The invention relates to battery testing. Certain embodiments of the invention relate to testing lead-acid batteries.
Batteries are used to supply electricity in a wide range of applications. In the automotive field, batteries are used to supply power for vehicle systems which may include engine starting, lighting, electronic accessories, propulsion, control systems and the like. Newer vehicles include an increasing number of systems that require electricity for operation. Some, such as electronically controlled braking systems and electronic engine control systems, are vital to safe vehicle operation.
Where a critical system is powered by a battery then it can be important to monitor the state of the battery. Battery testing systems are used to evaluate the state of charge (SoC) of batteries as well as the condition (sometimes referred to as the state of health (SoH)) of batteries. Battery testing systems typically monitor electrical characteristics of batteries. For example, some such systems monitor the impedance of a battery at various frequencies.
A problem with many existing battery testing systems is that the systems are not accurate, especially for batteries that are not new. Such systems can yield estimates of a battery's state of charge that are inaccurate.
There is a need for accurate systems and methods for monitoring the state of batteries.
The appended drawings illustrate non-limiting embodiments of the invention.
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
Apparatus and methods according to this invention measure battery state based on changes in the magnetic susceptibility of battery components. The battery component may comprise an electrode of the battery that undergoes a chemical change as the battery is charged or discharged.
The chemical composition of at least one of electrodes 14 changes as the battery is charged and discharged. Consider, for example, the case where battery 12 is a lead-acid battery. In a lead acid battery electrode 14B comprises a lead anode and electrode 14A comprises a lead dioxide cathode. Electrolyte 15 is an acid electrolyte.
During discharge, the following half reaction occurs at anode 14B:
Pb+HSO4−→PbSO4+H++2e− (1)
And the following half reaction occurs at cathode 14A:
Pb2++SO42−→PbSO4 (2)
During charging, the reactions at each electrode are reversed. What is of interest is that the chemical composition of each electrode changes as the battery is charged and discharged.
Apparatus 10 exploits changes in the magnetic susceptibility of an electrode 14, which correspond to the chemical changes in the electrode 14, to derive information indicative of the state of battery 12. For example, apparatus 10 may derive information indicative of the state of charge of battery 12. Magnetic susceptibility is a measure of the degree to which a material becomes magnetized in response to an applied magnetic field.
Lead has a magnetic susceptibility of −23×10−6 in cgs units while lead sulfate has a magnetic susceptibility of about −70×10−6. Thus, as battery 12 is discharged and the ratio of lead sulfate to lead in anode 14B increases, the magnetic susceptibility of anode 14B also increases (i.e., anode 14B become more diamagnetic, and will exhibit greater magnetization in response to a given applied magnetic field). Similarly, as battery 12 is charged, the ratio of lead sulfate to lead in anode 14B decreases and the magnetic susceptibility of anode 14B decreases (i.e., anode 14B become less diamagnetic, and will exhibit less magnetization in response to a given applied magnetic field). Thus, the magnetic susceptibility of anode 14B can be correlated to the state of charge of battery 12. The magnetic susceptibility of cathode 14A also changes with the state of charge of battery 12 but the changes at cathode 14A are smaller than the changes in magnetic susceptibility of anode 14B because the difference between the magnetic susceptibilities of lead dioxide and lead sulfate is smaller than the difference between the magnetic susceptibilities of lead and lead sulfate.
In the embodiment of
Controller 20 may comprise a programmed data processor, logic circuits or the like. In some embodiments, controller 20 comprises a calibration function that associates values of signal 19 with values indicative of battery state of charge. The calibration function may comprise a look-up table, a set of one or more parameters of an equation relating values of signal 19 to the state of charge of battery 12 or the like.
In some embodiments, conductor 37 is patterned on a circuit board. Conductor 37 may, for example, comprise a spiral patterned on a circuit board. The circuit board may have multiple layers each patterned with a conductor such that magnetic fields generated by current passing through the conductors of each layer reinforce one another. In other embodiments, conductor 37 may comprise one or more coils of fine wire.
Current source 35 may provide a current 36 that is time-varying such that the magnetic field of conductor 37 is time varying. This may cause signal 19 to be time-varying. Controller 20 may use the time variations in signal 19 to reject noise. The noise will not vary with time in the same way as current 36. In the example embodiment illustrated in
where:
If there is a material at point X then the magnetic field from current loop 40 will induce magnetism in the material. The magnitude, M, of the magnetization of the material depends upon the magnetic susceptibility of the material and the strength of the field B0. The magnetic field at a point away from point X will be perturbed by the magnetization of the material at point X. Therefore, changes in the magnetic susceptibility of material in the vicinity of point X can be monitored by measuring changes in the magnetic field at a location away from point X. The magnetic field could be measured, for example, in the plane of current loop 40. In some embodiments, magnetic field detector 34 is located substantially in the plane of current loop 40 inside current loop 40, for example at the center of current loop 40.
In the embodiment illustrated in
Sensor 44 has a sensitivity sufficient to detect changes in the magnetic field resulting from changes in the susceptibility of the material of an adjacent electrode 14B. Sensor 44 may optionally comprise a flux concentrator to amplify the magnetic field to be detected. In some embodiments, sensor 44 comprises a magnetic tunnel junction (MTJ). Such sensors are available, for example, from Micro Magnetics Inc. of Fall River Mass., USA. Magnetic field sensors based on a MTJ are described in:
A simple MTJ comprises two layers of magnetic material separated by a very thin insulating film. If a voltage is applied across this structure and the insulating layer is thin enough, electrons can flow by quantum mechanical tunnelling through the insulating film. For tunnelling between two magnetized materials, the tunnelling current is maximum if the magnetization directions of the two materials are parallel and minimum if they are aligned antiparallel. Therefore, the tunnelling current, and thus the resistance of the device, will change as external magnetic fields alter the relative magnetic orientations of the layers of magnetic material.
