US010446885B2

(12) United States Patent (10 ) Patent No.: US 10 ,446 ,885 B2

Clarke et al. (45) Date of Patent: Oct. 15, 2019
(54 ) BATTERY CHARGER WITH BATTERY USPC .. .... 320/107, 132, 149, 150; 324/427, 430,
STATE DETECTION 324 /433
See application file for complete search history.
(71) Applicant: Schumacher Electric Corporation , Mt.
Prospect, IL (US )
(56 ) References Cited
(72 ) Inventors : Patrick J. Clarke, St. Charles, IL (US ); U .S . PATENT DOCUMENTS
John S . Whiting, Hampshire , IL (US)
( * ) Notice : Subject to any disclaimer, the term of this 5,159,272 A * 10/1992 Rao .... . ......... GO 1R 324
31/3648
/ 429
patent is extended or adjusted under 35 5,729, 115 A 3/1998 Wakefield
U .S .C . 154 (b ) by 207 days. (Continued )
(21) Appl. No.: 15/594,822 FOREIGN PATENT DOCUMENTS
(22 ) Filed : May 15, 2017 2685269
2953202
1/ 2014
12 / 2015
(65 ) Prior Publication Data 08 - 130838 5 / 1996
US 2017/0331162 A1 Nov. 16 , 2017 OTHER PUBLICATIONS
Related U .S. Application Data Baccus Global LLC , Automatic Battery Charger Instruction Manual,
(60 ) Provisional application No. 62 / 370 ,317 , filed on Aug . Copyright Notice 2013, dated Jan . 2013, pp. 1-22.
3 , 2016 , provisional application No . 62 /336 , 118 , filed ( Continued )
on May 13 , 2016 .
(51) Int . Cl. Primary Examiner — Edward Tso
HOIM 10 /46 ( 2006 . 01) (74 ) Attorney, Agent, or Firm — Michael Stanley Tomsa ;
HOIM 10 /48 ( 2006 . 01) McAndrews, Held & Malloy , Ltd .
(Continued )
(52 ) U .S . CI. (57) ABSTRACT
CPC .......... HOLM 10 /48 (2013 .01 ); GOIR 31 /371 A battery charger and method is disclosed for detecting
(2019.01 ); GOIR 31/3835 (2019.01 ); GOIR when a battery has a low state of health while simultane
31/ 392 ( 2019 .01 ); HOIM 10 /4285 ( 2013 .01);
HOIM 10 /446 (2013 .01); H02J 770003 ously charging or maintaining the battery . A battery charger
(2013 .01); HO2J 770021 (2013.01); HO2J includes a processor; a non - transitory memory device; a
770036 (2013 .01) ; HO2J 7 /0047 ( 2013 .01) ; power management device to receive an input power and to
HO2J 770057 (2013 .01 ); HO2J 770075 output a charging current; a pair of electrical conductors to
electrically couple with a battery , and a display electrically
( 2013 .01 ); coupled to the processor. The display being configured to
(Continued ) indicate a bad battery indicator when the battery has a low
(58 ) Field of Classification Search state of health and whether the battery is good to start .
CPC .......... HO2J 7 /00 ; HO2J 7 /0021 ; HO2J 7 /0026 ;
HO2J 7 /0047 ; HO2J 2007/ 005 ; GOIR
31/ 364 ; GOIR 19 /0069; GO1R 1 /203 21 Claims, 15 Drawing Sheets

150

Schumachee
104 150a 150b !
I - - I - - I Charger
Time Remaining RD :HHSS
ARAN
H7/ WA Charge *
) Status :
Amps
100 "
Temp.
'

Performance
148 ! Les .. .
.

Status Start Slop Cond .

EN
WIN Communication
100 Network
106
110

104
 US 10 ,Page
446,2885 B2

(51) Int. Ci. 6 ,625, 477 B1

7 ,808 ,211 B2
9 / 2003 Wakefield
10 / 2010 Pacholok et al.
HOIM 10 /42 ( 2006 .01 ) 7 ,834 ,593 B2 11/2010 Johnson et al.
HOIM 10 / 44 ( 2006 . 01) 8 , 111, 037 B2 2/ 2012 Zhang et al.
GOIR 31/392 ( 2019 .01) 8 ,258, 751 B2 9 /2012 Esnard
GOIR 31/ 371 ( 2019 .01) 8 ,319 ,475 B2 11 /2012 Choksi et al.
GOIR 31 /3835 ( 2019.01 ) 8 , 575 , 899 B2 11/2013 Whiting et al.
HO2J 7700 ( 2006 .01) 8 , 947 ,054 B2 2 /2015 Johnson et al .
HO2J 7 /04 ( 2006 .01 ) 9 ,244 ,132 B2 1/ 2016 Bond et al.
GOIR 31/ 364 ( 2019 .01) 9 , 267, 997 B2 2 / 2016 Pisu et al.
9 ,368 , 269 B2 6 /2016 Chen et al.
GOIR 1/ 20 ( 2006 .01) 9 ,397 ,513 B2 7 / 2016 Butler et al.
GOIR 13/02 ( 2006 .01) 9 ,579 ,990 B2 2 / 2017 Butler et al.
GOIR 19 /00 ( 2006 .01 ) 2005/ 0088144 A1 4 / 2005 Pacholok et al.
HOIM 2 /20 ( 2006 .01 ) 2010 / 0090651 A1 4 / 2010 Sahu et al .
HOIM 2 /30 (2006 .01) 2011/0012561 A1 * 1 /2011 Whiting ................ HO1M 10 /44
320 / 149
HOIR 13 /02 ( 2006 .01 ) 2011/0148424 A1 6 / 2011 Chiang et al.
HOIR 13/66 ( 2006 .01 ) 2011 /0172939 AL 7 /2011 Uprety et al.
GOIR 31/00 ( 2006 .01) 2012/0249083 Al 10 /2012 Garrastacho et al.
GOIR 31 /378 (2019 .01) 2014 /0021906 A1* 1 /2014 Whiting .... HO1M 10 / 44
GOIR 31/3842 ( 2019 .01) 320 / 107
GOIR 31/379 ( 2019 .01)
(52) U . S . CI. OTHER PUBLICATIONS
CPC ......... H02J 770077 (2013.01); HO2J 770083 Publisher Hearst Communication ; Popular Mechanics Issue Mar.
( 2013 .01 ); HO2J 7 /0091 (2013 .01); H02J 2014 , Distributed Throughout the United States .
7 /045 ( 2013 .01); GOIR 1 / 203 ( 2013 .01); GOIR
13/02 ( 2013.01); GOIR 19 / 0069 ( 2013.01) ; Vector Products, Inc .; Smart Battery Charger Instruction Manual;
GOIR 31/006 ( 2013 .01 ) ; GOIR 31 /364 Published Feb . 2005, pp . 1 -8.
(2019. 01 ); GOIR 31/ 378 (2019 . 01 ); GOIR Vector Products , Inc, product packaging pp . 1- 7, published and
distributed throughout the United States beginning in May 2005.
31 / 379 ( 2019 .01 ); GOIR 31 / 3842 ( 2019 .01) ; International Search Report and Written Opinion , dated Aug. 4 ,
HOIM 2 / 202 (2013 .01) ; HOIM 2 / 305 2017 , in International application No . PCT/US2017 /032645 , filed
( 2013 .01) ; HOIR 13/025 ( 2013 . 01 ); HOIR May 15, 2017 .
13/ 6616 ( 2013 .01) ; HOIR 13 /6625 ( 2013 .01) ; Gould , C . R ., et al., New Battery Model and State -of-Health
HOIR 13/6683 ( 2013.01); HOIR 13/6691 Determination Through Subspace Parameter Estimation and State
( 2013 .01); HO2J 2007 /005 (2013 .01) Observer Techniques; IEEE Transactions on Vehicular Technology ,
vol. 58 , No. 8 , Oct. 2009.
(56 ) References Cited Juang , Larry W .; Online Battery Monitoring for State -of- Charge and
Power Capability Prediction ; A thesis submitted in partial fulfill
U .S . PATENT DOCUMENTS ment of requirements for the degree ofMaster of Science ( Electrical
Engineering ) at the University of Wisconsin - Madison 2010 .
6 , 175,211 B1 1/ 2001 Brotto
6 ,469,512 B2 10 /2002 Singh et al. * cited by examiner
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 US 10 ,446 ,885 B2
BATTERY CHARGER WITH BATTERY displaying , to the user, a battery 's SoH and SoC and for
STATE DETECTION determining /displaying whether a battery has a SoC and /or
SoH sufficient to start an engine .
CROSS -REFERENCE TO RELATED According to a first aspect, a method for identifying a bad
APPLICATION 5 battery condition via a battery charger having a display
device during a charging process of a lead acid battery
The present application claims the benefit under 35 comprises: measuring , using a voltage sensor, a first battery
U .S . C . § 119 ( e ) of Provisional Patent Application Ser. No. voltage of a lead acid battery connected to the battery
62/336 , 118 , filed May 13 , 2016 , and 62/ 370 ,317 , filed Aug . charger across a pair of electrical conductors; comparing,
3 . 2016 . the contents of each of which are hereby incorpo - 10 using a processor operatively coupled with a memory
rated by reference. device , the first battery voltage to a first predetermined
voltage value stored to thememory device; measuring, if the
TECHNICAL FIELD first battery voltage is less than the first predetermined
voltage value , a second battery voltage of the lead acid
The subject disclosure relates to a system and method for 15 battery using the voltage sensor after a first period of time;
detecting a battery ' s state . More specifically, the subject comparing, using the processor, the second battery voltage
disclosure relates to a battery charger system , method , and to a second predetermined voltage value stored to the
apparatus for quickly determining and alerting a user as to memory device ; and displaying a bad battery indicator via
a battery 's state of health and / or charge using, for example , the display device if the second battery voltage is greater
a bad battery indicator. 20 than or equal to the second predetermined voltage value.
According to a second aspect, a battery charger for
BACKGROUND identifying a bad battery comprises : a processor operatively
coupled with a voltage sensor; a non -transitory memory
It is often desirable to know the state -of-charge (SOC ) and device operatively coupled with the processor, a power
state-of-health (SoH ) of a battery . Rechargeable batteries 25 management device to receive an input power and to output
( e. g ., a storage battery , a secondary battery , etc .) are used in a charging current during a charging process ; a display
many applications, including starting an internal combustion device electrically coupled to the processor, wherein the
engine of, for example , an automobile , vehicle , or other display device is configured to display a bad battery indi
machinery . cator; and a pair of electrical conductors to electrically
The SOC indicates the charge state of a battery (or an 30 couple with a lead acid battery , wherein , to determine and
individual battery cell , or a battery pack ). The units of SoC display whether the lead acid battery has a low state of
are percentage points, where 0 % is empty and 100 % is full. health , the battery charger is configured to : measure, using
An alternate form of representing the same measurement is the voltage sensor, a first battery voltage of the lead acid
the depth of discharge (DoD ), which is the inverse of SoC battery connected across the pair of electrical conductors ;
(i.e., 0 % is full and 100 % is empty ). SoC is normally used 35 compare , using the processor, the first battery voltage to a
when discussing the current state of a battery in use , while first predetermined voltage value stored to the non - transitory
DoD is most often seen when discussing the lifetime of the memory device; measure , if the first battery voltage is less
battery after repeated use . than the first predetermined voltage value , a second battery
The SoH indicates the health of the battery (or an indi voltage of the lead acid battery using the voltage sensor after
vidual battery cell, or a battery pack ). Over time, a battery 40 a first period of time; compare the second battery voltage to
will age and degrade , causing a decrease in the battery 's a second predetermined voltage value stored to the non
ability to hold a charge and deliver its rated current to a load . transitory memory device ; and instruct the display device to
Eventually , the battery will need to be replaced — i.e ., once display the bad battery indicator if the second battery
it has degraded to the point that it can no longer effectively voltage is greater than or equal to the second predetermined
hold a charge . The SoH represents the condition of a battery 45 voltage value.
compared to its ideal conditions and /or design specifica - In certain aspects, the processor is further configured to
tions . Like the SoC , the units of SoH may be provided as a abort the charging process if the second battery voltage is
percentage . For example, a score of 100 % indicates that the greater than or equal to the second predetermined voltage
battery 's conditions substantially match the battery ' s origi- value .
nal manufacturing specifications 50 In certain aspects, the processor is further configured to
As can be appreciated , when charging a battery , in addi- commence a desulfation process if the second battery volt
tion to SoC , it is beneficial to determine whether the battery age is greater than or equal to the second predetermined
has a low SoH , which may indicate that the battery needs to voltage value .
be refurbished or replaced (i.e., a “ Bad Battery" ). Thus, a In certain aspects, the processor is further configured to
need exists for a system , method , and apparatus for deter- 55 measure a third battery voltage of the lead acid battery
mining and displaying , to the user, a battery ' s SoH and SoC connected across the pair of electrical conductors after a
while the battery is being charged ( e.g., during a charging second period of time if the second battery voltage is greater
cycle ). A need also exists for determining and displaying than or equal to the second predetermined voltage value .
whether a battery has a SoC and/or SoH sufficient to start an In certain aspects, the processor is further configured to
engine. 60 compare the third battery voltage to the second predeter
mined voltage value.
SUMMARY OF THE INVENTION In certain aspects , the processor is further configured to
instruct the display device to not display the bad battery
Briefly , the subject disclosure relates to a battery charging indicator if the third battery voltage is less than or equal to
system , method , and apparatus for determining and alerting 65 the second predetermined voltage value .
a user as to a battery ' s SoC and / or SoH . More specifically, In certain aspects, the processor is further configured to
to a system , method , and apparatus for determining and instruct the display device to display the bad battery indi
 US 10 ,446 ,885 B2
cator if the third battery voltage is less than the second current during a charging process; a display device electri
predetermined voltage value and lack of progress is cally coupled to the processor, wherein the display device is
detected . configured to display a bad battery indicator; and a pair of
In certain aspects , the processor is further configured to electrical conductors to electrically couple with a lithium
instruct the display device to display the bad battery indi- 5 battery , wherein , to determine and display whether the
cator if the third battery voltage is less than the second lithium battery has a low state of health , the battery charger
predetermined voltage value and a thermal runaway condi is configured to : measure , using the voltage sensor , a first
tion is detected .
