FIELD OF INVENTION
[001] The present invention relates to an apparatus for topping up deionized water in
wet cell battery in a calibrated manner. More particularly the present invention relates
to an improvement in wet cell electrolyte tester in which the reduction of the level of
the electrolyte of a wet cell battery below a predetermined level may be detected and
deionized water is filled up as per requirement.
BACKGROUND/ PRIOR ART OF THE INVENTION
[002] Lead acid batteries are the most commonly used type of wet cell battery in
photovoltaic systems and other applications. Although lead acid batteries have a low
energy density, only moderate efficiency and high maintenance requirements, they
also have a long lifetime and low costs compared to other battery types. One of the
major advantages of lead acid batteries is that they are the most commonly used form
of battery for most rechargeable battery applications (for example, in cranking car
engines), and therefore have a mature technology base.
[003] A lead acid battery consists of a negative electrode made of spongy or porous
lead. The lead is porous to facilitate the formation and dissolution of lead. The positive
electrode consists of lead oxide. Both electrodes are immersed in an electrolytic
solution of sulfuric acid and water. An electrically insulating, but chemically
permeable membrane separates the two electrodes. This membrane also prevents
electrical shorting through the electrolyte.
[004] The charging reaction converts the lead sulfate at the negative electrode to lead.
At the positive terminal the reaction converts the lead to lead oxide. As a by-product
of this reaction, hydrogen is evolved. During the first part of the charging cycle, the
conversion of lead sulfate to lead and lead oxide is the dominant reaction. However,
as charging proceeds and most of the lead sulfate is converted to either lead or lead

dioxide, the charging current electrolyzes the water from the electrolyte and both
hydrogen and oxygen gas are evolved, a process known as the "gassing" of the battery.
Water gets depleted through this process and electrolyte become more concentrated.
Which in turn reduces electrical power output and may further damage the cells. The
balance is restored by adding deionized water.
[005] Existing prior art such as “US6653843B2” discloses an apparatus for detecting
a reduction of a level of electrolyte in a wet cell battery includes an electrically
conductive sensing rod in contact with an electrolyte in a battery cell, a voltage
comparator connected to the rod for generating a first output signal when an input
voltage is greater than a reference voltage and generating a second output signal when
an input voltage is less than the reference voltage, and an indicator responsive to the
output signals for generating a green visual signal when the rod is immersed in the
electrolyte and generating a red visual signal when the rod is not immersed in the
electrolyte. The apparatus also includes an audio alarm device sounding an audio
indication when the red visual signal is generated. A sensing circuit can be connected
between the voltage comparator and a pair of battery voltage input terminals to
selectively connect the terminals to the comparator when a voltage of a battery
connected to the terminals exceeds a predetermined voltage level. In this patent a
method of detecting level of electrolyte is discussed but no provision for taking
corrective action if required.
[006] Another prior art such as “US4350885A”, discloses a battery hydrometer for
providing an analog electrical signal having a magnitude related to the specific gravity
of a battery electrolyte. The hydrometer includes a source of radiation for providing a
detectable beam of radiation and a piston member arranged to be submerged within
the electrolyte and to intercept and modulate the beam of radiation in response to the
specific gravity of the electrolyte. The piston member is suspended within the
electrolyte by a spring which exerts a compressive force upon the piston member

against which the electrolyte must act. The hydrometer further includes a radiation
detector aligned with the radiation source for providing an analog electrical signal
having a magnitude responsive to the modulated beam of radiation. In this patent a
method of detecting level of charge in battery but does not have capabilities to fill
water if required.
[007] It would therefore be advantageous to provide an apparatus for calibrated
filling of deionized water in a lead acid battery and provide the indication of the fluid
levels without spillage. Hence, the present invention has been introduced which can
serve the purpose efficiently for which it has been designed.
OBJECTS OF THE INVENTION
[008] It is therefore a principal object of the present invention is to develop an
apparatus for calibrated filling of deionized water in a lead acid battery to the precise
amount without spillage.
[009] Another object of the invention is to propose an improvement in wet cell
electrolyte tester in which the reduction of the level of the electrolyte of a wet cell
battery below a predetermined level is detected and deionized water is filled up as per
requirement.
[0010] These and other objects and advantages of the present subject matter will be
apparent to a person skilled in the art after consideration of the following detailed
description taken into consideration with accompanying drawings in which preferred
embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION

[0011] This summary is provided to introduce concepts relates to an apparatus for
topping up deionized water in wet cell battery in a calibrated manner.
[0012] The present invention relates to an electrolyte tester for detecting a reduction
of a level of electrolyte in a wet cell battery comprises an inlet nozzle that receives the
deionized water which is continuously supplied. An extruded tapered nozzle is
mounted in wet cell battery through an inspection hole. A pair of conductive probes to
measure level of electrolyte in the wet cell battery. A control valve is automated and
configured to adjust the flow of deionized water in battery after receiving feedback
from the conductive probes. A plurality of visual indicator being responsive for
generating visual alarm and configured to indicate level of water in battery. The
control valve senses the level of electrolyte in battery through longer probes, If the
level of electrolyte is below the longer probe, the control valve is fully opened and
generates the visual alarm through red visual indicator, such that the flow of water is
reduced if level of electrolyte reaches longer probe and the water continues to flow to
reach the smaller probe and the control valve is fully closed and visual alarm through
green visual indicator is generated.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0013] It is to be noted, however, that the appended drawings illustrate only typical
embodiments of the present subject matter and are therefore not to be considered for
limiting of its scope, for the invention may admit to other equally effective
embodiments. The detailed description is described with reference to the
accompanying figures. In the figures, a reference number identifies the figure in which
the reference number first appears. The same numbers are used throughout the figures
to reference like features and components. Some embodiments of system or methods
or structure in accordance with embodiments of the present subject matter are now

described, by way of example, and with reference to the accompanying figures, in
which:
[0014] FIG. 1 shows a front view of an electrolyte tester in accordance with the present
invention;
[0015] FIG. 2 shows a schematic view of probes of the electrolyte tester in accordance
with the present invention;
[0016] FIG. 3 shows a control valve in accordance with the present invention; and
[0017] FIG. 4 shows flow chart of a method for an electrolyte tester according to the
present invention.
[0018] The figures depict embodiments of the present subject matter for the purposes
of illustration only. A person skilled in the art will easily recognize from the following
description that alternative embodiments of the structures and methods illustrated
herein may be employed without departing from the principles of the disclosure
described herein.
DETAIL DESCRIPTION OF INVENTION WITH REFERENCE TO THE
DRAWINGS OF THE PREFERRED EMBODIMENTS
[0019] It should be appreciated by those skilled in the art that any block diagrams
herein represent conceptual views of illustrative systems embodying the principles of
the present subject matter. Similarly, it will be appreciated that any flow charts, flow
diagrams, state transition diagrams, pseudo code, and the like represent various
processes which may be substantially represented in computer readable medium and
executed by a computer or processor, whether or not such computer or processor is
explicitly shown.

[0020] While the present disclosure is susceptible to various modifications and
alternative forms, specific embodiment thereof has been shown by way of example in
the drawings and will be described in detail below. It should be understood, however
that it is not intended to limit the present disclosure to the particular forms disclosed,
but on the contrary the present disclosure is to cover all modifications, equivalents,
and alternative falling within the spirit and the scope of the present disclosure.
[0021] The terms "comprises", "comprising", or any other variations thereof,, are
intended to cover a non-exclusive inclusion, such that a setup, device or method that
comprises a list of components or steps does not include only those components or
steps but may include other components or steps not expressly listed or inherent to
such setup or device or method. In other words, one or more elements in a system or
apparatus proceeded by "comprises... a" does not, without more constraints, preclude
the existence of other elements or additional elements in the system or apparatus.
[0022] In the following detailed description of the embodiments of the disclosure,
reference is made to the accompanying drawings that form a part hereof, and in which
are shown by way of illustration specific embodiments in which the disclosure may be
practiced. These embodiments are described in sufficient detail to enable those skilled
in the art to practice the disclosure, and it is to be understood that other embodiments
may be utilized and that changes may be made without departing from the scope of
the present disclosure. The following description is, therefore, not to be taken in a
limiting sense.
[0023] The present invention is an innovative tool for filling deionized water in lead
acid batteries. An apparatus is developed for calibrated filling of deionized water in a
lead acid battery to the precise amount without spillage. An improvement in wet cell
electrolyte tester in which the reduction of the level of the electrolyte of a wet cell