Other magnetic sensors that are sensitive enough to detect changes in the magnetic field resulting from changes in the magnetic susceptibility of battery components may also be used. For example, magneto-electric sensors may be applied. Magnetic field sensors based in the giant magnetoelectric effect are described, for example, in:
Other sensitive magnetic field sensors that may have application in some embodiments include:
Nguyen Van Dau F., Magnetic sensors for nanotesla detection using planar Hall effect, Sensors and actuators. A, 1996, vol. 53, no 1-3, pp. 256-260.
The sensitivity required for magnetic field sensor 50 will depend on factors including: the strength of the magnetic field generated by magnetic field source 32; the geometries of magnetic field source 32 and magnetic field sensor 50; the geometry of the electrode 14 in which chemical changes occur; and the distances between magnetic field source 32, magnetic field sensor 50, and the electrode 14.
In some embodiments, the frequency of electrical current source 35 is variable. Such embodiments may obtain additional information regarding a battery by monitoring magnetic susceptibility of a battery component at two or more different frequencies. The depth of penetration of a magnetic field into a material decreases as frequency increases. The penetration depth is approximated by the skin depth given by:
where: ζ is the skin depth; μ, is the magnetic susceptibility of the material; θ is the electrical conductivity of the material and f is the frequency. At 10 kHz, ζ is about 2 mm in some materials of interest. By making measurements using magnetic fields which fluctuate at different frequencies (e.g. by varying the frequency of AC or pulsed DC current driving an electromagnet that generates a magnetic field), one can sense the degree to which chemical changes associated with charging or discharging a battery have occurred at different depths within an electrode of a battery.
In some embodiments, a tester according to the invention measures magnetization of an electrode of a battery under test in response to magnetic excitation at two or more frequencies and bases a determination of the state of charge of the battery on the measured magnetization at each of the two or more frequencies. Measurements at different frequencies may be made at different times or at the same time. Obtaining the measure of state of charge may comprise, for example taking an average or weighted average of values obtained for the two or more frequencies of magnetic excitation.
Some embodiments comprise a control system configured to adjust a frequency of magnetic excitation to a frequency that suits a particular battery. This may be done, for example, by varying the frequency to at least approximately identify a transition frequency that is the highest frequency at which the magnetic field fully penetrates the electrode being monitored. The transition frequency may be identified, for example, by sweeping the frequency down from a high frequency and determining the frequency at which the detected magnetism exhibits characteristics that indicate that the magnetic field of electrolyte on a far side of the electrode is being detected.
Some embodiments provide a sensor assembly that comprises a substrate that is attachable to a case of a battery and, supported on the substrate, some or all of:
Alternative embodiments differ from the example apparatus described above in various ways. For example:
In some embodiments, multiple magnetic fields induced in the component are measured. In such embodiments, different magnetic fields (e.g. magnetic fields having different intensities, different polarizations or different time variations may be used for some or all of the multiple measurements. In such embodiments, block 88 determines whether data collection is complete. If not, method 80 repeats blocks 82, 84 and 86 to obtain an additional measurement as indicated by path 89.
When data collection is complete (YES result from block 88) method 80 proceeds to block 90 which determines the state of the battery from the collected data. The state determined in block 90 may comprise the State of Charge of the battery. In block 92 the state of charge is compared to a threshold. If the comparison indicates that the battery is charged sufficiently then method 80 proceeds to block 93 and waits until an appropriate time to measure the state of the battery again. If block 92 determines that the state of charge of the battery is lower than some threshold then one or more appropriate actions are taken in block 94 due to a threshold being exceeded and then method 80 proceeds to block 95 and waits until an appropriate time to measure the state of the battery again.
The invention may be embodied in a range of ways including, without limitation:
Certain implementations of the invention comprise computer processors which execute software instructions which cause the processors to perform a method of the invention. For example, one or more processors in a battery tester may implement methods for determining the state of charge of batteries based on measured induced magnetic fields by executing software instructions in a program memory accessible to the processors. The invention may also be provided in the form of a program product. The program product may comprise any medium which carries a set of computer-readable instructions which, when executed by a data processor, cause the data processor to execute a method of the invention. Program products according to the invention may be in any of a wide variety of forms. The program product may comprise, for example, magnetic data storage media including floppy diskettes, hard disk drives, optical data storage media including CD ROMs, DVDs, electronic data storage media including ROMs, flash RAM, or the like. The computer-readable signals on the program product may optionally be compressed or encrypted.
Where a component (e.g. a software module, processor, assembly, device, circuit, sensor, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a“means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.
This application claims priority from U.S. patent application No. 61/059,151 filed on 5 Jun. 2008 and entitled: METHODS AND APPARATUS FOR BATTERY TESTING. For purposes of the United States, this application claims the benefit of application No. 61/059,151 under 35 U.S.C. §119.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/CA09/00777 | 6/5/2009 | WO | 00 | 11/26/2010 |
| Number | Date | Country | |
|---|---|---|---|
| 61059151 | Jun 2008 | US |