Apparatus for regeneration of nickel-metal hydride (NIMH) batteries

Abstract

An apparatus (100) for regeneration of NiMH batteries comprises, at least, an NiMH-Recovery module (102) for a recovery of NiHM batteries and an NiMH-Diagnostic unit (110). The NiMH recovery module (102) includes a data analytics system (104), an advanced power protection and power system (108), a management board (106), a battery docking station (1086) and a user interface (1022). Additionally, the NiMH diagnostic unit (110) includes a Data Acquisition and Control System (112), a data analysis and interface system (114), and a data collection and control center (116). The present invention is designed to be used specifically with nickel-metal hydride (NiMH) batteries, by employing a proprietary charging algorithm capable of breaking down crystal deposits and restoring the battery's lost capacity. The key feature of the present invention is its ability to monitor and regulate the charging and discharging loop process to ensure optimal battery performance and longevity.

Description

DESCRIPTIONAPPARATUS FOR REGENERATION OF NICKEL-MET AL HYDRIDE (NIMH) BATTERIESFIELD OF THE INVENTION[1] Embodiments of the present invention generally relate to the regeneration technologies used for different kinds of batteries, and more particularly to apparatus for regeneration of Nickel - metal Hydride (NiMH) batteries that can monitor and regulate the charging and discharging loop process to ensure optimal battery performance and longevity.BACKGROUND OF THE INVENTION[2] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of it being mentioned in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.[3] Regenerative technologies for batteries have come a long way in the present day and age, especially since the popularization of hybrid and electric vehicles. For example: Lead-acid batteries are one of the most commonly used and popular batteries. There are a no. of solutions that have been provided to regenerate the lead acid batteries. There are several patents worldwide, but most are delegated to recover the capacity of Lead-Acid based batteries.[4] For example, Shoytush & Farman, 2010 has a patent that describes a method for restoring the capacity of a lead-acid battery. The patent outlines a process of subjecting the battery to a high- frequency current, which causes the sulfation on the battery's electrodes to break down and dissolve back into the electrolyte. The dissolved sulfation can then be removed from the battery by flushing it out with water, restoring the battery's capacity.[5] Also, 2013) has a patent that describes a device for restoring the capacity of lead- acid batteries. The device is designed to be used in conjunction with a charging device, and it comprises a transformer, a diode bridge, a capacitor, and a control circuit. The device can subjectthe battery to a high-frequency current, which can break down and dissolve sulfation on the battery's electrodes, thereby restoring the battery's capacity.[6] Then, Pittman & Stefansson, 1997, have a patent that describes a method for restoring the capacity of lead-acid batteries. The patent outlines a process of subjecting the battery to a high- frequency current, which causes the sulfation on the battery's electrodes to break down and dissolve back into the electrolyte. The dissolved sulfation can then be removed from the battery by flushing it out with water, restoring its capacity.[7] Then came a significant breakthrough in the battery industry, as the Nickel Metal hydride (NiMH) batteries became widely used in various applications, particularly in hybrid vehicles. NiMH batteries have been around for some time now and have proven reliable and durable. However, they have a limited lifespan and can lose capacity over time, just like any other battery. This is because crystal deposits on the electrodes can reduce the battery's ability to hold a charge. However, it is not so simple to regenerate the NiMH battery using known techniques for other kind of batteries. So, traditionally, the only way to restore a NiMH battery's capacity was to replace it, which can be costly and time-consuming.[8] Hence, there exists a need for apparatus for regeneration of Nickel-metal Hydride (NiMH) batteries that can monitor and regulate the charging and discharging loop process to ensure optimal battery performance and longevity. Such an apparatus should not suffer from the deficiencies of the prior art or at least provide a viable alternative.SUMMARY OF THE INVENTION[9] Embodiments of the present invention disclose an apparatus for regeneration of Nickel- metal Hydride (NiMH) batteries. The apparatus comprises, but not limited to, an NiMH-Recovery module for a recovery of NiHM batteries, and an NiMH-Diagnostic unit connected with the NiHM recovery module. Herein, the NiHM recovery module includes, but not limited to, a data analytics system configured to determine an optimal approach or method for recovering and treating the battery; an advanced power protection and power system configured to protect against problems selected from reverse polarity, over-current, over-voltage, and short circuits, as well as adjust the output voltage and output current; a management board configured to measure the voltage and current with a high accuracy and control a controllable power supply via a control signal; a battery docking station adapted to house NiHM batteries for recovery and treatment; and a user interface configured to enable a user to choose, locally or remotely, a specification of the NiHM battery tobe recovered along with a desired method or approach for recovery. Furthermore, the NiMH- Diagnostic unit includes, but not limited to, a data acquisition and control system configured to measure voltage and current from the module of the battery, as well as manage a discharging process of the battery, collect data to analyze and diagnose the battery's condition, and adjust or stop the discharging process in case battery’s condition is deteriorating; a data analysis and interface system adapted to analyze and present the data collected throughout the battery diagnostic process, and display analytical results to the user while also enabling historical tracking of battery’s performance; and a data collection and control center configured to enable local or remote access of the apparatus to the user, using wired or wireless connections.