In certain aspects , the method further comprises the step battery voltage of a lithium battery connected to the battery
of aborting the charging process if the second battery voltage 10 using theacross
charger the pair of electrical conductors; compare ,
processor, the first battery voltage to a first
is greater than or equal to the second predetermined voltage predetermined voltage value stored to the memory device ;
value.
In certain aspects , the method further comprises the step supply , using the power management device , a first current
from the battery charger to the lithium battery for a first
of commencing a desulfation process if the second battery
voltage is greater than or equal to the second predetermined 15 period of time if the first battery voltage is less than the first
voltage value. predetermined voltage value ; measure , using the voltage
In certain aspects , the method further comprises the step sensor, a second battery voltage of the lithium battery during
of measuring a third battery voltage of the lead acid battery the first period of time; compare , using the processor, the
connected across the pair of electrical conductors after a second battery voltage to a second predetermined voltage
second period of time if the second battery voltage is greater 20 value stored to the memory device; and supply, using the
than or equal to the second predetermined voltage value. power management device , a second current from the bat
In certain aspects, the method further comprises the step tery charger to the lithium battery if the second battery
of comparing the third battery voltage to the second prede voltage is (1 ) greater than the first predetermined voltage
termined voltage value. value and (2 ) less than the second predetermined voltage
In certain aspects , the method further comprises the step 25 value .
of not displaying the bad battery indicator if the third battery In certain aspects , the battery charger is further configured
voltage is less than or equal to the second predetermined to : measure, using a voltage sensor, a third battery voltage
voltage value. of the lithium battery after a second period of time; compare ,
In certain aspects , the method further comprises the step using the processor, the third battery voltage to the second
of displaying the bad battery indicator if the third battery 30 predetermined voltage value; abort the charging process if
voltage is less than the second predetermined voltage value the third battery voltage is less than the second predeter
and lack of progress is detected mined voltage value after the second period of time; and
In certain aspects , the method further comprises the step
of displaying the bad battery indicator if the third battery supply a third current to the lithium battery if the third
value 3535 battery voltage is (1) greater than the second predetermined
voltage is less than the second predetermined voltage value
and a thermal runaway condition is detected . voltage value and (2 ) less than a third predetermined voltage
In certain aspects, the first predetermined voltage value
may be between 12 .0 and 12 . 4 volts , or about 12 .2 volts . The In certain aspects, the battery charger is further configured
second predetermined voltage value may be between 14. 0 to enter a maintenance mode if the third battery voltage is
and 16 . 0 volts, or about 14 .2 volts . 40 greater than or equal to the third predetermined voltage
In certain aspects, the first period of time may be between value .
1 minute and 10 minutes , or about 5 minutes . The second In certain aspects , the maintenance mode includes peri
period of timemay be between 1 minute and 10 minutes , or o dically supplying a fourth current to the lithium battery .
about 5 minutes. In certain aspects, the battery charger is further configured
According to a third aspect, a method for identifying a bad 45 to supply the third current to the lithium battery if a
battery during a charging process of a lithium battery measured battery voltage drops below a fourth predeter
comprises : measuring , using a voltage sensor, a first battery
voltage of a lithium battery connected to the battery charger In certain aspects , the battery charger is further configured
across a pair of electrical conductors ; comparing, using a to display a bad battery indicator via a display device on the
processor operatively coupled with a memory device ,, the
he 3050 batt
first battery voltage to a first predetermined voltageicevalue battery charger if the processor aborts the charging process.
In certain aspects, the battery charger is further configured
stored to the memory device ; supplying a first current from to display a bad battery indicator via a display device on the
the battery charger to the lithium battery for a first period of battery charger if the third battery voltage is less than the
time if the first battery voltage is less than the first prede
second predetermined voltage value after the second period
termined voltage value;measuring a second battery voltage 55 of
of the lithium battery during the first period of time; com time.
paring, using the processor, the second battery voltage to a of:Inmeasuring
certain aspects, the method further comprises the steps
, using a voltage sensor, a third battery voltage
second predetermined voltage value stored to the memory
device ; and supplying a second current from the battery of the lithium battery after a second period of time; com
charger to the lithium battery if the second battery voltage is 60 paring, using the processor, the third battery voltage to the
( 1 ) greater than the first predetermined voltage value and ( 2 ) second predetermined voltage value; aborting the charging
less than the second predetermined voltage value . process if the third battery voltage is less than the second
According to a fourth aspect, a battery charger for iden - predetermined voltage value after the second period of time;
tifying a bad battery comprises : a processor operatively and supplying a third current to the lithium battery if the
coupled with a voltage sensor; a non -transitory memory 65 third battery voltage is ( 1 ) greater than the second prede
device operatively coupled with the processor ; a power termined voltage value and ( 2 ) less than a third predeter
management device to receive an input power and to output mined voltage value .
 US 10 ,446 ,885 B2
In certain aspects , the method further comprises the step change for the first period of time; and display a bad battery
of entering a maintenance mode if the third battery voltage indicator via the display device if the first rate of change is
is greater than or equal to the third predetermined voltage greater than or equal to a first predetermined rate of change
value . value stored to the non -transitory memory device .
In certain aspects, the maintenance mode includes peri- 5 In certain aspects, the first predetermined rate of change
odically supplying a fourth current to the lithium battery. value may be a function of the state of charge for the lead
In certain aspects , the method further comprises the step acid battery .
of supplying the third current to the lithium battery if the of:Inmeasuring
certain aspects , the method further comprises the step
a third battery voltage of the lead acid battery
measured battery voltage drops below a fourth predeter
mined voltage value. 10 after a second period of time.
In certain aspects , the method further comprises the step In certain aspects , the method further comprises the step
of displaying a bad battery indicator via a display device on of: displaying the bad battery indicator via the display
device if the second rate of change is greater than or equal
the battery charger if the processor aborts the charging to a second predetermined rate of change value .
process . In certain aspects, the battery charger is further configured
In certain aspects , the method further comprises the step 15 to measure a third battery voltage of the lead acid battery
of displaying a bad battery indicator via a display device on after a second period of time.
the battery charger if the third battery voltage is less than the In certain aspects , the battery charger is further configured
second predetermined voltage value after the second period to display the bad battery indicator via the display device if
of time. the second rate of change is greater than or equal to a second
In certain aspects , the first predetermined voltage value 20 predetermined rate of change value . The second predeter
may be between 5 . 0 and 12 .4 volts , or about 8 .0 volts. The mined rate of change value may be a function of the state of
second predetermined voltage value may be between 8 . 0 and charge for the lead acid battery . The second predetermined
12 .0 volts , or about 10 .0 volts. The third predetermined rate of change value may be not equal to the first predeter
voltage value may be between 14 .0 and 15 .0 volts , or about mined rate of change value . For example , the second pre
14 .2 volts . The third predetermined voltage value may be a 25 determined rate of change value may be less than the first
fully charged voltage for the lithium battery . The fourth predetermined rate of change value .
predetermined voltage value may be between 12 .5 and 13. 5 In certain aspects , the first and second period of timemay
volts , or about 13 . 1 volts . be between 30 seconds and 5 minutes , or about 1 minute .
In certain aspects , the first current may be between 0 .01 DESCRIPTION OF THE DRAWINGS
and 0 . 5 amps, or about 0 . 1 amps . The second currentmay be 30
between 0 .25 and 1. 0 amps, or about 0 . 5 amps. The third These and other advantages of the subject disclosure will
currentmay be between 1 .0 and 3 .0 amps, or about 2 .0 amps . be readily understood with reference to the following speci
The fourth current may be between 0 . 1 and 0 .3 amps, or fications and attached drawings wherein :
about 0 . 2 amps. FIG . 1a illustrates a block diagram for an exemplary
In certain aspects , the second period of time may be 35 battery charger.
between 1 and 3 hours , or about 2 hours . The first period of FIG . 1b illustrates a front perspective view of an exem
time may be less than the second period of time. plary battery charger.
According to a fifth aspect, a method for identifying a bad FIG . 1c illustrates a rear perspective view of the exem
battery condition via a battery charger having a display plary battery charger.
device during a charging process of a lead acid battery 40 FIG . 1d illustrates a diagram for an exemplary network
comprises : determining a state of charge for a lead acid for a battery charger.
battery connected to the battery charger across a pair of FIG . 2 illustrates a flow diagram of an exemplary battery
electrical conductors; measuring , using a voltage sensor, a charging cycle .
first battery voltage of the lead acid battery ; measuring, FIG . 3 illustrates a flow diagram of an exemplary nominal
using the voltage sensor , a second battery voltage of the lead 45 voltage detection cycle .
acid battery after a first period of time; calculating , using a FIG . 4 illustrates a flow diagram of an exemplary battery
processor, a first rate of change for the first period of time; type detection cycle .
and displaying a bad battery indicator via the display device FIG . 5 illustrates a flow diagram of an exemplary desul
if the first rate of change is greater than or equal to a first fation cycle .
predetermined rate of change value . 50 FIG . 6 illustrates a flow diagram of an exemplary load
According to a sixth aspect, a battery charger for identi - detection cycle.
fying a bad battery comprises: a processor operatively FIG . 7 illustrates a flow diagram of an exemplary battery
coupled with a voltage sensor; a non -transitory memory engine -start detection cycle .
device operatively coupled with the processor ; a power F IG . 8 illustrates a circuit diagram of an exemplary
management device to receive an input power and to output 55 connection between a battery and a battery charger.
current during a charging process ; a display device electri- FIG . 9 illustrates a circuit diagram of a resistor -capacitor
cally coupled to the processor, wherein the display device is circuit model for a lead -acid battery .
configured to display a bad battery indicator; and a pair of FIGS. 10a and 10b illustrate example charge curves of
electrical conductors to electrically couple with a lithium dv /dt vis -à - vis a battery voltage curve for AGM and flood
battery , wherein , to determine and display whether the 60 lead acid batteries .
lithium battery has a low state of health , the battery charger FIG . 11 illustrates a flow diagram of an exemplary lithium
is configured to : determine a state of charge for a lead acid charging cycle .
battery connected across the pair of electrical conductors;
measure, using the voltage sensor, a first battery voltage of DETAILED DESCRIPTION
the lead acid battery ; measure , using the voltage sensor, a 65
second battery voltage of the lead acid battery after a first Preferred embodiments of the present invention will be
period of time; calculate, using the processor, a first rate of described hereinbelow with reference to the accompanying
 US 10 ,446 ,885 B2
drawings . The components in the drawings are not neces - fiber, circuit, and/ or link to be conveyed to a destination . The
sarily drawn to scale , the emphasis instead being placed term “ communication " as used herein means data so con
upon clearly illustrating the principles of the present veyed or delivered . The term “ communications” as used
embodiments. For instance , the size of an element may be herein includes one or more of a communications medium ,
exaggerated for clarity and convenience of description . 5 system , channel, network , device , wire , cable , fiber, circuit,
Moreover, wherever possible , the same reference numbers and /or link .
are used throughout the drawings to refer to the same or like The terms " coupled ," " coupled to ," and " coupled with ” as
elements of an embodiment. In the following description , used herein , each mean a relationship between or among two
well-known functions or constructions are not described in or more devices , apparatuses , files, circuits, elements , func
detail because they may obscure the invention in unneces - 10 tions, operations, processes, programs, media , components,
sary detail. No language in the specification should be networks, systems, subsystems, and/ or means , constituting
construed as indicating any unclaimed element as essential any one or more of: (1) a connection , whether direct or
to the practice of the embodiments . through one or more other devices, apparatuses, files, cir
Recitation of ranges of values herein are not intended to cuits , elements , functions, operations, processes, programs,
be limiting, referring instead individually to any and all 15 media , components , networks, systems, subsystems, or
values falling within the range , unless otherwise indicated means ; (ii) a communications relationship , whether direct or
herein , and each separate value within such a range is through one or more other devices , apparatuses , files, cir
incorporated into the specification as if it were individually cuits , elements, functions , operations , processes , programs,
recited herein . The words “ about,” “ approximately,” or the media , components , networks , systems, subsystems, or
like, when accompanying a numerical value , are to be 20 means; and/or (iii) a functional relationship in which the
construed as indicating a deviation as would be appreciated operation of any one or more devices , apparatuses , files ,
by one of ordinary skill in the art to operate satisfactorily for circuits , elements, functions, operations, processes, pro
an intended purpose . Ranges of values and/or numeric grams, media , components, networks, systems, subsystems,
values are provided herein as examples only, and do not or means depends, in whole or in part, on the operation of
constitute a limitation on the scope of the described embodi- 25 any one or more others thereof.
ments . The use of any and all examples , or exemplary The term “ data ” as used herein means any indicia , signals ,
language (“ e . g .," " such as," or the like ) provided herein , is marks, symbols, domains, symbol sets, representations , and
intended merely to better illuminate the embodiments and any other physical form or forms representing information ,
does notpose a limitation on the scope of the embodiments . whether permanent or temporary , whether visible , audible ,
No language in the specification should be construed as 30 acoustic , electric , magnetic , electromagnetic , or otherwise
indicating any unclaimed element as essential to the practice manifested . The term " data " is used to represent predeter
of the embodiments . mined information in one physical form , encompassing any
In the following description , it is understood that terms and all representations of corresponding information in a
such as “ first," " second,” “ top ," "bottom ," " side," " front,” different physical form or forms.
" back ," and the like, are words of convenience and are not 35 The term “ database ” as used herein means an organized
to be construed as limiting terms. The various data values body of related data , regardless of the manner in which the
( e. g ., voltages , seconds , etc .) provided herein may be sub - data or the organized body thereof is represented . For
stituted with one or more other predetermined data values example , the organized body of related data may be in the
and , therefore , should not be viewed limiting , but rather, form of one or more of a table, map , grid , packet, datagram ,
exemplary . For this disclosure , the following terms and 40 frame, file , email, message , document, report, list, or in any
definitions shall apply : other form .