battery below a predetermined level is detected and deionized water is filled up as per
requirement.
[0024] FIG. 1 shows a front view of an apparatus (100) in accordance with the present
invention. The apparatus (100) is an electrolyte tester comprises of a long hollow
nonreactive and electrically insulated pipe, along with a plurality of LED indicators
(3, 4). The apparatus (100) further comprises electronically regulated valve to control
flow of deionized water. The Deionized water is introduced through an inlet nozzle
(1), wherein continuous supply of water is provided. The other end of apparatus (100)
comprising of an extruded tapered nozzle (7), which is made up of electrically
insulated material, to avoid spillage of deionized water during filling of batteries. The
apparatus (100) also comprises of a pair of conductive probes (6a,6b) to measure level
of electrolyte in battery. The height of smaller probes (6a) are configured as per battery
manufacturer recommendation, to gauge max level of electrolyte in battery. The longer
probes (6b) are configured to detect current level of electrolyte in discharged battery.
The pair of conductive probes (6a, 6b) are connected to a control valve (2) through
conductive wires. Further the LED indicators (3, 4) are configured to indicate level of
electrolyte in battery. The control valve (2) is configured to adjust flow of deionized
water in battery after taking feedback from the pair of conductive probes (6a,6b). The
electrolyte tester (100) also comprises of an air vent (5) to allow discharge of air during
filling of batteries with deionized water.
[0025] FIG. 2 shows a schematic view of the pair of conductive probes (6a, 6b) of the
apparatus in accordance with the present invention. In an aspect of the invention the
controller valve (2) detects the present level of electrolyte in battery through longer
probes (6b) If the level of electrolyte is below longer probe (6b), the control valve (2)
is fully opened and visual alarm through red LED (3) is generated. As soon as level of
electrolyte reaches longer probe (6b), the flow of water is reduced.

[0026] In an aspect of the invention the developed apparatus (100) is made up of
hollow chemically stable but electrically insulated pipe, with the plurality of LED
indicators (3, 4). The apparatus (100) has singular electronically regulated valve to
control flow of the deionized water. The Deionized water is entered through the inlet
nozzle (1) and the other end is comprising of extruded tapered outlet nozzle (5), which
is made up of chemically stable and electrically insulated Material.
[0027] FIG. 3 shows a control valve (3) in accordance with the present invention. In
an aspect of the invention the water continues to flow in, till it reaches the smaller
probe (6a) and the control valve (2) is fully closed and visual alarm through green LED
(4) is generated.
[0028] In a preferred embodiment the apparatus (100) is designed as a tool for top up
of water in lead acid battery. The water top up tool is used for filling water in lead acid
battery which is easy to use, simple in design and also inexpensive. The apparatus
(100) eliminates water spillage during top up of the electrolyte by ensuring filling to
the precise and calibrated amount in all cells of the battery thereby improving
efficiency. The apparatus (100) is used to fill deionized water in batteries which are
not easily accessible and where visual inspection cannot be done.
[0029] FIG. 4 shows flow chart of a method (200) for electrolyte tester according to
the present invention. The method (200) comprises at least the following steps.
[0030] Step 202: Configuring an outlet nozzle (7) in wet cell battery through an
inspection hole.
[0031] Step 204: Level of electrolyte reaches the small probe (6a),

[0032] Step 206: Green LED (4) is switched on and the control (2) is closed and end
the process
[0033] Step 208: Level of electrolyte didn’t touch the small probe (6a) and If level of
electrolyte touches longer probe (6b),
[0034] Step 210: Red LED (3) is switched on and control valve (2) opens 25% and
refilling starts,
[0035] Step 212: If level of electrolyte not touched the longer probe (6b), then control
valve (2) opens fully and refilling starts and Red LED (3) is switched on.
APPLICATIONS
[0036] In an aspect of the invention in the Wet cell battery type, Lead–acid batteries
found application in a large number of diverse systems. Lead–acid batteries which
require frequent water top up as water in electrolyte tend to deplete while charging and
discharging cycle. Thus the apparatus (100) is designed as a tool for top up of water
in lead acid battery.The Lead–acid batteries used in the automotive industry for
starting motors and for powering electrical equipment, such as taillights, windows, and
displays. Other applications include PV energy storage, standby energy storage
(particularly for providing backup emergency power and uninterrupted power supply
for critical equipment), and transportation devices such as underground mining lifts,
underwater submarines (particularly for silent maneuverability when submerged), and
small electrically powered cars and trucks. Lead–acid batteries constitute
approximately 40% of the world's total battery sales, to their well-developed and
robust technology and significant cost advantage.
WORKING OF THE APPARATUS (100)