[0010] In accordance with an embodiment of the present invention, the optimal approach for recovering and treating the NiHM batteries involves subjecting the NiHM battery through a series of charge and discharge cycles that are meticulously controlled in different combinations depending upon a capacity of the NiHM battery, to prevent the NiHM battery from being damaged or overcharged, in order to break down crystal deposits and restore the NiHM battery's lost capacity.

[0011] In accordance with an embodiment of the present invention, the data analytics system of the NiHM recovery module further comprises a microcontroller and a user interface. Further, the microcontroller is configured to analyze the received data to determine the optimal approach for recovering and treating the battery. Additionally, the user interface is configured to display the analyzed data, allow the user to monitor the battery recovery process, and select the appropriate charging algorithm for recovering the battery.

[0012] In accordance with an embodiment of the present invention, the management board further comprises a voltage and current measurement circuit and an EXELX control circuit, configured to measures the voltage and current with high accuracy and controls the controllable power supply via the control signal from the microcontroller.

[0013] In accordance with an embodiment of the present invention, the advanced power protection and power system further comprises a protection circuit and a controllable DC power supply with an electromagnetic switch. Further, the protection circuit is configured to protect against problems selected from reverse polarity, over-current, over-voltage, and short circuits, while the controllable power supply is configured to be adjusted to the output voltage and current as CC or CV.

[0014] In accordance with an embodiment of the present invention, the data acquisition and control system of the NiHM diagnostic unit further comprises a current measurement circuit, a voltage measurement circuit, a microcontroller, an electromagnetic switch and a high-power load.

[0015] Herein, the current measurement circuit is configured to convert a current flowing through the NiHM battery into a voltage, which is then measured and processed by a high-accuracy current sensor to provide precise measurements of the current; wherein the current sensor then communicates the measured values to a microcontroller through a I2C interface, allowing the system to analyze and diagnose the battery's condition.

[0016] Further, the voltage measurement circuit configured to measure a voltage of the NiHM battery by utilizing the microcontroller's internal voltage reference. Additionally, the filtering components are configured to remove any noise or interference in the signal, ensuring clean and precise measurements of the battery's voltage as well as circuit protection components to ensure the safety of both the battery and the apparatus.

[0017] Besides, the microcontroller is configured to process the analog signals from the current and voltage measurement circuits to convert them into digital signals as well as measure and analyze the battery's state to manage the discharging process safely and efficiently.

[0018] Moreover, the electromagnetic switch is configured to disconnect the NiHM battery if any faults occur during the discharging and diagnosis process, thereby preventing any harm to the battery or the device; and manage the discharge process with safe discharge and aid in recovering batteries that may have been weakened or discharged too much, thereby assisting in extending a life of the NiHM battery.

