UPS with test discharge load to determine battery capacity

• US 8,324,865 B1
• Filed: 01/06/2011
• Issued: 12/04/2012
• Est. Priority Date: 06/07/2006
• Status: Active Grant

• Current Assignee: Schneider Electric IT Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Cohen, Daniel C., Owens, William L.
• Primary Examiner(s): Muralidar, Richard V
• Application Number:
  US12/986,129
• Time in Patent Office: 698 Days
• Field of Search: 320/132, 320/136, 320/152, 320/162, 320/157, 307/66, 307 43- 46, 307/48, 307/64
• US Class Current: 320/132
• CPC Class Codes: G01R 31/386 using test-loads
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• CPC Class Codes: H02J 9/061 for DC powered loads

Abstract

An uninterruptible power supply system includes an input configured to couple to a power source, an output configured to couple to a system load, a battery, power circuitry coupled to the input, the output, and the battery, and configured to transfer power from the input to the output and to transfer power from the battery to the output, a test load, a test switch coupled to the battery and the test load and configured to selectively couple the battery to the test load, a voltage monitor coupled to the battery and configured to provide an indication of a voltage provided by the battery, and a processor coupled to the test switch and the voltage monitor and configured to effect a first partial-discharge test on the battery by actuating the test switch to couple the battery to the test load to partially discharge the battery, and by using information from the voltage monitor regarding the voltage provided by the battery at different times during the test before a complete discharge of the battery to determine a capacity of the battery.

Claims

1. An uninterruptible power supply system comprising:

an input configured to couple to a power source;

an output configured to couple to a system load;

a battery;

power circuitry coupled to the input, the output, and the battery, and configured to transfer power from the input to the output and to transfer power from the battery to the output;

a test load;

a test switch coupled to the battery and the test load and configured to selectively couple the battery to the test load;

a voltage monitor coupled to the battery and configured to provide an indication of a voltage provided by the battery; and

a processor coupled to the test switch and the voltage monitor and configured to effect a first partial-discharge test on the battery by actuating the test switch to couple the battery to the test load to partially discharge the battery, and by using information from the voltage monitor regarding the voltage provided by the battery at different times during the test before a complete discharge of the battery to determine a capacity of the battery;

the processor is further configured to;

use first and second indications from the voltage monitor of the voltage provided by the battery at first and second, different, times before the battery is substantially discharged to determine the capacity of the battery,

determine that the battery is good if the determined battery capacity exceeds a threshold capacity, and

effect a second partial-discharge test on the battery in response to the processor determining that the battery is bad in the first partial-discharge test, the processor being configured to use third and fourth indications from the voltage monitor of the voltage provided by the battery at third and fourth, different, times to determine the capacity of the battery, the fourth time being substantially later in time than the second time and before full discharge of the battery.

2. The system of claim 1, wherein the second time is after the first time and is at a time from a start of the test that is about 20% of a theoretical maximum runtime given the test load for the battery voltage to reach an actual cutoff voltage.

3. The system of claim 1, wherein the first time is at a time from a start of the test that is about 5% of a theoretical maximum runtime given the test load for the battery voltage to reach an actual cutoff voltage.

4. The system of claim 1, wherein the fourth time is at a time from a start of the test that is about 50% of the theoretical maximum runtime given the test load for the battery voltage to reach an actual cutoff voltage.

5. The system of claim 1 wherein the test load is effectively a fixed resistance passive load.

6. The system of claim 1 further comprising a UPS housing containing the input, the output, the battery, the power circuitry, the test load, the test switch, the voltage monitor, and the processor such that the test load is internal to the UPS housing.

7. The system of claim 1 wherein the processor is configured to compensate for a temperature of the battery to determine the capacity of the battery.

8. The system of claim 1, wherein the processor configured to determine the capacity is configured to:

determine a predicted runtime of the battery, and

determine whether the predicted runtime exceeds a pre-determined fraction threshold of a theoretical maximum runtime of the battery.