The term “ and /or" means any one or more of the items in The term " exemplary ” means “ serving as an example ,
the list joined by " and/or” . As an example, " x and/or y ” instance, or illustration .” The embodiments described herein
means any element ofthe three -element set { (x ), (y ), (x , y ) } . are not limiting , but rather are exemplary only . It should be
In other words, " x and/ or y ” means “ one or both of x and y ” . 45 understood that the described embodiments are not neces
As another example , " x , y , and /or z " means any element of sarily to be construed as preferred or advantageous over
the seven -element set {(x ), (y), (2 ), (x , y ), (x , z ), (y, z ), (x , other embodiments . Moreover, the terms “ embodiments of
y , z )} . In other words, “ x , y, and /or z” means “ one or more the invention ," " embodiments,” or “ invention ” do not
of x , y, and z .” require that all embodiments of the invention include the
The terms " circuits ” and “ circuitry ” refer to physical 50 discussed feature , advantage, or mode of operation .
electronic components (e .g., hardware ) and any software The term “ network ” as used herein includes both net
and /or firmware (“ code” ) which may configure the hard works and inter-networks of all kinds, including the Internet,
ware , be executed by the hardware , and or otherwise be and is not limited to any particular network or inter -network .
associated with the hardware. As used herein , for example, The term “ processor” as used herein means processing
a particular processor and memory may comprise a first 55 devices , apparatuses, programs, circuits , components, sys
“ circuit ” when executing a first set of one or more lines of tems, and subsystems, whether implemented in hardware ,
code and may comprise a second “ circuit " when executing tangibly embodied software, or both , and whether or not it
a second set of one or more lines of code . As utilized herein , is programmable . The term “ processor ” as used herein
circuitry is “ operable ” to perform a function whenever the includes, but is not limited to , one or more computing
circuitry comprises the necessary hardware and code ( if any 60 devices , hardwired circuits , signal -modifying devices and
is necessary ) to perform the function , regardless of whether systems, devices and machines for controlling systems,
performance of the function is disabled , or not enabled ( e . g ., central processing units , programmable devices and sys
by a user -configurable setting , factory trim , etc .). tems, field -programmable gate arrays , application - specific
The terms “ communicate” and “ communicating” as used integrated circuits , systems on a chip , systems comprising
herein , include both conveying data from a source to a 65 discrete elements and / or circuits , state machines , virtual
destination and delivering data to a communications machines, data processors, processing facilities, and com
medium , system , channel, network , device, wire , cable , binations of any of the foregoing .
 US 10 ,446 ,885 B2
10
A number of approaches may be employed to determine battery depending on the present state of the charging
a battery 's SoH . For example , a first approach calculates the process, thereby resulting in a battery charger that can more
SoH by measuring an internal resistance of a battery . Spe- efficiently and quickly identify a battery having a low SoH
cifically, a high internal resistance is an indication that the and to more quickly alert the user of a " bad battery "
SoH is low . U . S . Patent Publication No . 2011 /0172939 Al 5 condition through a bad battery indicator without requiring
to Sandip Uprety discloses an example system and method that the battery be connected to the charger for an extended
for determining an internal resistance , SoC , SoH , and /or periods of time. To that end , the subject disclosure relates to
energy level of a rechargeable battery . The widespread a battery charger system , method , and apparatus for deter
application of different types of batteries, however, yields mining and alerting a user as to a battery ' s SoC and/ or SoH .
problems when trying to determine the SoH of a battery 10 In certain aspects , the battery charger system , method , and
based solely on internal resistance . Examples of the different apparatus may be further configured to determine whether a
battery types (i.e., chemistries ) include, for example , battery 's SoC and /or SoH is sufficiently high such that it can
lithium , lithium ion , lithium nickel , lead -acid , nickel - cad - start a vehicle to alert the user of a “ Battery Engine - Start ":
mium , nickel-metal hydride , etc . condition . Even further , the disclosed battery charger sys
Simply measuring the internal resistance of the battery to 15 tem , method , and apparatus may be configured to alert a
determine the SoH , however, results in inconsistencies remote user as to a battery ' s SoC and/ or SoHover a network .
across the different battery chemistries. A system that can Much of the disclosure will be described in connection
detect the type of battery , however, and then measure the with a six - cell nominal 12 - volt battery, but the various
internal resistance would alleviate these inconsistencies. techniques disclosed herein may be applied to virtually any
Further, the SoH can vary with temperature because the 20 battery by scaling (up or down) the thresholds ( e . g ., voltage
internal resistance fluctuates as a function of temperature . thresholds ) as a function of the number of cells/ nominal
Therefore , a temperature sensor may be used to monitor voltage of the battery. To that end , while various exemplary
temperature of the battery to further mitigate inconsisten predetermined voltage values ( e . g ., voltage thresholds) are
cies. Another factor that can affect the internal resistance of described in connection with a six -cell nominal 12 - volt
the battery is the battery charging process itself. 25 battery , it should be understood that the exemplary prede
The battery charger may be configured to perform one or termined voltage values are not intended to be applicable
more tests to detect and monitor additional dynamic indi- only to six -cell nominal 12 - volt batteries. Indeed , the pre
cations of the battery . For example , the battery charger may determined voltage values and ranges can be scaled up or
perform a full /partial discharge test where the battery is down for a particular battery as a substantially linear func
either fully or partially discharged by subjecting the battery 30 tion of the number of battery cells / nominal voltage for that
to a known constant load. During the discharge time, the particular battery . For example , if a 10 volt threshold is
battery voltage is monitored and the duration of time nec described in connection with a six -cell nominal 12 - volt
essary for the battery to drop to a predetermined ( e . g ., battery , one of skill in the art would appreciate that the 10
established , set , or otherwise determined in advance ) voltage volt threshold may be scaled for a three -cell 6 -volt battery by
is compared with know times of a healthy battery (which 35 dividing the 10 volt threshold by two because the ratio of the
may be standard values or based on test data from an initial six -cell nominal 12 - volt battery to the three - cell 6 -volt
test of the battery, e . g ., upon installation ). This comparison battery is 2 : 1 . Therefore , unless otherwise indicated herein ,
allows for the calculation of the SoH of the battery . Draw - each predetermined voltage value and range disclose herein
backs associated with this approach , however , include its should be understood as also disclosing a value or range on
relative expense , time requirements (i.e ., it is time consum - 40 a " per cell” basis and each " per cell” voltage value or range
ing to discharge the battery ), and requires that the battery be (expressed herein as volts per cell (VCELL)) is hereby
offline during testing. incorporated into the specification as if it were individually
Historic battery data may be used to determine the SoH of recited herein .
a battery ( e.g ., via a standalone battery monitoring system ). With reference to the figures , a battery charger 100 , as
During the aging of a battery , the system dynamically i.e ., 45 disclosed herein , may facilitate both charging and maintain
continuously in real- time or near real-time) measures and ing functions for a battery 104 , such as a battery of a vehicle .
monitors the value of one or more electrochemical param - The battery charger 100 may further provide a float mode to
eter(s) of the battery over time to generate a dataset of maintain the battery 104 in a fully charged state . The battery
historic battery data . The SoH of the battery is then deter - charger 100 may also be configured to start ( a /k / a “ boost” ,
mined based on the way the parameter (s ) changes over time. 50 " jump" , or " jump start” ) an engine ( e . g ., an internal com
However, because historic battery data must accumulate bustion engine) coupled to a battery 104 .
before the degradation of these parameter(s ) can be deter- The battery 104 may be a starting battery , a storage
mined , such systems cannot determine the SoH of the battery , a marine battery ( e . g ., a deep cycle battery , which is
battery without first acquiring a historic dataset for the designed to be regularly deeply discharged using most of its
battery . Though it is contemplated that a dataset of historic 55 capacity ), a storage battery , or another rechargeable battery .
battery data for a comparable battery ( e . g ., for a battery of Example automobile batteries include, without limitation ,
the same model, chemistry , etc .) may be loaded into the lead -acid batteries ( e . g ., wet/ flooded batteries , calcium - cal
battery charger ( e .g ., via an input/output interface ). The cium batteries, valve - regulated , lead - acid (VRLA ) batteries ,
capacity of the battery can also be monitored to determine gel cell, and absorbed glass mat (AGM )) , and other
the SoH of a battery . An example method includes charging 60 rechargeable batteries , such as lithium batteries . The battery
a battery to its maximum charge potential, and then waiting charger 100 may be configured to determine , automatically ,
a predetermined timeframe to measure the open - circuit the battery type /chemistry - AGM , gel, lithium ion , etc .
voltage (Voc ). The SoH may be determined by comparing Depending on the application , the battery 104 may be one
the Voc to an ideal Voc. An example of such a method is of a plurality of nominal voltages ( e .g ., 6V / 12V / 24V /36V /
described in U .S . Pat. No . 9, 244 , 132, filed Aug. 17 , 2012 . 65 48V / etc.) and may employ various battery cell counts and
It would be advantageous to provide a battery charger that arrangements . Typically , each battery cell in the battery 104
employs multiple processes to determine the SoH of the provides a nominal 2 -volts. Therefore , a 6 - volt battery
 US 10 ,446 ,885 B2
12
would employ three battery cells , a 12 -volt battery would detect automatically the battery type and /or the nominal
employ six battery cells , a 24 - volt battery would employ 12 voltage of the battery 104 . The battery charger 100 may
battery cells, etc . Accordingly, a desired nominal voltage further include start/stop technology. In other aspects, the
may be achieved by adapting the number of battery cells in processor may be configured to calculate the temperature of
a battery pack , array , etc . For example , a battery commonly 5 the battery 104 based at least in part on measured or
used in the automotive industry is a six -cell nominal 12 - volt calculated impedance , which can indicate heat dissipation
battery . In addition to nominal voltage , the battery 104 may through resistive loss.
employ one of a plurality of different battery types (i.e ., Power Management Device 132 .
chemistries), such example , lithium , lithium ion , lithium A power management device 132 can be used to manage
nickel, lead - acid , nickel -cadmium , nickel-metal hydride, 10 power needed to operate the battery charger 100 and
etc . Battery types commonly used in the automotive industry components thereof ) and to charge (or boost ) the battery
include lead acid and lithium . 104 . That is , alternating current (AC ) power may be drawn
In operation , the battery charger 100 may indicate to the from an AC power supply 102 via an AC input device 134 ,
user the number of ampere -hours put into battery 104 , and /or converted to direct current (DC ) power using an AC - to -DC
an indication of the SoC and /or SoH of the battery 104 . The 15 converter , and used to charge battery 104 using one ormore
battery charger 100 may further be configured to receive transformers pursuant to one or more selectable charging
inputs from the user to identify specifics of the battery 104 . modes. For instance , the battery charger 100 may be remov
For example , if a user inputs a battery size and/or model ably coupled with an AC power supply 102 located outside
number, the battery charger 100 will know the battery the housing ( e .g ., 110 - 120 VAC line current from a wall
manufacturer specifications (e. g., the original/target values , 20 outlet ) via the AC input device 134 ( e.g., a plug). In addition
including fully charged voltage ) and , therefore , may deter - to , or in lieu of, the AC input device 134 , the battery charger
mine and provide the SoH or determine other characteristics 100 may be coupled (e .g., removably ) with a solar power
of the battery 104 based at least in part on a dynamically supply 170 (or other external DC power supply ) via a DC
measured parameter of the battery 104. input device 168 . The one or more transformers may include
FIGS. la through 1c illustrate an example battery charger 25 a linear transformer, a switched mode transformer, or a
100 having a processor 128 ( e .g ., a central processing unit combination thereof. For example , the battery charger 100
(CPU ) ). The processor 128 is operatively coupled to one or may employ a hybrid of linear and switched mode trans
more memory devices , such as a read -only memory (ROM ) formers . An exemplary hybrid battery charger is disclosed
118 for receiving one or more instruction sets , a random by commonly owned U . S . Pat. No . 9 , 368 ,269 by Xiao Ping
access memory (RAM ) 120 having a plurality of buffers for 30 Chen et al., issued Jun . 14 , 2016 , and titled “Hybrid Battery
temporarily storing and retrieving information , and /or an Charger.”
internal data storage device 122 . The internal data storage The battery charger 100 can be removably coupled with
device 122 may be, for example , a hard drive ( e . g ., a solid the battery 104 ( e . g ., at its battery posts /terminals ) via a pair
state drive or other non -volatile data storage device ) or of electrical conductors 172a , 172b electrically coupled with
another non - volatile data storage device (e. g., flash memory, 35 the battery charger 100 via the DC output 136 . Each of the
including removable memory cards ). A clock 130 to provide electrical conductors 172a , 172b may be, for example , a
clock /timing signals or pulses may be coupled to the pro battery cable having a terminal connector (e .g., a battery
cessor 128 . clamp 152 , a ring connector, etc .) at its distal end . The
The processor 128 is also operatively coupled with a proximal end ofthe electrical conductors 172 , 172b may be
power management device 132 , an input/output interface 40 removably coupled with the battery charger 100 at the DC
126 , and a plurality of sensors 112 to provide measurement output 136 via , for example , one or more detachable elec
data descriptive of the surrounding environment, the battery trical ports/ connectors 154 ( e . g ., EC5 connectors, barrel
charger 100 , and/or the battery 104 . Those skilled in the art connectors, pin connectors , etc .). In another example , the
will understand that the battery charger 100 includes one or proximal end of the electrical conductors 172a , 172b may be
more bus structures for interconnecting its various compo - 45 fixedly coupled with the battery charger 100 . The housing
nents . Further , to increase ease of use in mobile applications 156 of the battery charger 100 may further include one or
(i.e ., to increase portability ), the various components of a more cable wrapping posts 164 and/ or a cable reel, around
battery charger 100 may be housed in a single housing . The which various cords may be wrapped .
plurality of sensors 112 may be internal to the battery In addition to conveying a charging current and/ or boost
charger 100 or positioned outside the battery charger 100 . 50 ing current to the battery 104 , the battery charger 100 can
The plurality of sensors 112 may include one or more of a also measure , inter alia , the battery voltage of the battery 104
voltmeter to measure voltage (i.e ., a voltage sensor), an and / or the current through the battery 104 via the electrical
ammeter to measure current, and /or a temperature sensor to conductors 172a , 172b . The electrical conductors 172a ,
measure a temperature, such as the temperature of the 172b may employ, for example , battery clamps 152 capable
environment, the battery 104 , the battery charger 100 , and /or 55 ofKelvin sensing ( four terminal sensing ). Kelvin sensing is
an auxiliary power source 108 . In certain aspects, the an electrical impedance measuring technique that uses two
processor 128 may receive sensor data from a remote sensor separate pairs of current- carrying and voltage - sensing elec
112 over a wired link 142 or a wireless device 144. trodes per conductor 172a , 172b to provide more accurate
As will be discussed , the processor 128 is configured to measurements than two -terminal (2T) sensing. To that end ,
perform calculations and comparisons to determine whether 60 each of the electrical conductors 172a , 172b may employ
the battery 104 is deemed to have a low SoH based at least multiple electrically isolated electrodes (i.e ., cables , conduc
in part on oneor more measured battery parameters from the tors, wires, etc .), whether sharing an insulated outer casing
plurality of sensors 112 . For example , the battery charger or otherwise bundled . By way of illustration , each of the
100 may be configured to send one or more small AC test electrical conductors 172a , 172b may employ two electrodes
signals to the battery 104 and to record the response , thereby 65 and provide two battery contacts ( e. g., via battery clamps
calculating the impedance of the battery 104 . In another 152 capable of Kelvin sensing ) as illustrated in FIG . 8 .