[0019] Also, the high-power load is adapted to create a high load on the NiHM battery during the discharging process, which helps to simulate the actual operating conditions of the battery in real- world applications.

[0020] In accordance with an embodiment of the present invention, the data analysis and interface system further comprises a mini computer and a user interface. Herein, the mini computer is adapted to run algorithms and software to interpret the data collected from the voltage and current measurement circuits, and display the results on the user interface for easy interpretation.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:

[0022] Fig. 1 A illustrates an apparatus for regeneration of Nickel-metal Hydride (NiMH) batteries, in accordance with an embodiment of the present invention;

[0023] Fig. IB illustrates a detailed view of a NiMH recovery module of the apparatus of Fig. 1 A, in accordance with an embodiment of the present invention;

[0024] Fig. 1C illustrates a detailed view of a NiMH diagnostic unit of the apparatus of fig. 1A, in accordance with an embodiment of the present invention;

[0025] Fig. 2 illustrates an exemplary flow diagram for showing the operation of the apparatus of Fig. 1A-1C, in accordance with another embodiment of the present invention.

[0026] Fig. 3A illustrates a screenshot of a user interface for an exemplary NiMH Recovery Process, in accordance with another embodiment of the present invention; and

[0027] Fig. 3B illustrates a screenshot of a user interface for an exemplary NiMH Diagnostic Process, in accordance with an embodiment of the present invention.DETAILED DESCRIPTION OF THE DRAWINGS

[0028] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling withinthe scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like is included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.

[0029] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element or group of elements with transitional phrases “consisting of’, “consisting”, “selected from the group of consisting of, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.

[0030] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.

[0031] In simple terms, the present invention aims to provide a solution for recovery / regeneration of NiMH batteries by addressing some of the shortcomings of existing battery chargingmanagement systems. To achieve the above, the present invention provides an apparatus that includes two units, first is the NiMH-Recovery module and the other one is the NiMH-Diagnostic unit. The present invention is designed to be used specifically with nickel-metal hydride (NiMH) batteries, commonly used in a range of Hybrid electric vehicles. The key feature of the present invention is its ability to monitor and regulate the charging and discharging loop process to ensure optimal battery performance and longevity.

[0032] To achieve the above, the present invention utilizes a no. of sensors that detect the current and voltage of the battery module and block during the loop of the charging process. This information is used to adjust the charging and discharging rate and prevent overcharging or undercharging, which can cause damage to the battery. In addition to its monitoring capabilities, it includes safety features such as short-circuit protection, voltage drop and reverse polarity protection. These features help prevent accidents and ensure the safe operation of the battery charging system. Overall, the present invention for NiMH batteries offers significant improvements over existing charging systems. Its advanced monitoring and safety features make it an ideal choice for anyone looking to extend the life of their NiMH batteries and ensure safe and reliable operation and maintenance of their Hybrid electric vehicle.

[0033] The present invention will now be described in detail with the help of accompanying drawings:

[0034] Figure 1 A illustrates an apparatus (100) for regeneration of Nickel-metal Hydride (NiMH) batteries, in accordance with an embodiment of the present invention. The advent of NiMH batteries are considered as a significant breakthrough in the battery industry. These are widely used in various applications, particularly in hybrid vehicles. These batteries have proven to be reliable and durable, however, they have a limited lifespan and can lose capacity over time, just like any other battery. This is because crystal deposits on the electrodes can reduce the battery's ability to hold a charge. The present invention is designed to be used specifically with nickel-metal hydride (NiMH) batteries, to address this issue by employing a proprietary charging algorithm capable of breaking down crystal deposits and restoring the battery's lost capacity.

