apparatus of claim 32 wherein said fourth circuit means further provides a readout that the battery under test is unacceptable if said battery voltage increases more than said predetermined amount during said time period.

34. The apparatus of claim 33 wherein said third circuit means further determines whether the battery voltage is less than a predetermined value at the end of a time period following the placing of said load on said battery.

35. The apparatus of claim 34 wherein said fourth circuit means further provides a readout that the battery under test is acceptable but should be recharged if the battery voltage exceeds said predetermined value at the end of said time period following the placing of said load on said battery.

36. The apparatus of claim 35 wherein said third circuit means further determines whether the battery terminal voltage exceeds a predetermined value at the end of a time period following the placing of said load on said battery.

37. The apparatus of claim 36 wherein said fourth circuit means further provides that the test performed by said first circuit means is the first of said tests to be performed on the battery under test, the test performed by said second circuit means is the second of said tests to be performed on the battery under test, and the tests performed by said third circuit means are the last of said tests to be performed on the battery under test.

38. The apparatus of claim 37 wherein said fourth circuit means further provides a readout that the battery under test should be recharged and retested if said battery terminal voltage exceeds said predetermined value at the end of said time period.

39. The apparatus of claim 38 wherein said fourth circuit means further provides a readout that the battery under test is unacceptable if said battery terminal voltage is less than said predetermined value at the end of said time period.

40. The apparatus of claim 26 wherein said third circuit means further determines whether the battery terminal voltage at the end of a first time period following the placing of said load on said battery and the battery terminal voltage at the end of a second time period following the removal of said load from said battery fulfill a predetermined relationship.

41. The apparatus of claim 40 wherein said fourth circuit means further provides that the test performed by said first circuit means is the first of said tests to be performed on the battery under test, the test performed by said second circuit means is the second of said tests to be performed on the battery under test, and the tests performed by said third circuit means are the last of said tests to be performed on the battery under test.

42. The apparatus of claim 41 wherein said fourth circuit means further provides readouts that either the battery under test is unacceptable or should be recharged and retested dependent upon whether said predetermined relationship is fulfilled.

43. The apparatus of claim 26 further including fifth circuit means for indicating that the battery under test is thought to be fully charged and said fourth circuit means further provides that only the tests of said first and second circuit means are performed when the battery under test is thought to be fully charged.

44. The apparatus of claim 43 wherein said fourth circuit means further provides that said load test is the first of said tests to be performed on the battery under test and said voltage bounce back test is the last of said tests to be performed on the battery under test when the battery under test is thought to be fully charged and provides a readout that the battery under test is acceptable if said load test is passed, that the battery under test is unacceptable if said load is failed test and said voltage bounce back test is passed, and that the battery under test should again be recharged and retested if said load test is failed and said voltage bounce back test is failed.

45. The method of determining the acceptability of an electrical storage battery comprising:

the first step of performing an electrical load test on said battery;

the second step of performing a voltage bounce back test on said battery;

the third step of performing a test responsive to whether the battery voltage increases greater than a predetermined amount during a time period while the battery is under a load; and

the fourth step of determining from the results of said first, second, and third steps the acceptability of said battery.

46. The method of determining the acceptability of an electrical storage battery comprising:

the first step of placing a load on said battery, determining whether the battery terminal voltage is above a first predetermined level after a first predetermined period of time, and removing said load from said battery;

the second step of determining whether the battery terminal voltage is above a second predetermined level after a second predetermined period of time following the removal of said load from said battery;

the third step of determining whether the rate of change of the battery voltage increases greater than a predetermined amount during a time period while the battery is under load; and

the fourth step of determining from the results of said first, second, and third steps whether said battery is acceptable.

47. The method of claim 46 wherein said first, second, and third steps are performed in the order recited.

48. The method of claim 47 wherein said fourth step further comprises the steps of:

generating an indication that the battery under test is acceptable when the battery terminal voltage is above said first predetermined level after said first period of time;

generating an indication that the battery under test is unacceptable when the battery terminal voltage is below said first predetermined level after said first period of time and above said second predetermined level after said second period of time; and

generating an indication that the battery under test is either unacceptable or should be recharged and retested in response to the results of said third step when the battery terminal voltage is below said first predetermined level after said first period of time and below said second predetermined level after said second period of time.

49. The method of claim 48 wherein said last recited step further generates an indication that the battery under test is unacceptable if the increase in the battery voltage while the battery is under load is above said predetermined amount and generates an indication that the battery under test should be recharged and retested if the increase in the battery voltage while the battery is under load is below said predetermined amount.

50. The method of claim 48 further comprising the step of determining whether the open circuit terminal voltage of said battery is below a third predetermined value prior to said first step and generating an indication that the battery under test is unacceptable if said open circuit terminal voltage is below said third predetermined value.