[0037] Referring to FIG. 1, in the apparatus (100), the length of smaller probe is
adjusted according to recommendation of battery manufacturer (maximum level of
electrolyte in battery) if the current level of electrolyte in battery, touches the smaller
probe (6a), visible signal through green LED (4) is generated and control valve remain
in close state. This indicates that level of electrolyte in battery is satisfactory and no
topping of deionized water is required.
[0038] In another aspect of the invention, if level of electrolyte is not up to smaller
probe (6a) but touches the longer probe (6b), the control valve (2) is opened partially
(25 %) and Red LED (3) is switched ON, and refilling starts till level of electrolyte
touches smaller probe (6a).
[0039] In another aspect of the invention, if level of electrolyte in battery is too low
and does not touches both smaller probes and longer probes, control valve is opened
100% and visible alarm through RED LED (3) is generated till electrolyte is filled up
to small probe(6a).
TECHNICAL ADVANTAGES
[0040] The present disclosure proposes an apparatus for detecting a reduction of a
level of electrolyte in a wet cell battery which is portable and used to inspect wet cell
batteries in tight spots, where physical inspection is not possible.
[0041] The present disclosure proposes an apparatus which has the capability to refill
electrolyte up to manufacturer recommendation. The spillage of water during refilling
of wet cell batteries can be avoided by use of this tool
[0042] It should be noted that the description and figures merely illustrate the
principles of the present subject matter. It should be appreciated by those skilled in the
art that conception and specific embodiment disclosed may be readily utilized as a

basis for modifying or designing other structures for carrying out the same purposes
of the present subject matter. It should also be appreciated by those skilled in the art
that by devising various arrangements that, although not explicitly described or shown
herein, embody the principles of the present subject matter. Furthermore, all examples
recited herein are principally intended expressly to be for pedagogical purposes to aid
the reader in understanding the principles of the present subject matter and the
concepts contributed by the inventor(s) to furthering the art and are to be construed as
being without limitation to such specifically recited examples and conditions. The
novel features which are believed to be characteristic of the present subject matter,
both as to its organization and method of operation, together with further objects and
advantages will be better understood from the following description when considered
in connection with the accompanying figures.
[0043] These and other advantages of the present subject matter would be described
in greater detail with reference to the following figures. It should be noted that the
description merely illustrates the principles of the present subject matter. It will thus
be appreciated that those skilled in the art will be able to devise various arrangements
that, although not explicitly described herein, embody the principles of the present
subject matter and are included within its scope. The present invention will now be
described more specifically with reference to the following specification.
[0044] It should be noted that the description and figures merely illustrate the
principles of the present subject matter. It should be appreciated by those skilled in the
art that conception and specific embodiment disclosed may be readily utilized as a
basis for modifying or designing other structures for carrying out the same purposes
of the present subject matter. It should also be appreciated by those skilled in the art
that by devising various arrangements that, although not explicitly described or shown
herein, embody the principles of the present subject matter and are included within its
spirit and scope. Furthermore, all examples recited herein are principally intended

expressly to be for pedagogical purposes to aid the reader in understanding the
principles of the present subject matter and the concepts contributed by the inventor(s)
to furthering the art and are to be construed as being without limitation to such
specifically recited examples and conditions. The novel features which are believed to
be characteristic of the present subject matter, both as to its organization and method
of operation, together with further objects and advantages will be better understood
from the following description when considered in connection with the accompanying
figures.
[0045] Although embodiments for the present subject matter have been described in
language specific to package features, it is to be understood that the present subject
matter is not necessarily limited to the specific features described. Rather, the specific
features and methods are disclosed as embodiments for the present subject matter.
Numerous modifications and adaptations of the system/device of the present invention
will be apparent to those skilled in the art, and thus it is intended by the appended
claims to cover all such modifications and adaptations which fall within the scope of
the present subject matter.
[0046] It will be understood by those within the art that, in general, terms used herein,
and especially in the appended claims (e.g., bodies of the appended claims) are
generally intended as “open” terms (e.g., the term “including” should be interpreted as
“including but not limited to,” the term “having” should be interpreted as “having at
least,” the term “includes” should be interpreted as “includes but is not limited to,”
etc.). It will be further understood by those within the art that if a specific number of
an introduced claim recitation is intended, such an intent will be explicitly recited in
the claim, and in the absence of such recitation no such intent is present. For example,
as an aid to understanding, the following appended claims may contain usage of the
introductory phrases “at least one” and “one or more” to introduce claim recitations.
However, the use of such phrases should not be construed to imply that the