example , the battery charger 100 may be configured to Specifically , FIG . 8 illustrates a circuit diagram 800 of an
 US 10 ,446 ,885 B2
13 14
exemplary connection between a battery charger 100 and a The battery charger 100 may employ one or more charg
battery 104 where electrodes 806 and 812 are configured to ing techniques, including conventional, fast charging , and
apply and sense current using an ammeter 802 and elec - the like. The power management device 132 and processor
trodes 810 and 808 are configured to sense voltage using a 128 may provide one or more features , such as reverse
voltmeter 804 . As illustrated , electrodes 806 and 808 are 5 hook -up protection , automatic battery voltage detection , and
provided via a first conductor 172a , while electrodes 810 battery type detection . Commonly owned U . S . Pat. No.
and 812 are provided via a second conductor 172b . 7 ,808 ,211 discloses an example of a switched -mode battery
In certain aspects, Kelvin sensing may be simulated using charger for automotive and marine battery applications .
three electrodes. For example , with separate load and sense Further, commonly owned U .S . Pat. No . 8 , 947 ,054 discloses
electrodes at one battery terminal and a single ( common ) ^ a battery charger and method utilizing alternating DC charg
electrode on the other terminal. Voltage drop in the common ing current, while commonly owned U .S . Pat. No . 8 ,575 , 899
electrode is compensated for by assuming that it is the same discloses a battery charger with automatic voltage detection .
as in the load electrode, of the same gauge and length . While The battery charger 100 may be further configured to
the subject disclosure primarily discusses embodiments 15 determine, automatically, different battery chemistry ( e. g .,
where the battery charger 100 measures parameters of the AGM , gel, lithium ion , etc.) and the battery 's 104 nominal
battery 104 via the electrical conductors 172a , 172b , the voltage . The charging characteristics of a battery charger
battery charger 100 may receive dynamically monitored may be configured to match the battery chemistry of the
battery parameters via the wired link 142 or the wireless battery 104 to be charged. For example, lead -acid batteries
device 144. 20 may be charged with constant power , constant current,
The DC power from the power management device 132 constant voltage , or combination thereof. Such batteries may
may be further used to charge an internal auxiliary power be charged using both linear and /or switched -mode (high
source 108 (e .g ., a supercapacitor, a rechargeable lithium ion frequency) transformers . In addition to charging and /or
battery , or lead -acid battery ) via the AC input device 134 . In maintaining the battery 104 , the power management device
operation , when external power ( e . g ., the AC power supply 25 132 and processor 128 may provide jump - starting function
102 ) is unavailable ( e .g ., disconnected or out of service ), the ality . For example , the battery charger 100 may use one or
battery charger 100 may draw the power needed to operate more of the auxiliary power source 108 , the linear trans
the battery charger 100 's components from the battery 104 former, and /or switched mode transformer to provide the
and/ or auxiliary power source 108, thereby enabling the user jump -starting functionality to jump- start the vehicle . Exem
to determine the status of the battery charger 100 (including 30 plary battery -boosting functionality that may be incorpo
SoH , SOC , or other parameters of the battery 104 ) even when rated is disclosed by commonly owned U .S . Pat. No. 9 , 397 ,
AC power supply 102 is unavailable (e . g ., when a circuit 513 by Brian F . Butler et al., issued Feb . 18 , 2016 , and titled
breaker is blown ). To that end , the battery charger 100 may “ Compact Multifunctional Battery Booster.”
report the AC power supply 102 failure (e .g ., as an alert) to While the power management device 132 and processor
the one or more interface devices ( e .g ., a portable electronic 35 128 are illustrated as separate components , one of skill in the
device 110 ) via the communication network 106 . art would appreciate that power management functionality
In certain aspects , the powermanagement device 132 may (e. g., battery charging, battery maintaining , etc .) may be
be configured to charge and monitor, in addition to automo- provided as a single component that combines the function
tive batteries, one or more portable user devices ( e.g ., cell ality of the power management device 132 and processor
phones , computers, etc .) or AC - powered devices coupled to 40 128 .
the battery charger 100 . To that end , one or more DC output Input/Output Interface 126 .
ports (e.g ., USB ports 158 or other DC sockets 166 , such as The battery charger 100 may further include an input/
12 -volt DC cigarette lighter ports ) may be provided on the output interface 126 to interface the processor 128 with one
housing 156 of the battery charger 100 . The USB ports 158 , or more peripheral and /or communicative devices, such as a
for example , may output a charging current of 3.0 to 5.0 A 45 user interface (s) 138, a Global Positioning System (GPS )
at 5 VDC . Further different currents may be provided such transmitter 140, the wired link 142, the wireless device 144 ,
that one USB port may provide a charging current of 1. 0 A and a speaker 124 , which may be used to signal an alert ( e. g .,
at 5 VDC , while a second USB port may provide a charging SoH , SoC , charge complete , error, etc .) or other status
current of 2 . 1 A / 2 . 4 A / 3 .0 Aletc . at 5 VDC to yield faster information .
charging ( e.g., for larger devices ). To activate the DC output 50 The wired link 142 and the wireless device 144 may be
ports, one or more DC power buttons ( or other user select- provided to manage communication and/ or transmission of
able element , such as a digital soft button ) may be provided signals or data between the processor 128 and another
on the housing 156 via a user interface 138 or remotely over device . The wired link 142 may be a port ( and /or cable ) to
a network ( e.g ., with a portable electronic device 110 over w iredly couple with another data port 146 positioned outside
a communication network 106 ). The DC output port(s ) may 55 the battery charger 100 , such as on -board diagnostics (OBD )
be activated by pressing the DC power button , and disabled data ports and other data ports (e.g., RS- 232 , Universal
by, for example, pressing the DC power button a second Serial Bus (USB ), and /or Ethernet ports). The wireless
time, two or more times in quick succession , or held for a device 144 may be a wireless transceiver configured to
predetermined timeframe. Similarly, an AC output port 162 communicate via one or more wireless standards such as
may be provided to output AC current to an AC powered 60 Bluetooth ( e . g ., short-wavelength , Ultra -High Frequency
device . The AC output port 162 may employ a pass through (UHF) radio waves in the Industrial, Scientific , and Medical
to convey AC power from the AC input device 134 , which ( ISM ) band from 2 .4 to 2 . 485 GHz ), near- field communi
may bypasses the power managementdevice 132 . In another cation (NFC ), Wi-Fi ( e.g., Institute of Electrical and Elec
aspect, the power management device 132 may include an tronics Engineers' (IEEE ) 802 .11 standards ), etc . The user
inverter to convert DC power stored to the internal auxiliary 65 interface ( s) 138 may further provide one ormore connection
power source 108 to a desired AC power signal ( e .g ., 110 to status icons to indicate the connection status of the wired
120 volt AC at 60 Hz). link 142 and/ or the wireless device 144 .
 US 10 ,446 ,885 B2
15 16
The processor 128 may be operatively coupled to a Remote Monitoring/ Control.
display device 114 via a display driver 116 . The display FIG . 1d illustrates a battery charging system and network
device 114 may comprise one or more light emitting diodes configured to facilitate remote monitoring and control of a
(LEDs) 114a, a liquid crystal display (LCD ) screen 114b, remote battery ( e.g ., battery 104) and/or remote battery
and /or a segmented display device 114c. For example , the 5 charger (e.g ., battery chargers 100). As illustrated , the bat
display device 114 may be an alphanumeric segmented tery charging system may comprise a communication net
LED /LCD display or a matrix LCD display. In certain work 106 (e.g ., the Internet) that is communicatively
embodiments , the display device 114 may further provide coupled example
, via one or more data transmission devices, with , for
, a battery management server 150 , one or more
touch screen functionality to facilitate a user input device via 10 battery chargers
a thin layer of sensing circuitry present either beneath the devices 110 . 100 , and one or more portable electronic
visible portion of display device 's 114 surface , or as part of In operation , the battery charger 100 may be configured to
a thin , clear membrane overlying the display device 114 that communicate with one or more portable electronic devices
is sensitive to the position of a pen or finger on its surface . 110 ( e.g ., phones , tablet computers, portable computers, or
The display device 114 may be used to provide an 15 other handheld user terminals) within a battery monitoring
indication of a poor SoH for a battery , indicating a “ Bad system via a communication network 106 . For example , the
Battery ” or “ Battery Good To Start” indicator, which may be battery charger 100 may wirelessly communicate with a
compatible with multiple nominal battery voltages, chem wireless transceiver 148 ( e . g ., Wi- Fi router and /or modem ),
istries, and constructions , including, for example, 6 -, 8 -, 12 -, which , in turn , may be wiredly couple to a network 106 . In
16 -, 24 - volt lead -acid , AGM , GEL , lithium ion , etc . 20 other aspects, the battery charger 100 may wirelessly com
The “ Bad Battery ” or “ Battery Good To Start” indicators municate directly with one or more portable electronic
may be text or graphical displays (e .g., an icon on an LCD devices 110 (e. g., via Bluetooth , Wi- Fi, NFC , etc .).
display ) or back -lit displays (e .g ., a backlit LED translite ). The battery management server 150 may be configured to
The display device 114 also may be used to indicate an receive data and , therefore , may be communicatively
operating mode of battery charger 100 . For example , the 25 coupled with one or more non -transitory data storage
display device 114 may display that battery 104 is in devices 150b . In certain aspects, the portable electronic
desulfation mode , and /or to indicate when the battery 104 is devices 110 may be used to monitor and remotely control the
charging , fully charged , etc . In operation , the display driver battery charger 100 . A suitable example battery monitoring
116 may receive display data from the processor 128 via system is disclosed in greater detail by commonly owned
input/output interface 126 and display that display data via 30 U . S . Pat. No . 9 , 579 , 990 by Brian F . Butler et al., issued on
the display device 114 . For example , interactive LEDs Feb . 28 , 2017 , and titled “ Battery Charger Status Control
and / or an easy -to - read digital LCD display may be provided
System And Method .”
on the housing to provide the user with status information Battery Charging Protocol.
and /or input capability (e .g., via a touch screen ). FIG . 2 illustrates a flow diagram depicting an example
Once an AC power supply 102 is connected , for example, 35 battery charging cycle 200 . As illustrated , upon startup at
a first LED may be illuminated to indicate that the battery step 202 ( start mode ), the battery charger 100 may be
charger 100 is ready to use . When the AC power supply 102 configured to , via said processor 128, cycle through multiple
is connected and the battery charger 100 is successfully modes , including, for example , a diagnostics mode 204
connected with the communication network 106 or wireless (which may include nominal voltage detection , battery type
transceiver 148 , a second LED on the unit may be illumi- 40 detection , etc .), a soft start mode 208, a bulk mode 210 , an
nated . Finally, when the DC output 136 are successfully absorption mode 212 , a di/dt charging mode 214 , and a
coupled (e . g ., clamped , or otherwise electrically coupled ) to maintenance mode 216 before terminating at step 220 .
a battery 104 , a third LED may be illuminated . Rather than While the example battery charging cycle 200 is illus
employing separate LEDs, a single multi - color LED (e .g ., a trated as having seven differentmodes , one of skill in the art
tricolor LED (RGB ) ) may be employed that changes color 45 would appreciate that fewer or additional modes may be
depending on the status of the battery charger 100 . implemented . For example , one or more modes may be
The user interface 138 may include user-actuated input omitted from the battery charging cycle 200 , or performed
devices 160 to enable the user to input commands, switch separately and / or upon request from a user . Moreover, the
the charging mode, the battery type , amperage (e . g ., 1 A , 10 order in which the modes are cycled may be rearranged
A , 50 A , etc . ), or another setting . Example user - actuated 50 depending on the needs of the user. Further, at one or more
input devices 160 include physical buttons, physical points in the battery charging cycle 200 , the processor 128
switches , a digitizer (whether a touch pad , or transparent may perform one or more battery engine -start checks 218 to
layer overlaying the display device 114 ) , and other input indicate to the user whether the battery 104 is sufficiently
devices. For instance , using the digitizer, a user may control charged and / or in a sufficient SoH to start a vehicle. If the
or interact with the battery charger 100 by writing , or 55 battery 104 is considered by the battery charger 100 ( via the
tapping on the display device 114 using , a pen , stylus, or processor 128 ) to be sufficiently charged and /or in a suffi
finger. The battery charger 100 may be configured to modify cient SoH to start a vehicle, the display device 114 may
an algorithm for a charge cycle based on input (via the display “ Battery Good To Start” or an equivalent icon . An
input/output interface 126 or the portable electronic device example battery engine-start detection cycle 700 is
110 ) from a user, such as battery type , battery size , geo - 60 described below in connection with FIG . 7 .
graphic location of the battery 104/battery charger 100, and In start mode 202 , the battery charger 100 initializes its
charge history . Indeed , the battery charger 100 can charge various hardware and software systems. For example , the
the battery 104 differently to compensate for the age of the input/output ports on the processor 128 are initialized along
battery 104 as the battery 104 ages . In certain aspects , if a with the clock 130 . The display device 114 may also be
wrong setting is entered ( e . g ., by the user ), the battery 65 tested and set to its initial state . The various system variables
charger 100 may update the setting to a new setting for the may be initialized (e . g ., a default state /value or an initial
next charge cycle . measured value). In one embodiment, the battery charger
 US 10 ,446 ,885 B2
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100 enters start mode 202 automatically upon power up charge current during the soft start mode 208 until the rate
( e . g ., when plugged into to an AC power supply 102 ), or of change of voltage is 0 . 00875 V /min and 0 .0175 V /min
upon receipt of an initiation signal, which may be triggered (which is expected for a rate of change of the battery voltage
through actuation of a user- actuated input devices 160 on the in the 0 . 1 to 0 .2 C range ) to determine the correct charging
battery charger 100 (e .g ., a power button or a “ start charge ” 5 current.
button ) or over a communication network via a remote The battery charger 100 also dynamically monitors for a
portable device . sulfation condition , which is a condition that occurs in
In diagnostics mode 204 , the battery charger 100 may lead -acid batteries where the battery cannot hold a charge
determine , inter alia , one or more characteristics of the due to the crystallization of lead sulfate . The desulfation
battery 104 , a vehicle coupled to the battery 104 , or the 10 mode 206 may employ a process of repeatedly sending short
battery charger 100 . For example , the battery charger 100
may determine the nominal voltage of the battery 104 and /or current surges through the sulfated /damaged battery . The
the type of battery 104 , which can be used to dictate the current pulses tend to break down and dissolve the sulfate
charging protocol used to charge the battery 104 . The 15 crystals
time . To
, restoring some of the battery 's 104 capacity over
identify a sulfation condition , the battery charger
nominal voltage and /or the type of battery 104 may be 15 tim
determined as described with regard to FIGS. 3 and 4 . The 100 may dynamically monitor the battery voltage for rapid
battery charger 100 may also determine whether the battery increases in battery voltages . If the battery 104 is not
104 is properly connected to the DC output 136 by checking sulfated , or if the battery 104 is not a lead-acid battery , the
for a predetermined measurement across the DC output 136 battery charging cycle 200 may proceed to bulk mode 210 .
