DESC:[001] The present disclosure generally relates to a battery monitory system and method of manufacturing thereof. Particularly it relates to the battery monitory system for the commercial vehicles and method of manufacturing thereof
[002] Currently there is no technology or methodology available on built in the vehicle to detect battery capacity or battery condition. It is only during maintenance period that the battery is checked, and this is done by taking battery out of the vehicle.
[003] Generally, in colder climates, the batteries have a tendency to get damaged or discharged in middle of a journey without any warning causing disruption to the service offered by the vehicle. Therefore, pre-mature battery disposal occurred. Since presently there is no method to predict battery life or battery condition, in order to prevent mid-journey disruption, the vehicle batteries are replaced on a periodic interval basis. Doing so many, time batteries with a considerable amount of service life remaining are also discarded pre-maturely and not used optimally. Thus, the investment of the battery is not completely recovered.
[004] Additionally, there is a need to measure the safety and detect failure of the battery. In the battery with redox chemical reactions taking place continuously during the charging and discharging process of the battery, there always lies a possibility of reaction hazards. Presently no methods can detect any abnormalities in the chemical reaction over, the standard process. The overlooking of abnormal battery charging and discharging relations can lead to explosions or damage the vehicular electrical circuit.
[005] Further with a variety of battery and battery capacities operating in a vehicular fleet there lies no universalized vehicle on-board battery monitoring system to detect battery capacity, battery condition and battery abnormalities. It is only during routine maintenance the battery operation is verified.
[006] Also, vehicle SLI batteries are checked for functionality only during maintenance activities or during failures. All methods for testing are invasive in nature and require time as well as disruption of power supply from the vehicle. When diagnosed during failures in majority of the cases the batteries are damaged beyond repair and cannot be recovered. If the battery deterioration is detected in an early stage, there always lies a possibility of battery restoration through pulsed charging or other non-invasive battery recovery methods.
[007] Therefore, there is a need of system and method to check the battery conditions and safety parameters during onboard of the vehicle without taking out battery from the vehicle.
[008] The present subject matter solves the aforementioned and other problems by providing an onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery.
[009] In one embodiment, the present subject matter relates to an onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery comprising onboard SLI-battery monitoring system to continuous monitor the life and health of the battery on the on-board condition of the vehicle.
[0010] Here the onboard system in a vehicle continuously monitors the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery in an on-board condition.
[0011] The onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery provides a continuous measurement of electrical parameters and correlating them with the internal cell chemistry of the battery in the on-board condition of a vehicle to detect the life of battery and battery failures with sufficient time margin to allow for interventional corrective measures.
[0012] While in operation a vehicle SLI battery is designed to deliver the highest amount of current during starting for a brief interval. The SLI battery also provides electricity to run vehicular onboard systems, when the engine is switched off. Not designed for deep discharge, typical misuse and harsh operating conditions impact the battery life. It is not possible to put an exact date as the battery service life as this variable varies between battery types, and battery operational scenarios.
[0013] The utilization of the onboard SLI-battery monitoring system allows continuous monitoring of the battery. Through measurement of electrical parameters and correlating them with the internal cell chemistry of the battery, thereby reducing the necessity of invasive battery testing procedures. The continuous measurement of these parameters on-board a vehicle will allow the detection of battery life and battery failures with sufficient time margin to allow for interventional corrective measures.
[0014] The system of present subject matter measure electrical parameters such as terminal potential difference (accuracy of +/- 0.001v), vehicle current consumption (accuracy of +/- 0.75A), battery impedance (accuracy of 0.01 ohms) and ambient temperature (accuracy of 0.1 °C)
[0015] The further independent and combinational utilization of these parameters are used to compute additional battery parameters co-relating to battery cell chemistry allowing detecting battery charge and health condition. The computation of these parameters allows derivation of the following battery conditions and failure states such as state of charge (SOC), state of health (SOH), parasitic discharge, deep discharge, overload/undercharge of the battery, battery end-of-life and battery electrode degradation/sulphation system.
[0016] FIG 1 illustrates the internal operation mechanism of the battery monitoring system.
[0017] An inbuilt power filter and conditioning circuit supplies power to the system and filters transient noise or voltage spike that may be detrimental to the functionality of the system.
[0018] The impedance monitoring is a periodic sampling system, operated post vehicle shut down for a brief period to detect battery internal resistance. Battery internal resistance increases with cell ageing and sulphation, disabling a battery’s ability to deliver the momentary high current during vehicle cranking. The impedance is measured on larger interval as this battery parameter does not witness any instantaneous change.
[0019] A voltage divider in tandem with a 16-bit high gain ADC is used to determine precise terminal voltage. Voltage measurement over time domain used as an interdependent entity can determine voltage drop on vehicle cranking which is utilized to determine battery health. Further, rate of voltage drop can further delineate the rate of reaction within the cells. The voltage is further utilized to determine charging and discharging capabilities of the battery by measuring rate of charge and discharge cycle to cycle variation. Utilized in tandem with current is used to determine SOC through the use of empirical, linearized pre-set plots.
[0020] Current measurements performed through a current shut and are used for determination of the instantaneous load on the battery. The current measurement in time domain clarifies the charge and discharge capacity of the battery along with the presence of parasitic loads. The current measurement is a factor utilized for the determination of SOC along with terminal voltage.