introduction of a claim recitation by the indefinite articles “a” or “an” limits any
particular claim containing such introduced claim recitation to inventions containing
only one such recitation, even when the same claim includes the introductory phrases
“one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a”
and/or “an” should typically be interpreted to mean “at least one” or “one or more”);
the same holds true for the use of definite articles used to introduce claim recitations.
In addition, even if a specific number of an introduced claim recitation is explicitly
recited, those skilled in the art will recognize that such recitation should typically be
interpreted to mean at least the recited number (e.g., the bare recitation of “two
recitations,” without other modifiers, typically means at least two recitations, or two
or more recitations). Furthermore, in those instances where a convention analogous to
“at least one of A, B, and C, etc.” is used, in general such a construction is intended in
the sense one having skill in the art would understand the convention (e.g., “a system
having at least one of A, B, and C” would include but not be limited to systems that
have A alone, B alone, C alone, A and B together, A and C together, B and C together,
and/or A, B, and C together, etc.). In those instances where a convention analogous to
“at least one of A, B, or C, etc.” is used, in general such a construction is intended in
the sense one having skill in the art would understand the convention (e.g., “a system
having at least one of A, B, or C” would include but not be limited to systems that
have A alone, B alone, C alone, A and B together, A and C together, B and C together,
and/or A, B, and C together, etc.). It will be further understood by those within the art
that virtually any disjunctive word and/or phrase presenting two or more alternative
terms, whether in the description, claims, or drawings, should be understood to
contemplate the possibilities of including one of the terms, either of the terms, or both
terms. For example, the phrase “A or B” will be understood to include the possibilities
of “A” or “B” or “A and B.”
[0047] It will be further appreciated that functions or structures of a plurality of
components or steps may be combined into a single component or step, or the

functions or structures of one-step or component may be split among plural steps or
components. The present invention contemplates all of these combinations. Unless
stated otherwise, dimensions and geometries of the various structures depicted herein
are not intended to be restrictive of the invention, and other dimensions or geometries
are possible. In addition, while a feature of the present invention may have been
described in the context of only one of the illustrated embodiments, such feature may
be combined with one or more other features of other embodiments, for any given
application. It will also be appreciated from the above that the fabrication of the unique
structures herein and the operation thereof also constitute methods in accordance with
the present invention. The present invention also encompasses intermediate and end
products resulting from the practice of the methods herein. The use of “comprising”
or “including” also contemplates embodiments that “consist essentially of” or “consist
of” the recited feature.
[0048] Although embodiments for the present subject matter have been described in
language specific to structural features, it is to be understood that the present subject
matter is not necessarily limited to the specific features described. Rather, the specific
features and methods are disclosed as embodiments for the present subject matter.
Numerous modifications and adaptations of the system/component of the present
invention will be apparent to those skilled in the art, and thus it is intended by the
appended claims to cover all such modifications and adaptations which fall within the
scope of the present subject matter.

WE CLAIM
1. An apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery comprising:
an inlet nozzle (1) that receives the deionized water;
an extruded tapered nozzle (7) mounted in wet cell battery;
a pair of conductive probes (6a, 6b) to measure level of electrolyte in the wet
cell battery are connected to a control valve (2);
the control valve (2) is automated and configured to adjust the flow of
deionized water in battery after receiving feedback from conductive probes (6a,
6b),
a plurality of visual indicator (3,4) being responsive for generating visual alarm
and configured to indicate level of water in battery; wherein
the control valve (2) senses the level of electrolyte in battery through longer
probes (6b),
If the level of electrolyte is below the longer probe (6b), the control valve (2)
is fully opened and generates the visual alarm through red visual indicator (3), that
the flow of water is reduced if level of electrolyte reaches longer probe (6b) and
the water continues to flow to reach the smaller probe (6a) and the control valve
(2) is fully closed and visual alarm through green visual indicator (4) is generated.
2. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, wherein the inlet nozzle (1) receives the deionized
water which is continuously supplied.
3. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1 or 2, wherein the extruded tapered nozzle (7) is
mounted in wet cell battery through an inspection hole.

4. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1 or 3, wherein the extruded tapered nozzle (7), is made
up of chemically stable and electrically insulated material.
5. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, wherein the visual indicator (3,4) are Light emitting
diodes (LEDs).
6. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, further comprises an air vent (5) to allow discharge
of air during filling of batteries with deionized water.
7. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, wherein the wet cell battery includes lead acid
battery.
8. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1 or claim 4, wherein the apparatus (100) is configured
as water top up tool for filling water in the lead acid battery.
9. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, wherein the apparatus (100) is used to eliminate
water spillage during top up of the electrolyte by ensuring filling to the precise and
calibrated amount in all cells of the battery thereby improving efficiency.
10. The apparatus (100) for detecting a reduction of a level of electrolyte in a wet cell
battery as claimed in claim 1, is configured to use as an electrolyte tester.