Battery testers for modern batteries
With the demand for batteries rapidly growing, battery manufacturing may be outpacing the supply of suitable equipment to test them. This void is apparent in the mobile phone market where large quantities of batteries are being returned under warranty. Many are discarded without first checking or attempting to restore them. The dealers are simply not equipped to handle the influx of returned batteries, neither is the staff trained to perform this task on a customer service level. Testing and restoring batteries ( Dell Inspiron 6400 battery ) has become a complex procedure that lies outside the capabilities of most customer service clerks.
With the move to maintenance-free batteries and the need to test larger volumes of batteries, battery test equipment is shifting to quick testing and boosting. In this article we examine the duty of the modern charger and battery (Sony VGP-BPS9 battery)analyzer, and observe how well these units satisfy the current demands.
Conditioning ChargersCharging batteries is often not enough, especially when it comes to nickel-based chemistries. Periodic maintenance is needed to optimize battery life. Some innovative manufacturers offer chargers with conditioning features. The most basic models provide one or several bays with discharge capability. More advanced chargers include a display to reveal the battery capacity. Discharging lithium-based batteries for the purpose of prolonging life is neither necessary, nor advisable.
Some chargers offer pulse charge methods. This is done to improve charge efficiency and reduce the memory phenomenon on nickel-based batteries. Improved charge performance is achieved by using a pulse charge that intersperses discharge pulses between charge pulses. Commonly referred to as ‘burp’ or ‘reverse load’ charge, this method promotes high surface area on the electrodes and helps recombine the gases generated during charge. Pulse charging benefits mainly Nickel-based batteries (HP Pavilion TX1000 battery).
Some manufacturers claim that the pulse charge method conditions and restores NiCd batteries and makes the periodic discharges redundant. Research carried out by the US Army has revealed that pulse charging does indeed reduce the crystalline formation on the NiCd battery. If properly administered, batteries charged with these pulse chargers prolong service life. For batteries with advanced memory, however, a full discharge or recondition cycle is needed to break down the more stubborn crystalline formation.
Battery AnalyzersThere are two types of battery analyzers: the fixed current units and the programmable devices. While fixed current units are less expensive and generally simpler to operate, programmable analyzers are more accurate and faster. Programmable units can better adapt to different battery needs and are more effective in restoring weak batteries .
Fixed current analyzers perform well in organizations that use medium size batteries ranging from 600mAh to 1500mAh. If smaller or larger batteries are serviced, the charge and discharge currents are compromised and the program time is prolonged. Here is the reason why.
A fixed current battery analyzer with a charge and discharge current of 600mA, for example, services a 600mAh battery in about three hours, roughly one hour for each cycle starting with charge, followed by discharge and a final charge. Servicing an 1800mAh battery would take three times as long. A very small batteries, say a 400mAh, may not be capable of accepting a charge rate that is higher than 1C and the battery (VGP-BPL8 ) could sustain damage.
When purchasing a battery analyzer, there is a tendency to buy on price. With the need to service a larger volume of batteries of a wider variety, second-generation buyers find the advanced features on upscale models worth the extra cost. These features manifest themselves in reduced operator time, increased, throughput, simpler operation and the use of less trained staff. Adaptation to new battery systems is also made easier. Figure 1 illustrates an advanced battery (HP Pavilion DV9000 battery )analyzer made by Cadex Electronics.
An advanced battery analyzer evaluates the condition of a battery and implements the appropriate service to restore the battery’s performance. On nickel-based systems, a recondition cycle is applied automatically if a user-selected capacity level cannot be reached.
Battery chemistry, voltage and current ratings are user-programmable. These parameters are stored in interchangeable battery adapters and configure the analyzer to the correct function when the adapter is installed. In the Cadex 7000 Series battery (SONY VGN-FZ battery )analyzers, for example, each adapter is preprogrammed with up to ten distinct configuration codes (C-codes) to enable service for all batteries with the same footprint.
Battery-specific adapters are available for all major batteries; user-programmable cables with alligator clips accommodate batteries for which no adapter is on hand. Batteries with shorted, mismatched or soft cells are identified in minutes and their deficiencies are displayed on the LCD panel.
User‑selectable programs service different battery needs. In the case of the Cadex 7000 Series, Primeprepares a new battery for field use and Auto tests and reconditions weak batteries. Custom allows the setting of unique cycle sequences composed of charge, discharge, recondition, trickle charge or any combination, including rest periods and repeats.
Many battery analyzers are capable of measuring the internal battery resistance. Obtained in only a few seconds, the resistance reading works well with lithium-based batteries because the level of cell resistance is in direct relation to the performance. Internal resistance readings can also be used for nickel-based batteries, however, the readings do not accurately disclose the battery’s condition.
More accurate methods are achieved by using quick test programs. The CadexQuicktest™ is based on fuzzy logic and lasts about three minutes. Good results are achieved with three learn cycles taken from batteries of different SoH readings. The matrices from the learn cycles are stored in the adapters. Most battery adapters are equipped with the matrices when purchased.
New requirements of battery( Pavilion DV9000 battery ) analyzers are the ultra-fast charge and quick prime features. When a battery is inserted, the analyzer evaluates the battery, applies an ultra-fast charge if needed, and prepares the battery for service within minutes. Such a feature helps the mobile phone industry to handle the large number of warranty return batteries. With the right equipment, many of these presumably faulty batteries can be jump-started and given back to the customer instead of being replaced.
To accurately test batteries that power digital equipment, modern battery analyzers are capable of discharging a battery under a simulated digital load. The GSM waveform, for example, transmits voice data in 567 ms bursts with currents of 1.5A and higher. By simulating these pulses, the performance of a battery can be tested under these field conditions. Not all analyzers are capable of simulating such short current bursts. Instead, medium-priced battery analyzers use lower frequencies.
Another application involving uneven load demand is the so-called 5‑5‑90 program used to simulate the runtime of analog two-way radios. The battery is loaded 5 percent of the time on transmit, 5 percent on receive and 90 percent on standby. Other combinations are 10-10-80. Each stage can be programmed to the appropriate discharge current. Because of the complex load conditions, calculating the predicted runtime in the absence of a battery analyzer would be difficult.
Easy operation is an important attribute of any battery (Thinkpad T43p battery) analyzer. Displaying the battery capacity in percentage of the nominal capacity rather than in milliampere-hours (mAh) is preferred by many. With the percentage readout, the user does not need to memorize the ratings of each battery tested because this information is stored in the system. The percentage readout allows an added level of automation by implementing a recondition cycle if the set target capacity level cannot be reached.
Some analyzers are capable of setting the appropriate battery parameters automatically when a battery is inserted. An intelligent battery adapter reads a passive code that is imbedded in most batteries. The code may consist of a jumper, resistor or specified thermistor value. Some battery packs contain a memory chip that holds a digital code. On recognition of the battery, the adapter assigns the correct service parameters. Automatic battery identification minimizes training and allows battery service by untrained staff.
Most analyzers are capable of printing service reports and battery labels. This feature simplifies the task of keeping track of batteries. Marking batteries with the service date reminds the user when a battery is due for service. Labeling works well because the basic service history is available where it is needed most — on the battery.
A battery analyzer should be automated and require minimal operator time. His or her task should be limited to scheduling incoming batteries for testing, marking the batteries (VGP-BPS8 ) after service, and replacing those that did not meet the performance criteria. Occasional selection of the correct current rating and chemistry may also be necessary.