( e. g ., by taking a voltage measurement, a resistance mea - 20 For example , if the peak voltage in a nominal six -cell
surement, capacitance measurement, impedance measure 12 - volt voltage battery is greater than a first predetermined
ment, etc .). For example, battery charger 100 may require value (e. g ., 11 volts , which is 1. 834 VCELL ), but the initial
that the voltage measured across the DC output 136 meet a voltage is less than a second predetermined voltage (e.g ., 3
predetermined voltage value (e .g ., a voltage threshold ), such volts , 0 .5 VCELL) , the processor 128 assumes a sulfation
as 0 . 1 volts . 25 condition exists and initiates a desulfation process at step
If the battery 104 is not properly connected to the DC 206 .
output 136 , the display device 114 may indicate accordingly During the desulfation mode 206 , the display device 114
( e. g., the LCD may display “ Battery Not Connected ” or an may indicate that the battery charger 100 is in desulfation
LED may be illuminated ). During diagnostics mode 404 , the mode ( e . g ., displaying " Battery Sulfated ” or equivalent
battery charger 100 may measure and record one or more 30 icon ) or the status may be communicated to a portable
parameters of the battery 104 such as, the maximum voltage electronic device 110 . If the desulfation process is successful
(Vmax) and minimum voltage (VMIN ) of battery 104 . In (i.e., the battery 104 is restored /usable ), the charge cycle
certain aspects , the processor 128 may further be configured proceeds to step 210 , otherwise the process continues to step
to perform a battery engine -start check 218 during diagnos - 220 and a bad battery indication is provided via display
tics mode 404 to determine and /or display whether the 35 device 114 ( e. g., " Battery Sulfated ” or a representative
battery 104 is sufficiently charged and / or in a sufficient SoH icon ). An exemplary desulfation process 500 is described
to start a vehicle. Alternatively, the battery engine - start below in connection with FIG . 5 .
check 218 may be triggered through actuation of a user - In bulk mode 210 , the battery charger 100 may output a
actuated input device 160 or over the communication net maximum charging current while the voltage increases . A
work 106 via a remote portable electronic device 110 . 40 bulk mode 210 may be run for a second timeframe or until
In soft startmode 208 , the battery charger 100 may output the battery 104 received a predetermined SoC (e . g ., 80 to
a reduced charging current. For example , a soft start mode 90 % of the batteries rated capacity ) and commences after the
208 may run for a shortened timeframe ( e . g ., 1 to 10 soft start mode 208 . For example , charging a 100 AH battery
minutes, more preferably about 2 minutes ). During the soft with a 10 A charger would take approximately 8 hours in the
start mode 208 , the battery charger 100 charges the battery 45 bulk mode 210 to reach 80 AH (80 % capacity or 0 . 8 C ) ,
104 using a reduced charging current (e . g ., about half the without taking into account any losses in the charging
maximum charging current for a given battery type until the process. During the bulk mode 210 , the battery charger 100
battery reaches a predetermined state of charge ). Assuming charges the battery 104 using a constant maximum current
a lead -acid battery is used and / or detected , the battery until the battery 104 rises to an absorption mode 212 level.
charger 100 may determine whether the battery 104 is 50 In other words, the battery charger 100 can provide the
sulfated during the soft start mode 208 . maximum amount of current that the battery 104 will accept
The soft start mode 208 may also be used to determine the (up to charger capacity, e. g., 25% of battery capacity in amp
capacity of the battery . The rate of change of the battery hours ). The temperature of the battery 104 may also be
voltage (as a function of the SoC of the battery ) during the monitored ( e. g ., directly via a sensor 112 , such as a ther
charging mode is used to determine the actual capacity of the 55 mometer, or indirectly as a function of the current supplied
battery . As a battery ages the actual capacity drops below the to the battery and measured battery parameters ) to ensure
rated capacity (which is dictated by the battery manufacturer that it does not exceed a predetermined temperature ( e. g .,
specifications). Manually setting the charging current based 125° F . for a wet battery , 100° F . for an AGM or GEL , etc .).
on a percentage of rated battery capacity can damage the In absorption mode 212 , the battery charger 100 may
battery . Charging a six - cell 12 -volt battery at 20 % capacity 60 output a predetermined charging current until the SoC of the
(i.e ., a 0 .2 C battery ), for example , would generate a rate of battery achieves a predetermined charge percentage ( e. g .,
change of voltage of about 0 .0175 V /min . At 10 % capacity 80 - 90 % ). If the SoC of the battery 104, for example, fails to
(i.e ., 0. 1 C ), however, the rate of change would be about achieve a predetermined charge percentage within a period
0 .00875 V /min . Therefore, the SoC of the battery 104 may of time (e.g ., a predetermined period of time value stored to
first be determined to identify an expected rate of change for 65 the memory device ), the display device 114 may indicate
the voltage . For example , if the SoC is calculated to be that the battery is bad ( e . g ., displaying “ Bad Battery ” or
between 10 and 20 % , the battery charger 100 may vary the equivalent icon ).
 US 10 ,446 ,885 B2
20
Absorption mode 212 begins at the start of di/dt, which is In one aspect, the processor 128 can dynamically monitor
the rate of change of the charge current (i) over time (t). In whether the VMin and Vmax of the battery 104 connected
di/dt charging mode 214 , for example , the battery charger across the DC output 136 is greater than or equal to a stored
100 may hold the battery voltage constant and wait for the VMax, where the stored Vmax represents the previously
charge current to level off, or at least stop declining, which 5 measured highest voltage of the battery 104 . If the voltage
is the preferred over setting a current limit ( e . g ., 0 . 5 amps ) of the battery 104 connected to the DC output 136 is greater
because certain batteries can draw a greater number of amps than or equal to Vmax then Vmax is set to the current value
( e. g., 2 .0 amps or more ) even when fully charged . A di/dt of the voltage of the battery 104 connected to the DC output
charging mode 214 exploits the fact that, as the battery 104 136 . During the charging period, the system also continually
charges at a constant voltage , the current rise slows and 10 checks whether the voltage of the battery 104 connected to
eventually stops . In other words, at a constant voltage, the its DC output 136 is less than or equal to VMN. V MIN
decrease in current slows and eventually flat lines. Further, represents the previously measured lowest voltage of the
if the battery charger 100 detects that the current has battery 104 . If the voltage of the battery 104 connected to the
increased , the battery charger 100 may conclude that the DC output 136 is less than or equal VMIN , then VMIN is set
battery 104 is in thermal runaway condition . 15 to the present value of the voltage of the battery 104
The di/dt charging mode 214 may initiate when the connected across the DC output 136 . During a charging
measured battery voltage dips below a predetermined volt- cycle, the processor 128 continuously monitors the differ
age after charging for more than a predetermined timeframe ence between Vmax and VMin . If the difference between the
( e.g ., within 48 hours ,more preferably within about 36 , most Vmax and VMIN (i.e., a rate of change) is more than a
preferably within about 24 hours ), or the predetermined 20 predetermined value, then the battery 104 is deemed to have
timeframe has elapsed since the last point of progress a low SoH and the display device 114 will indicate accord
(voltage increasing ), or battery voltage is greater than the ingly that the battery 104 is bad . The difference between the
maximum voltage. This maximum voltage may be the Vmax and Vuiy should be less than a predetermined value ,
maximum voltage for the battery type or the current battery which may be a function of the SoC (e .g ., the rate of change
voltage if greater than a predetermined voltage ( e .g ., 14 . 2 25 at 10 % of the rating of the battery , such as 0 .00875 V /min
volts for a 12 -volt battery, 2 .367 VCELL ) and the current or 0 .525 V /hour ).
battery voltage is not increased within a preceding time- In another aspect, the processor 128 can dynamically
frame ( e .g ., the prior 5 to 60 minutes , more preferably the monitor the voltage of the battery 104 connected across the
prior 30 minutes ). output terminals to detect a bad battery. For instance, if the
The di/ dt charging mode 214 may also end if the charge 30 battery 104 voltage does not exceed predetermined threshold
current drops below a predetermined current ( e . g ., 100 - 500 voltages after predetermined amounts of time, then the
mA, more preferably about 200 - 300 mA ) and /or the percent battery 104 is deemed to have a low SoH . The display device
charge reaches 100 % ( or another near capacity value ). Two 114 will indicate accordingly that the battery 104 is bad . For
other conditions thatmay terminate the di/dt charging mode example , if for a nominally 12 -volt battery the voltage of
214 include , for example, where the current increases more 35 battery 104 is less than or equal 10 volts ( 1 .667 VCE ) for
than a predetermined current ( e .g ., about 250 mA) in more more than two hours , then the charging will abort and the
than 1 minute and where the current does not decrease display device 114 will indicate that the battery 104 is bad .
within a predetermined period ( e. g., about 30 minutes ). The Another low SoH indication for a battery 104 is lack of
duty cycle of charging current is repeatedly monitored . In progress. For example , lack of progress can be identified
general, the voltage is held constant at Vmax by continu - 40 when the voltage of the battery 104 does not increase by a
ously reducing the current by reducing the duty cycle . Once predetermined voltage amount during a predetermined time
the current levels off and the voltage is maintained , the frame. For example , in a six -cell nominal 12 - volt battery , if
system assumes that the battery 104 is fully charged . Once the voltage is below a predetermined voltage ( e.g., a fully
the battery 104 is fully charged , the system enters a main charged voltage , such as 14 .2 volts, 2 .367 VCELL ) and the
tenance mode 216 . 45 voltage does not increase by at least 0 .05 volts (0 .008333
In maintenance mode 216 , the battery charger 100 Vcrw ) in a predetermine period of time (e . g., 5 minutes to
dynamically monitors the current that the battery 104 is 60 minutes , or about a 20 -minute period ), then the charging
drawing to maintain the battery 104 in a fully charged state . will abort and the display device 114 will indicate that the
During maintenance mode 216 , the charge voltage may be battery 104 is bad .
reduced and held constant at a predetermined voltage (e .g ., 50 By way of illustration , an example bad battery process for
for a 12 - volt lead -acid battery , between 13 . 0 VDC and 13 . 8 identifying a bad battery condition via a battery charger 100
VDC , i.e., 2 .167 to 2 .3 V CELL), while the current is reduced having a display device 114 during a charging process of a
to less than 1 % of battery capacity . If the current that the six -cell nominal 12 - volt lead acid battery 104 will be
battery 104 draws is more than a predetermined value for a described in accordance with one embodiment. Upon start
predetermined time value , then the display device 114 will 55 up , the battery charger 100 determines , via a processor 128
indicate that the battery 104 is deemed to have a low SoH . and a sensor 112 (e.g ., a voltage sensor), a state of charge for
For example, in one embodiment, if the battery 104 is a lead acid battery 104 connected to the battery charger 100
drawing more than 1 .0 A for more than 12 hours , then the across a pair of electrical conductors 172a , 172b . The battery
display device 114 will indicate that the battery 104 is bad . charger 100 then measures, using the voltage sensor, a first
Bad Battery Detection . 60 battery voltage of the lead acid battery 104 . After a first
While in the various charging modes, the battery charger period of time (e .g ., a first predetermined period of time
100 dynamically monitors the battery charging progress and value stored to the memory device ), the battery charger 100
various battery parameters via the one or more sensors 112 then measures , using the voltage sensor, a second battery
to identify a bad battery . The process for detecting a bad voltage of the lead acid battery 104 . Using the first and
battery may adjusted depending on the type of battery , the 65 second battery voltages as a function of the first period of
nominal voltage, and / or the current mode of the charging time, the battery charger 100 may calculate ( via processor
process . 128 ) a first rate of change for the first period of time. If the
 US 10 ,446 ,885 B2
21
first rate of change is greater than or equal to a first wise, the processor 128 can identify a thermal runaway
predetermined rate of change value (e .g ., a predetermined condition when the battery 104 voltage fails to reach a
rate of change value stored to the memory device ), the predetermined voltage within a predetermined amount time
battery charger 100 may display a bad battery indicator via Internal Impedance/Conductance Calculations.
the display device 114 . As can be appreciated , the first 5 The battery charger 100 may also dynamically calculate
predetermined rate of change value may be a function of the and monitor the internal impedance and/ or conductance of
state of charge for the lead acid battery 104 . For example, a the battery 104 to determine whether the battery has a low
higher rate of change would be expected in a battery at a SoH by measuring the internal resistance of the battery 104 .
higher state of charge . As can be appreciated , the conductance of the battery 104 is
Therefore , the battery charger 100 may measure a third 10 simply the inverse of the impedance .
