Arrangement for testing battery while under load and charging

• US 6,992,487 B1
• Filed: 05/29/2003
• Issued: 01/31/2006
• Est. Priority Date: 05/29/2003
• Status: Expired due to Fees

• Current Assignee: La Marche Manufacturing Co.
• Original Assignee: La Marche Manufacturing Co.
• Inventors: Steinke, Thomas O.
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US10/447,596
• Time in Patent Office: 978 Days
• Field of Search: 324/426, 324/427, 324/430, 324/433, 324/429
• US Class Current: 324/426
• CPC Class Codes: G01R 31/3646 for indicating electrical conditions or variables, e.g. visual or audible indicators
• CPC Class Codes: G01R 31/386 using test-loads
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A live circuit battery tester allows for determining the condition of batteries under load without disconnecting the batteries and a battery charger from the load or in any way disrupting system operation during the test. Battery testing is prevented when the batteries are being used in an emergency or if they are recharging from a recent discharge. The battery tester is under microcomputer control and incorporates automatic-self diagnostics and provides a visual indication if the batteries are good or if a specific problem is detected such as if the batteries are missing, have open cells, are sulfated or are in imminent danger of failure. The battery tester determines if the charger is operating properly and tests for an open cell, bad battery connection, sulfated battery, and a weak battery and provides a visual indication of any of these problems as well as an indication of a properly operating battery.

Claims

1. An arrangement for testing a battery connected to a battery charger and a work load, said arrangement comprising:

first conductor means for connecting the battery to the battery charger and work load under normal operating conditions allowing the battery to drive the work load and the battery charger to charge the battery;

second conductor means coupled in parallel across said first conductor means, wherein said second conductor means is nonconductive under normal operating conditions;

user selectable means responsive to an input for initiating testing of the battery; and

control/detection means coupled to said first and second conductor means and to said selectable means for conducting a battery test, wherein said control/detection means renders said first conductor means nonconductive and said second conductor means conductive during a battery test for isolating the battery from the battery charger while permitting the battery to continue to energize the work load during testing, and wherein said control/detection means applies a test load across the battery for measuring battery voltage during testing.

2. The arrangement of claim 1 wherein said first conductor means comprises first relay contacts and said second conductor means comprises a unidirectional conductor.

3. The arrangement of claim 2 wherein said unidirectional conductor is a diode.

4. The arrangement of claim 3 wherein said test load comprises serially connected second relay contacts and a resistor coupled across first and second terminals of the battery.

5. The arrangement of claim 4 wherein said control/detection means closes said first relay contacts and opens said second relay contacts under normal operating conditions, and opens said first relay contacts and closes said second relay contacts for battery testing.

6. The arrangement of claim 1 further comprising means for detecting and providing an indication of failure of the battery charger.

7. The arrangement of claim 1 further comprising means for detecting and providing an indication of failure of the arrangement for testing a battery.

8. The arrangement of claim 1 further comprising means for manually testing the battery as desired or for automatically testing the battery at predetermined time intervals.

9. The arrangement of claim 1 further comprising means for charging the battery in a auto-equalized mode following detection of a weak battery.

10. The arrangement of claim 1 further comprising means for delaying for a selected time period testing of the battery following loss of power to the battery and battery charger.

11. A method for testing the condition of a battery connected to a battery charger and a work load comprising the steps of:

measuring a first output voltage V_o of the battery;

comparing the first output voltage V_o with a float voltage V_F and providing a first indication that the battery is being charged if V₀>

V_F;

applying a test load to the battery and measuring a second output voltage under load V₁ and providing a second indication of an open cell in the battery if V₁<

0.75 Volts per cell; and

comparing the second output voltage under load V₁ to a reference voltage V_R, where V_R<

V_F, and providing a third indication of a good battery if V₁>

V_R or a fourth indication of a weak battery if V₁<

V_R.

12. The method of claim 11 further comprising the step of initiating an auto-equalized test mode in the case where the test indicates a weak battery, where V₁<

V_R.

13. The method of claim 11 wherein the step of measuring the first output voltage V_o of the battery includes isolating the battery charger from the battery while continuing to allow the battery to energize the work load.