[0021] All measurements are obtained in time domain and selectively stored in a memory buffer for comparative analysis, as all battery initial conditions don’t remain same. Parameters such as impedance, cranking voltage drop, rate of voltage drop and peak load current samples are saved for comparative evaluation.
[0022] FIG 2 provides flow of battery monitoring system:
[0023] SOC: The relative difficulty in measuring SOC of a lead acid battery through just voltage alone is despite the linear relation the batter’s tendency to accumulate surface charge on the electrode plates result in false reading of battery open circuit voltage. In the present disclosure the discharge/charge current and voltage, both are used as parametric inputs to determine SOC. Generally, each battery has a SOC, voltage and discharge map which can be used to determine the SOC, but this map is unique for various battery capacities and will limit the use of the monitoring system to batteries of a fixed capacity. Further on deterioration of battery health as the capacity of the battery varies the SOC prediction will deviate reducing prediction accuracy.
[0024] In this scope the voltage is sampled at the zero crossing of the current (When current reaches zero between charge and discharge cycle). In this process the active use of the battery eliminates the surface charge accumulation while maintaining the ability to measure the SOC as a direct proportionality of the terminal voltage. This linear relation is common across batteries of all capacities enabling us to use one monitoring system to diagnose batteries of all types.
[0025] SOH: Is the direct correlation between the reduction in battery capacity from its initial condition. When a battery ages its internal resistance increases. This increase in resistance is due to the reduction in available active reaction area of the electrode plates. The reduction is a result of plate deterioration and sulphation. The change in internal resistance is directly proportional to the SOH of a battery. In this scope two methods are employed to detect SOH in an innovative manner. A load test method was developed to detect battery resistance as a function of voltage drop in 2 cases:
[0026] During cranking (Active Load Starter Motor). When the starter motor is engaged a high current follow, significantly drops battery terminal voltage. Measuring current during this phase allows us to detect the active load/resistance from the vehicle side (starter motor+ accessory loads).
[0027] During Shutdown (Internal discharge resistor) In this case a relay within the circuit activates and passes current through a pre-calibrated set of discharge resistors. In this scenario we know the resistance value and we measure the voltage drop.
[0028] From both scenarios on receiving the voltage drop and active resistance, voltage divider formula is utilized to find the internal resistance of the battery. On initial installation of the monitoring system, the first resistance data is measured and stored within the controller. On subsequent impedance measures, the deviation from the initial data is complied. In case o a lead acid battery any deviation greater than 20% of the impedance as a new battery is considered to be the end of life of the battery.
[0029] Diagnostics: Rate of voltage drop is compiled by measuring voltage over the time domain. Any voltage drops greater than 120V/s indicates a weak battery and reduced vehicle cranking capacity. The drop in voltage for a prolonged time post ignition switch off indicates parasitic discharge/ battery self-discharge. The current direction and magnitude measure during operation indicates the charge and discharge characteristics of the battery and any deviations noticed directly translated to fault in the battery.
[0030] Through the use of the above stated ideology and logic frameworks the battery monitoring system is utilized to compute instantaneous battery internal parameters, while onboard a vehicle. The warnings and curial observations made by the system are displayed to the driver on the dashboard allowing a safe time margin to take preventative and precautionary actions.
[0031] The present subject matter provides a single unit system to do precursive failure prediction, preventing service disruption and improved safety and functionality of the battery on the onboard condition of the vehicle. Further it measures backward and universally cross compatible with optimized battery utilization, delivering better utilization of investment with compromising on the modification in existing harness. It provides a direct fitment and easier on-time maintenance.
[0032] The system of present subject matter provides a warning about battery condition to driver sufficiently in advance to take precautionary measures. Further on detection of initiation of battery failure warring is given in advance to the drive to take repair actions. Earlier actions are taken, the battery can be recovered. Here battery life and SOH continually measured and displayed, so battery is replaced when it has genuinely reached its end of life, delivering best value. Here instant warning from system on detection of reduced charging capability or parasitic current draw from internal systems. Thereby the system is capable of deriving internal cell chemistry though the parametric measurements and indicate fault.
[0033] It is compatible across all vehicle range with backward compatibility, using direct fitment and no wiring modification.
[0034] Addition of an active onboard battery monitoring system allows continual monitoring of crucial battery parameters, allowing instantaneous preventative action before an impending breakdown. This reduces the chances of service disruption as a result of unpredicted battery/electrical system failure.
[0035] The battery service life cannot be measured and dated. To prevent mid-service breakdowns, generally batteries are replaced in intervals, irrespective of their actual conditions. Premature-battery disposal is not only is a source of pollution but also, the optimal value of the battery remains unutilized. Through active and continuous battery monitoring the battery can be optimally utilized till its potential.
[0036] The implementation of continuous battery monitoring and fault on-board vehicle allowing optimized utilization of battery service life. The utilizing with no modifications in the fitment strategy and wiring harness develop a single standalone product. It ensures vehicle uptime, with added operational cost saving
[0037] The system of present invention continuously measures vehicle battery electrical operational parameters to determine battery state of charge (SOC) to determine available battery capacity to monitor usage and cranking operations. It also battery State of Health (SOH) to determine available battery service life, to predict optimal battery service life. It warns faults associated with vehicle battery and electrical system.
[0038] It has wide applicability on complete truck and bus range delivering optimal battery service life while protecting against battery faults.