battery voltage of the lead acid battery 104 after a second If the internal resistance of a battery is too high , excess
period of time ( e. g ., a second predetermined period of time energy will be dissipated inside the battery 104 ( e .g ., as heat )
value stored to the memory device ). The battery charger 100 and the battery 104 may have insufficient power to achieve
may display the bad battery indicator via the display device its intended purpose , for example starting a vehicle . There
114 if the second rate of change is greater than or equal to 15 fore , a battery with a high internal resistance ( i.e ., greater
a second predetermined rate of change value. The rate of than a predetermined resistance value) is deemed to have a
change is expected to be higher (e .g ., spike ) at the start of a low SoH and the display device 114 will accordingly indi
charge cycle . Therefore , different rate of change values may cate that the battery is bad . The internal resistance of the
be employed throughout the charge cycle as a function of battery normally increases as the battery ages. A battery with
charge time (i.e ., depending on the elapsed time). Therefore , 20 a measured (or calculated ) internal resistance that is less
the second predetermined rate of change value may be not than 60 % of its rated internal resistance will typically have
equal to the first predetermined rate of change value. For insufficient power to start an engine under all conditions and ,
example , the second predetermined rate of change value therefore, should be replaced . Accordingly , a battery with an
may be less than the first predetermined rate of change internal resistance that is less than 60 % of their rated internal
value. The first and second period of time may be the same, 25 resistance may be flagged as a bad battery .
for example , between 30 seconds and 5 minutes, or about 1 To determine the internal resistance of the battery 104, the
minute . battery charger 100 may dynamically compare the open
Thermal Runaway Detection . circuit voltage (Voc ) of the battery 104 to the voltage of the
During the various charging modes, the battery charger battery 104 when a current is applied . Equation 1 provides
100 may also check for a thermal runaway condition . A 30 a formula for calculating the internal resistance (R ) of a
thermal runaway condition exists when the electrical con - given battery 104 , where V is the voltage measured across
ductors and / or electrolyte in the battery 104 increase in the battery 's 104 terminals when a predetermined current (1)
temperature during a charging cycle . Since , the resistance of is applied to the battery 104 .
an electrical conductor is inversely proportional to the Equation 1
temperature of the conductor, the resistance of the electrical 35 V = Voc- (I* R )
conductor decreases as temperature increases. Thus , if the In certain aspects , the battery 104 may be modeled as a
battery charger 100 is providing a constant voltage to the resistor-capacitor (RC ) circuit 900 to determine, inter alia ,
battery 104 under charge , the current will increase in pro - the impedance and conductance . For example , a lead - acid
portion to the decrease in resistance . During such a condi- battery can be modeled as a Randles equivalent electrical
tion , the battery 104 voltage does not increase even though 40 circuit . FIG . 3 illustrated an example RC circuit 900 having
the charging current is increased , instead either remaining a first resistor 902 in series with two parallel resistor
the same or decreasing. capacitor combinations , including a first capacitor 906 in
During an initial phase of a normal charging cycle , the parallel with a second resistor 904 and a second capacitor
voltage of the battery 104 will continually ramp up to a 908 in parallel with a third resistor 910 . The first resistor 902
predetermined value or to a point at which dv/dt: 0 . Further, 45 models the resistance of the battery ' s 104 terminals and
a decreasing amount of charging current is typically required inter -cell connections ( e. g ., between about 5 and 100 m2 ),
to maintain a constant battery voltage . In view of these whereas the second resistor 904 ( 10 -500 m2) and the first
tendencies, a number of techniques may be used to detect a capacitor 906 (e .g., between about 1,000 and 20 ,000 farad
thermal runaway condition during the initial phase by moni- (F )) represent transient effects resulting from shifting ion
toring the voltage and charging current of the battery 104 . 50 concentrations and plate current densities. The third resistor
For example , the processor 128 can identify a thermal 910 represents the self- discharge resistance (approximately
runaway condition when an increase in charging current is 5 kg ) of the battery 104 , while the second capacitor 908
detected or an increase is detected with respect to time, i.e .
represented the battery ' s 104 main charge storage (i.e .,
di/dt. capacity ), which is an equivalent to - 1x10 farad ( F ) for a
Consequently, the processor 128 can monitor the duty 55 fully charged healthy nominal 12 - volt battery . The voltage
cycle of the charging current and track the trend in the duty across second capacitor 908 is a suitable indicator of SoC ,
cycle throughout a charging cycle . When the trend in the whereas the SoH is inferred by observing a significant
duty cycle indicates an anomaly , a thermal runaway condi- change in the second capacitor 908 over time due to aging
tion is indicated . Whenever a thermal runaway condition is effects of the battery 104 , such as active mass degradation
indicated , the battery charger 100 will abort the charge , and 60 and crystallization of the active mass . While the RC circuit
the display device 114 will indicate a bad battery . Com 900 is a suitable technique for determining a battery 's 104
monly owned U .S . Pat. No. 7 , 834 ,593 describes additional SoH and/ or SoC , other modeling circuits are contemplated .
suitable methods for detecting a thermal runaway condition . For example, Gould discloses an adaptive battery model
For example , the processor 128 may also identify a thermal based on a variant of the Randles ' lead - acid model. See
runaway condition when the battery 104 voltage fail to 65 Gould , C . R ., et al., “ New Battery Model and State -of -Health
continually ramp up , or when additional charging current Determination Through Subspace Parameter Estimation
(beyond the nominal) is required to achieve dv /dt:0 . Like and State -Observer Techniques,” IEEE Transactions on
 US 10 ,446 ,885 B2
23 24
Vehicular Technology ( Volume: 58 , Issue : 8 , October 2009). termined voltage value (e.g., about 12 .0 to 12 .4 volts , 2 .0 to
In another example , the internal resistance may be calculated 2 .067 VCELL, or about 12 . 2 volts , 2 .034 V CELL ) stored to the
CEL
using Kelvin four -wire sensing . memory device , using , for example , a processor 128 opera
In operation , the battery charger 100 may be configured to tively coupled with a memory device (e. g ., ROM 118 , RAM
output a known input signal (e . g ., a test signal, such as a 5 120 , and /or other data storage 122 ). If the first battery
predetermined AC signal) to the battery 104 via the DC voltage is less than the first predetermined voltage value, the
output 136 and to dynamically monitor and record the battery charger 100 may then measure a second battery
battery ' s 104 response ( e . g ., a voltage waveform ) to the voltage of the lead acid battery 104 using the voltage sensor
known input signal. The processor 128 can then compare the after a first period of time ( e .g ., 1 minute to 10 minutes, or
battery ' s 104 response with the known input signal ( e . g ., 10 about 5 minutes ). The battery charger 100 may then compare
using Ohm ' s law ) to calculate the impedance and /or con - the second battery voltage to a second predetermined volt
ductance of the battery 104 . age value (e.g., about 14 .0 to 16 .0 volts, 2.334 to 2.667
Capacity Calculations. VCELL , or about 14 .2 volts, 2 .367 VCEL ) stored to the
The battery charger 100 may also dynamically calculate memory device using the processor 128 . If the second
and monitor the capacity of the battery 104 to determine 15 battery voltage is greater than or equal to the second
whether the battery has a low SoH . In connection with predetermined voltage value, the battery charger 100 may
secondary batteries, capacity generally refers to the avail display a bad battery indicator via the display device 114 . In
able number of amp hours that the battery 104 can discharge addition to displaying the bad battery indicator, the battery
into a load . If the capacity of the battery 104 is lower than charger 100 may further abort the charging process if the
a predetermined capacity value , the battery charger 100 will 20 second battery voltage is greater than or equal to the second
determine that the battery 104 has a low SoH and the display predetermined voltage value . Alternatively , in an attempt to
device 114 will accordingly indicate that the battery 104 is repair the lead acid battery 104 , the battery charger 100 may
bad . For example , if after a predetermined time value commence a desulfation process 500 (or portion thereof) if
charging the battery 104 does not reach a predetermined the second battery voltage is greater than or equal to the
capacity ( e . g ., 225 A for 3 seconds), then the battery 104 is 25 second predetermined voltage value .
deemed to have a low SoH , and the display device 114 will The battery charger 100 may periodically check the lead
indicate a bad battery condition . acid battery 104 to determine whether the lead acid battery
In certain aspects , the capacity can be derived from the 104 has started to accept a charge , for example , after or
conductance of the battery . For example , the phase shift of during the desulfation process 500 . For example , if the
the response to the known input signal can be used to 30 second battery voltage is greater than or equal to the second
determine the proportions of the impedance that are reactive predetermined voltage value, the battery charger 100 may
and resistive, where the reactive component represents the measure a third battery voltage of the lead acid battery 104
capacity of the battery 104 and the resistive component connected across the pair of electrical conductors 172a ,
represents the internal resistance of the battery 104 . The 172b after a second period of time (e. g., 1 minute to 10
processor 128 can compare the conductance to values stored 35 minutes, or about 5 minutes ). The battery charger 100 may
in the read only memory 118 or data storage 122 to estimate compare the third battery voltage to the second predeter
the battery ' s 104 current capacity. mined voltage value stored to the memory device using the
In another embodiment, after a predetermined time value processor 128 . If the third battery voltage is less than or
in maintain mode ( e. g., 4 to 16 hours, more preferably 6 to equal to the second predetermined voltage value, the battery
12 hours , and most preferably , about 8 hours ) the battery 40 charger 100 may instruct the display device 114 to not
charger 100 will measure the Vor of the battery 104 , which display ( e . g ., disable ) the bad battery indicator . If, however,
corresponds to the capacity in a rested battery . The processor the third battery voltage is less than the second predeter
128 can then compare the measured Vecto values stored in mined voltage value , upon detection of a lack of progress
the read only memory 118 or data storage 122 to determine (i. e ., the third battery voltage is within a predetermined
the battery ' s 104 current capacity . The processor may also 45 deviation of the second battery voltage , which may be a
take in to account the temperature of the battery in its function of the second period of time), and /or upon detection
calculations . If the processor 128 determines that the capac - of a thermal runaway condition , the battery charger 100 may
ity is lower than a predetermined value, then the battery 104 instruct the display device 114 to continue displaying (e. g.,
is deemed to have a low SoH . The typical lead acid battery enable ) the bad battery indicator, whereupon the battery
has a nominal Voc of 12 .8 volts . If the Voc value drops 50 charger 100 may further abort the charging process .
more than 3 % within an 8 hour period and the batteries SoH Lithium SoH Monitoring .
is below 60 % , the lead acid battery should be replaced . The The battery charger 100 can also determine whether a
display device 114 will accordingly indicate that the battery lithium battery is deemed to have a low SoH based on its
is bad . charging characteristics . During the charging phase , the
12 - Volt Lead Acid Battery Example . 55 battery charger 100 dynamically records the battery 104
By way of illustration , an example bad battery process for voltage and the current through the battery 104 . The pro
identifying a bad battery condition via a battery charger 100 cessor 128 continuously compares the battery 104 voltage
having a display device 114 during a charging process of a and current to determine whether the current draw is too low
six - cell nominal 12 - volt lead acid battery 104 will be for the measured voltage . For example , if the battery 104
described in accordance with one embodiment. The example 60 voltage is between 2 volts (0 . 333 VCE ) and 8 volts ( 1 .334
bad battery process may be perform once per charge cycle , Vre ), and the current accepted is less than 800 mA , then
periodically, or upon instruction from a user. Upon start up , the processor will determine that the lithium battery is
for example, the battery charger 100 may measure, using a deemed to have a low SoH . The display device 114 may then
voltage sensor , a first battery voltage of a lead acid battery indicate that the battery 104 is bad .
104 connected to the battery charger 100 across a pair of 65 FIG . 11 illustrates an example lithium charging cycle
electrical conductors 172a , 172b . The battery charger 100 1100 for identifying a bad battery condition during a charg
may then compare the first battery voltage to a first prede- ing process of a lithium battery 104 . The lithium charging
 US 10 ,446 ,885 B2
25 26
cycle 1100 starts at step 1102 . At step 1102 , the battery dictated by the manufacturer 's rating for the battery (i.e., per
charger 100 measures ( e . g ., via a voltage sensor, which may the battery manufacturer specifications) or a predetermined
be measure dynamically ), the battery voltage (a measured voltage value associated with a fully charged battery for a
battery voltage ) of a lithium battery 104 connected to the particular application . For example, a six -cell nominal
battery charger 100 ( e .g ., across a pair of terminals or 5 12 - volt battery ' s fully charged voltage may be set to 14 .2
clamps ). volts , which equates to 2 . 367 VCELL
At step 1104 , the processor 128 , via a voltage sensor, If the measured battery voltage is less than the third
determines a voltage of the lithium battery 104 . The pro - predetermined voltage value (but greater than the second
cessor 128 may be configured to determine the voltage predetermined voltage value ), the battery charger 100 sup
dynamically, periodically (e. g ., at regular intervals ), or upon 10 plies a third current (e. g., about 1. 0 to 3 .0 A , more preferably
a triggering event. about 2 . 0 A ) to the lithium battery 104 for a third period of
At step 1106 , the processor 128 determines whether a time at step 1118 . If the measured battery voltage third
timer has expired . If the timer has expired , the lithium predetermined voltage value is greater than or equal to the
charging cycle 1100 may abort/terminate at step 1124 until third predetermined voltage value at step 1112 , the battery
reset or restarted . If the lithium charging cycle 1100 aborts 15 charger 100 enters a maintenance mode at step 1114 . During
at step 1124 , the battery charger 100 may display a bad the maintenance mode, the battery charger 100 may peri
battery indicator via the display device 114 . Otherwise , the odically supply a maintaining current ( e. g ., about 0 . 1 to 0 .4
lithium charging cycle 1100 proceeds to step 1108. A , more preferably about 0 .2 A ) to the lithium battery 104 .