[0035] As shown in figure 1A, the apparatus (100) for regeneration of NiMH batteries comprises, at least, an NiMH-Recovery module (102) for a recovery of NiHM batteries and an NiMH- Diagnostic unit (110) connected to the NiMH recovery module (102). The NiMH recovery module (102) includes a data analytics system (104), an advanced power protection and power system(108), a management board (106), a battery docking station and a user interface (1022). Additionally, the NiMH diagnostic unit (110) includes a Data Acquisition and Control System (112), a data analysis and interface system (114), and a data collection and control center (116). Both these components have been separately co vered / illu strated in figures IB and 1C using bock diagrams.

[0036] Fig. IB illustrates a detailed view of the NiMH recovery module (102) of the apparatus (100) of Fig. 1A, in accordance with an embodiment of the present invention. The layout of the recovery module (102) is designed to optimize a flow of power and data between the various components while minimizing the apparatus’s overall size. The design also considers the necessary safety features, such as short-circuit and reverse polarity protection and incorporate them into the overall layout. Individual components will now be discussed in more details below:

[0037] (Al ) Data analytics system ( 104 . This comprises a mini computer and touch screen (1024) that analyzes data from the microcontroller (1042) to determine the optimal approach for recovering and treating the battery. The touch screen (1024) displays analyzed data, allowing users to monitor the battery recovery process and select the appropriate charging algorithm. In accordance with an embodiment of the present invention, the mini-computer may be, but not limited to, a microprocessor, a microcontroller or a Raspberry Pi. In that sense, the mini-computer may be a multipurpose, clock driven, register based, digital integrated circuit that accepts binary data as input, processes it according to instructions stored in its memory and provides results as output. The microprocessor may contain both combinational logic and sequential digital logic. In some embodiments, the mini-computer may implement artificial intelligence and machine learning-based technologies for, but not limited to, data analysis, collating data & presentation of data in real-time. Additionally, the touch screen may have a touch-input based screen and / or multiple buttons for enabling inputs / interaction with the apparatus (100).

[0038] (B.l) Advanced Power Protection and Power system (108}: This system includes a protection circuit and a controllable DC power supply (1084) with an electromagnetic switch (1086). The protection circuit (1082) protects against problems like reverse polarity, over-current, over-voltage, and short circuits. At the same time, the controllable power supply (1084) can be adjusted to the output voltage and current as CC or CV.

[0039] (C.2) Management board (106}-. The Management board (106) contains a voltage (1064) and Current measurement circuit (1066) and an EXELX control circuit (1066). It measures thevoltage and current with high accuracy and controls the controllable power supply (1084) via the control signal from the microcontroller (1042).

[0040] (D.2) Battery Docking Station (1086): This station is where the batteries are placed for recovery and treatment.

[0041] (E) U ser Interface (1022): The intelligent user platform provides a user-friendly interface for selecting charging algorithms and battery specifications, such as 7.2v, 14.4v, 9.6v, and QR code sorting for managing and controlling battery recovery, either locally or remotely, through a server. For remote connection, the NiMH recovery module (102) may include a communication module (not shown) to connect the apparatus (100) with a wireless communication network. The communication network (110) may be implemented using a number of protocols, such as but not limited to, TCP / IP, 3GPP, 3GPP2, LTE, IEEE 802.x etc. The communication network (110) may be wireless communication network selected from one of, but not limited to, Bluetooth, radio frequency, or WIFI network providing maximum coverage.

[0042] Integrating these components in the battery recovery module (102) enables efficient and effective battery recovery by leveraging data-driven insights and user-friendly interfaces.

[0043] Fig. 1C illustrates a detailed view of a NiMH diagnostic unit (110) of the apparatus (100) of fig. 1A, in accordance with an embodiment of the present invention. The NiMH Diagnosis Unit (110) can be understood as a unit which diagnoses batteries with high accuracy whether it’s (strong, weak, reversed polarity or voltage dropped) and can manage the discharging process. The main concept of this unit (110) is to speed up the working flow and reduce time to diagnose batteries with high accuracy and minimal human errors. Individual components will now be discussed in more details below:

[0044] (A) Data Acquisition and Control System (112): To achieve an accurate diagnosis of a NiMH battery module, the Data Acquisition and Control System (112) is made of various interconnected components that work in harmony with one another to ensure optimal performance. The system includes measurement circuits (1122, 1124) that measures voltage and current from the module of the battery, as well as a control system that manages the discharging process. The control system adjusts the discharging rate based on the battery's condition to prevent damage and ensure safe discharge.