[0039] Although the present disclosure is described in terms of certain preferred embodiments and examples, other embodiments and examples will be apparent to those of ordinary skill in the art, given the benefit of this disclosure, including embodiments and examples that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the true spirit and scope of the present invention.
[0040] It is to be understood that other embodiments of the present disclosure will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the disclosure by way of illustration. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive.
[0041] It would become abundantly clear to a person in the art, after reading this specification that the present subject matter also provides a real time system to protect the overcharging and over discharging of battery of the electric vehicle. More specifically, the present subject matter discloses a system to protect the overcharging and over discharging of the battery of electric vehicle in the real time manner effectively and without departing from the spirit of the present subject matter. While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the present subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject matter, some features may be omitted. Alternatively, in some other cases some features may be emphasized while others are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternatively, the methods may be performed in manner or order different than what is explained without departing from the spirit of the present subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter.

Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)

,CLAIMS:We claim:

1) An onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery comprising onboard SLI-battery monitoring system to continuous monitor the life and health of the battery on the on-board condition of the vehicle.
2) The onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery as claimed in Claim 1, wherein said system provides on-board battery monitoring system.
3) The onboard system in a vehicle to continuously monitor the battery state of charge (SOC), state of health (SOH), charging/discharging cycles and predict possible failure modes at the earliest to allow time for preventative interventions or recovery of the battery as claimed in Claim 1, wherein said system provides a continuous measurement of electrical parameters and correlating them with the internal cell chemistry of the battery in the on-board condition of a vehicle to detect the life of battery and battery failures with sufficient time margin to allow for interventional corrective measures.
.

Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)