The timer may be purely a function of time or a function The battery charger 100 may also periodically measure
of both time and of battery voltage measured during the 20 the voltage of the lithium battery 104 and , if the measured
lithium charging cycle 1100 (e .g ., at step 1104 ). For voltage drops below a fourth predetermined voltage value
example , the lithium charging cycle 1100 may be configured (e . g ., about 12 .5 to 13 .5 volts , 2 . 083 to 2 . 25 V CELL, more
to charge the lithium ion battery only for a predetermined preferably about 13 . 1, 2 . 183 V CELL ), the battery charger 100
total period of time (e. g ., 5 to 15 hours, more preferably may return to step 1102 to restart the lithium charging cycle
about 10 hours ), whereby the lithium charging cycle 1100 25 1100, or simply supply the third current at step 1118 .
may abort/terminate until reset, restarted , or after a prede- Automatic Nominal Voltage Detection 300 .
termined rest period of time to allow the battery to rest or The battery charger 100 may be configured with an
cool off . In another example , if the measured battery voltage automatic nominal voltage detection function whereby the
is less than a predetermined voltage value ( e . g ., about 8 .0 to battery charger 100 can determine the nominal voltage of the
12 .0 volts, 1 . 333 to 2 .0 VCELL , more preferably about 10 .0 30 battery 104 . When presented with nominal 6 -volt and
volts , 1.667 V CELL ) after a period of time ( e . g ., about 1 to 3 12 -volt batteries, the battery charger 100 may determine that
hours, more preferably about 2 hours) , the processor 128 the battery 104 is a nominal 12 -volt battery (as opposed to
may determine that the lithium ion battery is not accepting a nominal 6 -volt battery ) if the original voltage upon con
a charge (also indicating a bad battery condition , which can nection of the battery 104 to the battery charger 100 is
trigger the bad battery indicator via the display device 114 ) 35 greater than a first predetermined voltage ( e. g ., about 7 - 10
and the lithium charging cycle 1100 should be terminated . volts, more preferably about 8 volts ); otherwise a decision
At step 1108 , the processor 128 compares the measured on the battery type may not be made until one of a plurality
battery voltage to a first predetermined voltage value ( e . g ., of conditions is met . As a first example , if the battery 104
about 5 .0 to 10 .0 volts, 0 .834 to 1.667 VCELL, more prefer- voltage exceeds a second predetermined voltage (e .g ., about
ably about 8 .0 volts , 1.334 VCELL). If the measured battery 40 9 to 12 -volts, more preferably about 10 volts) within a
voltage is less than the first predetermined voltage value , the predetermined timeframe (e . g ., within 48 hours , more pref
battery charger 100 supplies a first current (e .g ., about 0 .01 erably within about 36 , most preferably within about 24
to 0 .5 A , more preferably about 0 . 1 A ) to the lithium battery hours), the battery charger 100 may determine that the
104 for a first period of time at step 1122 . battery 104 is a 12 - volt battery . As a second example, if the
At step 1110 , the processor 128 compares the measured 45 battery 104 voltage decreases by a third predetermined
battery voltage to a second predetermined voltage value voltage (e . g ., 0 .1 or more volts ); the battery charger 100 may
( e. g ., about 8 . 0 to 12 .0 volts , 1. 334 to 2 .0 VCEL , more determine that the battery 104 is a 6 - volt battery (e . g ., a
preferably about 10 .0 , 1.667 V CELL ). If the measured battery three -cell 6 -volt battery battery ).
voltage is less than the second predetermined voltage value FIG . 3 shows an exemplary automatic voltage detection
(but greater than the first predetermined voltage value ), the 50 process 300 . As illustrated the battery charger 100 may
battery charger 100 supplies a second current ( e . g ., about determine, for example , whether a battery is a nominal
0 .25 to 1 .0 A , more preferably about 0 .5 A ) to the lithium 12 - volt battery (six - cell ) or a nominal 6 - volt battery (three
battery 104 for a first period of time at step 1120 . cell) . The process starts at step 302, where the battery
At step 1110, the processor 128 compares the measured charger 100 proceeds to dynamically measure the voltage of
battery voltage to a second predetermined voltage value 55 the battery 104 at step 304 . If the measured voltage is greater
( e. g., about 8 .0 to 12 .0 volts,more preferably about 10 .0 ). If than first predetermined value at step 306 , then the battery
the measured battery voltage is less than the second prede - charger 100 flags the battery as a nominal 12 - volt battery at
termined voltage value (but greater than the first predeter - step 312 . Otherwise , the process proceeds to the next step .
mined voltage value ), the battery charger 100 supplies a At step 308 , the battery charger 100 determines whether the
second current ( e . g ., about 0 .25 to 1 . 0 A , more preferably 60 measured voltage exceeds a second predetermined value
about 0 .5 A ) to the lithium battery 104 for a second period within a first predetermined timeframe. If the measured
of time at step 1120 . voltage exceeds the second predetermined value within the
At step 1112, the processor 128 compares the measured first predetermined timeframe at step 308 , then the battery
battery voltage to a third predetermined voltage value ( e . g .,
charger 100 flags the battery 104 at step 314 as a nominal
about 14 to 15 .0 volts , more preferably about 14 .2 ). The 65 12 -volt battery. Otherwise, the process proceeds to the next
third predetermined voltage value may be a fully charged step . At step 316 , the battery charger 100 charges the battery
voltage for battery. The fully charged voltage may be in accordance with a charging protocol for a nominal 12 -volt
 US 10 ,446 ,885 B2
27 28
battery. At step 310 , the battery charger 100 determines voltage drop and multiplying that by the percentage gives
whether the measured voltage has decreased by a predeter the expected drop during that actual engine start. If that
mined value within a second predetermined timeframe. If value is below the nominal required voltage, the battery SoH
the measured voltage has decreased by a predetermined is determined to be below 60 % and the battery 104 should
value within a second predetermined timeframe, then the 5 be replaced . Based on this comparison , the processor 128
battery charger 100 flags the battery as a 6 - volt battery at can identify the battery type. In another example , a voltage
step 318 . Otherwise , the process proceeds to the next step . may be applied to the battery 104 in series with a known
At step 320 , the battery charger 100 charges the battery in resistance to form a voltage divider circuit . The voltage
accordance with a charging protocol for a 6 - volt battery . At across the battery 104 may then be measured to determine
step 306 , the battery charger 100 charges the battery in 10 the impedance of the battery 104 . Different battery types
accordance with a default charging protocol, which may be , have different impedances values, therefore the processor
for example , the protocol for a 6 -volt battery . 128 can determine the battery type by comparing the cal
While the above automatic nominal voltage detection 300 culated impedance to values stored in the read only memory
techniques are discussed in connection with nominal 6 - volt 118 and/or the data storage 122 .
and 12 - volt batteries , the principles may be similarly applied 15 A temperature sensor may record the temperature of the
and adapted to other nominal battery voltages , such as 24 -, battery 104 and deliver the information to the processor 128 .
36 -, and 48 - volt batteries (e . g ., typically - 2 .0 nominal volts The temperature of the battery may affect the responses of
per cell),by scaling the predetermined value thresholds. For the battery to loads and voltages. The processor may be
example , to automatically distinguish between nominal capable of figuring the temperature ofthe battery 104 into its
12 - volt and 24 - volt batteries, the predetermined value 20 response comparisons. In certain aspects , the read only
thresholds may be multiplied by two . memory 118 or data storage 122 may have voltage and load
Automatic Battery Type Detection 400 . responses stored corresponding to various battery types at
The battery charger 100 may be configured with auto various temperatures .
matic battery type detection ( e.g ., AGM , gel, lithium ion , Desulfation Mode 500 .
etc .). FIG . 4 shows an exemplary battery type detection 25 FIG . 5 illustrates an exemplary desulfation process 500 . If
process 400 for determining the battery type. For example, the system determines that the battery 104 is a lead - acid
after determining the nominal battery voltage , the battery battery , then during the first portion of the charging cycle
charger 100 may send a test signal to the battery 104 at step (e .g ., during a soft start mode 208), the system checks for a
402. The battery charger 100 will then dynamically monitor sulfation condition . A sulfation condition is typically indi
and record the voltage response of the battery 104 in the 30 cated by a low initial voltage followed by a rapid rise in
random access memory 120 at step 404 . The processor 128 voltage once the battery 104 is connected to the charger. For
can then compare the voltage response to predetermined example in a 12 - volt battery , if the peak voltage is > 11 volts ,
voltage responses stored in either the data storage 122 or the for example , but the initial voltage was less than 3 volts , for
read only memory 118 at step 406 using , for example , a example , the system assumes a sulfation condition exists
lookup table . The lookup table may include a plurality of 35 and initiates a desulfation charge.
known battery types (e.g ., lead -acid , lithium , etc .) and At step 502 , the battery charger 100 determines whether
associated voltage response characteristics or ranges. Bat- the battery 104 is a lead-acid battery (e.g ., using the battery
tery type can be determined by applying a constant current type detection process 400 ). At step 504 , the battery charger
charge and measuring the rate of change of voltage (dv /dt) 100 ( via processor 128 ) determines whether the battery 104
as the battery charges from , for example , 70 % to 80 % SOC . 40 is sulfated . Sulfation detection may be accomplished by
By way of illustration , the charge curve at FIG . 10a continuously monitoring the difference between Vmax and
illustrates a graph 1000a of a dv / dt curve 1002a vis - à - vis a Vyiv . If the difference is more than a predetermined value
battery voltage curve 1004a for a 22 AH AGM battery being (e. g., 8 volts), then the battery 104 is considered to be in a
charged with a 2 . 0 A constant current charge. For purposes sulfated condition and will indicate that the battery 104 is
of this illustration , the dv /dt is measured at 60 second 45 sulfated on the display device 114 at step 506 . As illustrated
intervals from 14.0 to 14 .7 volts (2 .334 to 2 .450 VCEL ). The at steps 508 through 512, the desulfation charge is conducted
maximum dv / dt is below 0 .04 V , which is characteristic of for a predetermined timeframe ( e . g ., 8 hours, as indicated at
an AGM battery. At the 80 % SoC , charge level as the charger step 508 ). After the predetermined timeframe, the desulfa
normally switches to the di/ dt stage because the battery will tion charge is terminated at step 516 . During the desulfation
no longer accept the bulk rate current. FIG . 10b illustrates a 50 charging period , the battery 104 voltage is regulated at a
graph 1000b of a dv /dt curve 1002b vis - à - vis a battery predetermined voltage (e . g ., 5 . 4 volts ), by way of current
voltage curve 1004b for a 120 minute reserve capacity pulses applied to the battery 104 at step 510 . The current
flooded lead acid battery being charged with a 2 .0 A constant pulses are applied to the battery 104 until the battery 104
current charge . For purposes of this illustration , the dv/ dt is accepts a charge at step 512 . If the battery 104 accepts a
measured at 60 second intervals from 11. 34 to 14 .77 volts 55 charge at step 512 , then the battery charger 100 may start a
(1 .890 to 2 .462 VCELL ). This allows a relatively small normal charge cycle at step 514 .
amount of current to be used to test a wide range of battery The processor 128 can determine whether the battery 104
capacities . Based on this comparison , the processor 128 can is accepting the charge by comparing the duty cycle to the
identify the battery type and flag it accordingly at step 408 . max sulfation , and by comparing the periodic peak voltage
In another example , the battery charger 100 may apply a 60 to a predetermined voltage ( e . g ., 11 volts ). Specifically, if the
test load to the battery 104 and then record the response of duty cycle is greater than the max sulfation or the periodic
the battery 104 to the test load in the random access memory peak voltage is less than a predetermined voltage (e .g., 11
120. The processor 128 can then compare the response to the volts ), the battery 104 is determined to notbe accepting a
load to predetermined load responses stored in either the charge , and the desolation process continues to step 508 .
data storage 122 or the read only memory 118 . The load 65 If the battery 104 does not recover within a predetermined
applied to the battery 104 is a percentage to the current amount of time ( e .g ., 8 hours ), the battery charger 100 will
required to start a vehicle . Measuring the corresponding abort the desulfation process 500. The processor 128 will
 US 10 ,446 ,885 B2
29 30
determine that the battery 104 is deemed to have a low SoH , At step 704 , the processor 128 determines an initial
and the display device 114 will indicate that the battery 104voltage difference (AV ). According to one aspect , the initial
has gone bad at step 516 . If the battery is deemed to be voltage difference (AV ) may be the initial difference
desulfated (i.e., accepting a charge) at step 512 , the charging
between the peak and valley of the voltage signal. For
cycle will start at 514 . Commonly owned U . S . Pat. No. 5 example , the voltage difference (AV) can bemeasured in the
8 ,575 ,899 B2 describes a process for determining whether a zero cross period of the 60 Hz AC input line (e.g ., AC power
supply 102).
battery is sulfated as well as the desulfation process during At step 706 , the battery charger 100 may supply a
a desulfation mode . plurality of predetermined currents into the battery 104 and
Load Detection Cycle 600 .
FIG . 6 shows an exemplary load detection cycle 600 forOp 10 detect/monitor the results . This is possible for a number of
use in the battery charger 100 . A substantial voltage drop decrease. First
reasons
as
, the value of the voltage difference (AV ) will
the battery 104 starts to accept a charge . Second ,
across the battery 104 indicates that an engine coupled to the the value of the voltage difference (AV ) changes as a
battery 104 is attempting to start . Therefore , throughout a function of the amount of current being put into the battery
charging cycle, the processor 128 may perform the load 15 104 by the battery charger 100 . By passing a plurality of
detection cycle 600 in a loop to dynamically monitor the different predetermined currents into the battery 104 , the
battery 104 until a drop is detected at step 602, otherwise the battery charger 100 can dynamically monitor and record the
load detection cycle 600 proceeds to step 610 , where the voltage response ( e . g ., the AV ) in the random access
battery charger 100 continues its current charging mode . memory 120 at step 704 . Using the voltage response, the
At step 602, a drop in voltage indicates to the processor 20 processor 128 can generate a database of data comparing the
128 that an engine coupled to the battery 104 is starting or current passed to the battery vs . the AV. Using this database ,
attempting to start . If a drop in voltage is detected at step the processor 128 can dynamically monitor the trend to
602 , the load detection cycle 600 proceeds to step 604 . At determine whether the battery 104 is accepting a charge . If
step 604 , a predetermined external load is applied to the the processor 128 determines that the battery 104 is not
battery 104 . The processor 128 will then record the lowest 25 accepting a charge , the display device 114 may be enabled
battery voltage during the remainder of the engine-starting to display ( e . g ., in addition to a bad battery condition ) that
phase . If, during this phase , the battery 104 voltage drops the battery 104 is not expected to start the engine / vehicle at
below a predetermined value, then the battery 104 is deemed step 718 .
to have a low SoH and the display device 114 will indicate At step 708 , the battery charger 100 determines the
as such ( e. g ., displace a bad battery indicator ). For example , 30 capacity of the battery 104 . If the processor 128 determines
for a nominally 12 - volt battery , if the voltage drops below 7 that the capacity is below a predetermined capacity thresh
volts during this phase at step 606 , the battery 104 is deemed old , the display device 114 may be enabled to display that
to have a low SoH . The processor 128 will recognize the low the battery 104 is not expected to start the engine/vehicle at
SoH , and output to the display device 114 that the battery step 718 .