9. An uninterruptible power supply system comprising:

an input configured to couple to a power source;

an output configured to couple to a system load;

a battery;

power circuitry coupled to the input, the output, and the battery, and configured to transfer power from the input to the output and to transfer power from the battery to the output;

a test load;

a test switch coupled to the battery and the test load and configured to selectively couple the battery to the test load;

a voltage monitor coupled to the battery and configured to provide an indication of a voltage provided by the battery; and

a processor coupled to the test switch and the voltage monitor and configured to effect a first partial-discharge test on the battery by actuating the test switch to couple the battery to the test load to partially discharge the battery, and by using information from the voltage monitor regarding the voltage provided by the battery at different times during the test before a complete discharge of the battery to determine a capacity of the battery;

wherein the processor is configured to use first and second indications from the voltage monitor of the voltage provided by the battery at first and second times, and to use a linear estimation of a rate of voltage decrease between the first and second times to extrapolate future voltage decrease of the battery during the first test to determine a runtime of the battery to reach a virtual cutoff voltage associated with an actual cutoff voltage associated with the battery.

10. The system of claim 9, wherein the second time is after the first time and is at a time from a start of the test that is about 20% of a theoretical maximum runtime given the test load for the battery voltage to reach an actual cutoff voltage.

11. The system of claim 9, further comprising a UPS housing containing the input, the output, the battery, the power circuitry, the test load, the test switch, the voltage monitor, and the processor such that the test load is internal to the UPS housing.

12. The system of claim 9, wherein the processor is configured to compensate for a temperature of the battery to determine the capacity of the battery.

13. The system of claim 9, wherein the processor configured to determine the capacity is configured to:

determine a predicted runtime of the battery, and

determine whether the predicted runtime exceeds a pre-determined fraction threshold of a theoretical maximum runtime of the battery.

14. A method of determining a capacity of an uninterruptible power supply system battery, the method comprising:

discharging the battery into a load for substantially less time than to fully discharge the battery using the load;

determining first and second voltages provided by the battery at first and second times while discharging the battery into the load;

determining whether a predicted runtime of the battery, determined based on the first and second voltages, exceeds a pre-determined fraction threshold of a theoretical maximum runtime of the battery; and

determining whether the battery is bad based on the determined predicted runtime and an acceptable runtime for the battery, and if the battery is determined to be bad, then;

recharging the battery,

discharging the battery into the load,

determining third and fourth voltages provided by the battery at third and fourth times while discharging the battery into the load, the fourth time being later than the second time relative to a start of the discharging and before full discharge of the battery, and

using the third and fourth voltages to make a second determination of the runtime of the battery until the voltage provided by the battery will reach the actual cutoff value associated with the battery and the load.

15. The method of claim 14 wherein the second time is later than the first time and is about 20% of a maximum time to discharge the battery using the load such that the battery will provide the actual cutoff voltage.

16. The method of claim 14 wherein the second time is later than the first time and is about 50% of the theoretical maximum runtime to discharge the battery using the load such that the battery will provide the actual cutoff voltage.

17. The method of claim 14, wherein determining whether the battery is bad comprises determining that the battery is bad if the determined runtime is less than the acceptable runtime and the acceptable runtime about 50% of the theoretical maximum runtime of the battery when powering the load until the voltage provided by the battery will reach the actual cutoff value associated with the battery and the load.

18. The method of claim 14 further comprising determining that the battery is bad if the voltage provided by the battery drops below a test threshold voltage during the discharging.

19. The method of claim 14 further comprising compensating for a temperature of the battery to make the first determination.

20. A method of determining a capacity of an uninterruptible power supply system battery, the method comprising:

discharging the battery into a load for substantially less time than to fully discharge the battery using the load;

determining first and second voltages provided by the battery at first and second times while discharging the battery into the load;

using the first and second voltages to make a first determination of a runtime of the battery until the voltage provided by the battery will reach an actual cutoff value associated with the battery and the load; and

determining whether the battery is bad based on the determined runtime and an acceptable runtime for the battery, and if the battery is determined to be bad, then;

recharging the battery,

discharging the battery into the load,

determining third and fourth voltages provided by the battery at third and fourth times while discharging the battery into the load, the fourth time being later than the second time relative to a start of the discharging and before full discharge of the battery, and

using the third and fourth voltages to make a second determination of the runtime of the battery until the voltage provided by the battery will reach the actual cutoff value associated with the battery and the load.