104 is bad at step 614 and the charging operation or mode 35 At step 710 , the battery charger 100 determines the
may be aborted . internal resistance of the battery 104 . If the processor 128
If the voltage drops remains at or above 7 volts at step determines that the resistance is below a predetermined
606 , the process continues to step 608. At step 608 , the capacity threshold , the display device 114 may be enabled to
processor 128 compares the current voltage of the battery to display ( e. g., in addition to a bad battery condition ) that the
the voltage of battery before ignition attempt ( e . g ., the last 40 battery 104 is not expected to start the engine/vehicle at step
stored voltage). If the current voltage is less than the voltage 718 .
before the sudden drop at step 608, then the external load is At step 712 , the battery charger 100 determines the
reapplied at step 604 and the battery test is repeated . If the number of times an attempt has been made to start the
current voltage is greater than or equal to the voltage before vehicle , whereby each ignition or ignition attempt causes the
the sudden drop at step 608 , the battery charging process 45 counter to increment by one at step 720 .
continues at step 610 , where the battery charger 100 con - At step 714, the battery charger 100 analyzes the wave
tinues (or returns to its current charging mode . Upon form during starting. For example, the processor 128 can
returning to the charging mode at step 610 , the battery compare two or more ignition waveforms ( e .g ., two con
charger 100 dynamically measures and records battery volt- secutive ignition attempts ) to compare the valley voltage of
age at step 612 until a drop in voltage is detected to indicate 50 each waveforms. In addition , the consecutive starts will also
at step 602 that an engine coupled to the battery 104 is help to recover some of the battery capacity . The minimum
starting or attempting to start . voltage required before either the starter solenoid or elec
Battery Engine -Start Detection Cycle 700 . tronic ignition of the vehicle drops out is typically 6 volts .
In addition to , or in lieu of, the forgoing battery SoH For example, if during a start attempt, the valley voltage
determination and display methods, the display device 114 55 drops below the 7 .2 -volt threshold or the percentage differ
may display whether a battery is sufficiently charged and /or ence between the two consecutive is greater than 5 % , the
in a sufficient SoH such that it can start a vehicle. Accord battery SoH is determined to be below 60 % and the display
ingly, the display device 114 may be configured to provide device 114 may be enabled to display (e. g., in addition to a
an indication ( e. g., icons, words, etc.) that the battery 104 is bad battery condition ) that the battery 104 is not expected to
not expected to start an engine based at least in part on the 60 start the engine /vehicle at step 718 .
SoC and/or SoH of the battery 104 . FIG . 7 shows an At step 716 , thebattery charger 100 is configured to apply
exemplary battery engine -start detection cycle 700 for use in a micro load ( e . g ., approximately 80 to 250 A ) for a
the battery charger 100 or other device ( e.g . vehicle , battery predetermined timeframe ( e.g ., 1 to 10 milliseconds, more
monitor, etc .). Upon startup at step 702 , the processor 128 preferably 2 to 7 milliseconds, most preferably 3 to 5
may cycle through one or more steps to determine whether 65 milliseconds). An analysis of the voltage response can be
the battery 104 is capable of starting an internal combustion used to indicate the ability of the battery 104 to start the
engine . vehicle .
 US 10 ,446 ,885 B2
31 32
At step 718 , the battery charger 100 is configured to features , and the like, these are not intended to exhaust all
enable the display device 114 to display that the battery 104 possible arrangements or features, and indeed many other
is not expected to start the engine / vehicle at step 718 . For embodiments , modifications, and variations will be ascer
example, the display device 114 may display an icon ( e. g., tainable to those of skill in the art. Thus, it is to be
an engine graphic with a slash or X mark ) or phrase ( e . g ., No 5 understood that the teachings of the subject disclosure may
Engine Start) . therefore be practiced otherwise than as specifically
In another example , the battery charger 100 may apply a described above .
test load to the battery 104 and then record the response of what is claimed is :
the battery 104 (to the test load ) in the random access 1. A battery charger for identifying a bad battery , the
memory 120 . The processor 128 can then compare the 10 battery charger comprising :
response to the test load to predetermined load responses a processor operatively coupled with a voltage sensor;
stored in either the data storage 122 or the read only memory a non -transitory memory device operatively coupled with
118 . The load applied to the battery 104 is a percentage to the processor,
the current required to start a vehicle . Measuring the corre a power management device to receive an input power
sponding voltage drop and multiplying that by the percent- 15 and to output a charging current during a charging
age gives the expected drop during that actual engine start. process ;
If that value is below the nominal required voltage, the a display device electrically coupled to the processor,
battery SoH is determined to be below 60 % and the battery wherein the display device is configured to display a
104 should be replaced . Based on this comparison , the bad battery indicator ; and
processor 128 can identify the battery type . In another 20 a pair of electrical conductors to electrically couple with
example , a voltage may be applied to the battery 104 in a lead acid battery , wherein , to determine and display
series with a known resistance to form a voltage divider whether the lead acid battery has a low state ofhealth ,
circuit . The voltage across the battery 104 may then be the battery charger is configured to :
measured to determine the impedance of the battery 104 . measure, using the voltage sensor, a first battery voltage
Different batteries types have different impedances values, 25 of the lead acid battery connected across the pair of
and the processor 128 can determine the battery type by electrical conductors ;
comparing the calculated impedance to values stored in the compare , using the processor, the first battery voltage to
read only memory 118 and /or the data storage 122 . a first predetermined voltage value stored to the
As discussed above , in some embodiments , the battery non - transitory memory device ;
charger 100 may be configured to charge or start (a / k / a 30 measure , if the first battery voltage is less than the first
" boost" , " jump" , or " jump start" ) an engine coupled to a predetermined voltage value , a second battery volt
battery . When starting an engine coupled to a battery, if the age of the lead acid battery using the voltage sensor
battery 104 voltage drops below a certain threshold voltage , after a first period of time;
there is an indication that the battery 104 is deemed to have compare the second battery voltage to a second prede
a low SoH . Accordingly , if the battery 104 is considered 35 termined voltage value stored to the non -transitory
insufficient for starting the vehicle 's engine , the processor memory device ;
128 may automatically initiate a jump- startmode to provide instruct the display device to display the bad battery
jump -starting functionality . In the jump - start mode , the indicator if the second battery voltage is greater than
battery charger 100 may use one or more of the auxiliary or equal to the second predetermined voltage value ;
power source 108 , the linear transformer , and/ or the 40 and
switched mode transformer to provide additional current to abort the charging process if the second battery voltage
jump -start the vehicle . is greater than or equal to the second predetermined
While the various battery monitoring and battery testing voltage value.
techniques disclosed herein are described in connection with 2 . The battery charger of claim 1 , wherein the processor
a battery charger to charge the battery , one of skill in the art 45 is further configured to commence a desulfation process if
would appreciate that one of more of the features , tech - the second battery voltage is greater than or equal to the
niques , etc . may be embodied in other devices. The other second predetermined voltage value .
devices may be include, inter alia , the vehicle itself (i.e ., 3. The battery charger of claim 1, wherein the processor
integral with one or more the onboard vehicle systems), a is further configured to measure a third battery voltage of the
monitoring-only device ( e. g., battery charger 100 without 50 lead acid battery connected across the pair of electrical
charging capability ), portable battery jump starters (e. g ., conductors after a second period of time if the second battery
having an internal power source), etc. In certain aspects , for voltage is greater than or equal to the second predetermined
example , the various battery monitoring and battery testing voltage value.
techniques may be implemented as a pass through device 4 . The battery charger of claim 3, wherein the processor
that couples with a battery charger. For example, the pass 55 is further configured to compare the third battery voltage to
through device may couple to the battery and received the second predetermined voltage value , and wherein the
ved
power from , and optionally send instructions (e. g., as feed processor is further configured to instruct the display device
back ) to , a battery charger. to not display the bad battery indicator if the third battery
The above -cited patents and patent publications are voltage is less than or equal to the second predetermined
hereby incorporated by reference in their entirety . Where a 60 voltage value .
definition or the usage of a term in a reference that is 5 . The battery charger of claim 3 , wherein the processor
incorporated by reference herein is inconsistent or contrary is further configured to compare the third battery voltage to
to the definition or understanding of that term as provided the second predetermined voltage value, and wherein the
herein , the meaning of the term provided herein governs and processor is further configured to instruct the display device
the definition of that term in the reference does not neces - 65 to display the bad battery indicator if the third battery
sarily apply. Although various embodiments have been voltage is less than the second predetermined voltage value
described with reference to a particular arrangementof parts, and lack of progress is detected .
 US 10 ,446 ,885 B2
33 34
6 . The battery charger of claim 3, wherein the processor 11. The battery charger of claim 7 , wherein the battery
is further configured to compare the third battery voltage to charger is further configured to supply the third current to
the second predetermined voltage value , and wherein the the lithium battery if a measured battery voltage drops below
processor is further configured to instruct the display device a fourth predetermined voltage value.
to display the bad battery indicator if the third battery 5 12 . The battery charger of claim 11, wherein the lithium
voltage is less than the second predetermined voltage value battery is a nominal 12 - volt battery , and wherein the first
and a thermal runaway condition is detected . predetermined voltage value is between 5 .0 and 12 . 4 volts ,
7 . A battery charger for identifying a bad battery, the the second predetermined voltage value is between 8 . 0 and
battery charger comprising: 12 . 0 volts , the third predetermined voltage value is between
a processor operatively coupled with a voltage sensor; 10 14 . 0 and 15 .0 volts, and the fourth predetermined voltage
a non -transitory memory device operatively coupled with value is between 12 . 5 and 13 . 5 volts .
the processor; 13. The battery charger of claim 12, wherein the lead acid
a power management device to receive an input power battery is a nominal 12 - volt battery and the first predeter
mined voltage value is between 12 .0 and 12 . 4 volts .
and to output current during a charging process ; 15 14 . The battery charger of claim 12. wherein the lead acid
a display device electrically coupled to the processor, battery is a nominal 12 - volt battery and the second prede
wherein the display device is configured to display a termined voltage value is between 14.0 and 16 .0 volts .
bad battery indicator; and 15 . The battery charger of claim 7 , wherein the battery
a pair of electrical conductors to electrically couple with charger is further configured to display a bad battery indi
a lithium battery, wherein , to determine and display 20 cator via a display device on the battery charger if the
whether the lithium battery has a low state ofhealth , the processor aborts the charging process .
battery charger is configured to : 16 . The battery charger of claim 7 , wherein the battery
measure , using the voltage sensor , a first battery voltage charger is further configured to display a bad battery indi
of a lithium battery connected to the battery charger cator via a display device on the battery charger if the third
across the pair of electrical conductors ; 25 battery voltage is less than the second predetermined voltage
compare , using the processor, the first battery voltage to value after the second period of time.
a first predetermined voltage value stored to the 17 . A battery charger for identifying a bad battery, the
memory device; battery charger comprising:
supply, using the power management device , a first a processor operatively coupled with a voltage sensor;
current from the battery charger to the lithium bat - 30 a non - transitory memory device operatively coupled with
tery for a first period of time if the first battery the processor;
voltage is less than the first predetermined voltage a power management device to receive an input power
value; and to output current during a charging process;
measure, using the voltage sensor, a second battery a display device electrically coupled to the processor,
voltage of the lithium battery during the first period 35 wherein the display device is configured to display a
of time; bad battery indicator; and
compare , using the processor, the second battery volt a pair of electrical conductors to electrically couple with
age to a second predetermined voltage value stored a lithium battery , wherein , to determine and display
to the memory device ; whether the lithium battery has a low state ofhealth , the
supply , using the power management device , a second 40 battery charger is configured to :
current from the battery charger to the lithium bat determine a state of charge for a lead acid battery
tery if the second battery voltage is ( 1 ) greater than connected across the pair of electrical conductors ;
the first predetermined voltage value and ( 2 ) less measure , using the voltage sensor, a first battery voltage
than the second predetermined voltage value ; of the lead acid battery ;
measure , using a voltage sensor , a third battery voltage 45 measure , using the voltage sensor, a second battery
of the lithium battery after a second period of time; voltage of the lead acid battery after a first period of
compare, using the processor, the third battery voltage time;
to a second predetermined voltage value ; calculate , using the processor, a first rate of change for
abort the charging process if the third battery voltage is the first period of time;
less than the second predetermined voltage value 50 display a bad battery indicator via the display device if
after the second period of time; and the first rate of change is greater than or equal to a
supply a third current to the lithium battery if the third first predetermined rate of change value stored to the
battery voltage is ( 1 ) greater than the second prede non - transitory memory device ; and
termined voltage value and ( 2 ) less than a third abort the charging process if the first rate of change is
predetermined voltage value. 55 greater than or equal t the first predetermined rate of
8 . The battery charger of claim 7, wherein the battery change value.
charger is further configured to enter a maintenance mode if 18 . The battery charger of claim 17 , wherein the first
the third battery voltage is greater than or equal to the third predetermined rate of change value is a function of the state
predetermined voltage value . of charge for the lead acid battery .
9 . The battery charger of claim 7 , wherein the mainte - 60 19 . The battery charger of claim 17 , wherein the battery
nance mode includes periodically supplying a fourth current charger is further configured to measure a third battery
to the lithium battery . voltage of the lead acid battery after a second period of time.
10 . The battery charger of claim 9, wherein the first 20 . The battery charger of claim 19 , wherein the battery
current is between 0 .01 and 0 .5 amps, the second current is charger is further configured to calculate , using the proces
between 0 .25 and 1 .0 amps, the third current is between 1.0 65 sor, a second rate of change for the second period of time.
and 3 .0 amps, and the fourth current is between 0 . 1 and 0 . 3 21 . The battery charger of claim 20 , wherein the battery
amps. charger is further configured to display the bad battery
 US 10 ,446 , 885 B2
35 36
indicator via the display device if the second rate of change
is greater than or equal to a second predetermined rate of
change value , wherein the second predetermined rate of
change value is a function of the state of charge for the lead
acid battery and wherein the second predetermined rate of 5
change value is not equal to the first predetermined rate of
change value.