[0045] The data acquisition system (112) is configured to collect data from the measurement circuits (1122, 1124) and send it to a minicomputer (such as a microprocessor, a microcontroller, a Raspberry Pi etc.) (1126) that uses algorithms to analyze and diagnose the battery's condition. The computer (1126) processes the data and provides a diagnosis based on the analysis, which is then used to manage the discharging process.

[0046] The system (112) also includes safety features to prevent damage to the battery. If the battery's condition deteriorates, the control system is adapted to adjust the discharging rate or stop the discharge process altogether to prevent further damage.

[0047] To be more precise, the Data Acquisition and Control System (112) includes the following components (A1-A5):

[0048] (A.l ) Current measurement circuit (1122): The most critical component of the data acquisition system is a current measurement circuit (1122). The current measurement circuit (1122) converts the current flowing through the battery into a voltage, which is then measured and processed by, say, the INA219 IC. The INA219 is a high-accuracy current sensor that provides precise measurements of the current and communicates them through the I2C interface. The INA219 then communicates the measured values to the microcontroller (1126) through an I2C interface, allowing the system to analyze and diagnose the battery's condition. The conversion of current to voltage is accomplished by using a shunt resistor in series with the battery. The voltage drop across the shunt resistor is proportional to the current flowing through it, and this voltage is amplified and filtered before being measured by the INA219.

[0049] (A.2) Voltage measurement circuit (1124): The circuit (1124) is designed to provide precise and reliable measurements of the battery's voltage. It achieves this by utilizing the microcontroller's (1126) internal voltage reference, which is a stable and accurate voltage source that compensates for any power supply fluctuations, resulting in highly accurate measurements. The circuit (1124) also incorporates filtering components to remove any noise or interference in the signal, ensuring clean and precise measurements of the battery's voltage. In addition to its measurement capabilities, the circuit (1124) also includes protection features such as polarity reversal and high voltage protection to ensure the safety of both the battery and the system. Theseprotection features prevent any damage to the battery or the system in the event of a reversed polarity or high voltage situation.

[0050] (A.3} Microcontroller (1126}: The microcontroller ( 1126) is responsible for processing the analog signals from the measurement circuits (1122, 1124) and converting them into digital signals. This data is then analyzed by the mini computer, which determines the battery's state and provides instructions to the microcontroller (1126) on how to manage the discharging process. The microcontroller's (1126) programming is designed to ensure that the discharging process is safe and efficient, preventing damage to the battery or the system (112). Additionally, the microcontroller (1126) is designed to minimize power consumption, enabling it to operate efficiently and conserve battery life. Its programming includes various features such as timers and interrupts, which simplify the system's design and enable it to function at a high level of accuracy.

[0051] In summary, the microcontroller (1126) in NiMH-DU plays a vital role in the system's operation (112), enabling it to accurately measure and analyze the battery's state and manage the discharging process safely and efficiently. Its efficient programming and design enable it to function at a high level of accuracy while minimizing power consumption, making it a crucial component in the success of the NiMH-DU device.

[0052] (A.4) Electromagnetic switch (1128}: The electromagnetic switch (1128) in a NiMH-DU is a crucial component that helps to manage the discharging process of batteries with high accuracy and reliability, while also protecting the battery and the NiMH-DU from any potential damage. The switch (1128) can quickly disconnect the battery if any faults occur during the discharging and diagnosis process, thereby preventing any harm to the battery or the device. Additionally, the switch (1128) can help extend the life of the battery by managing the discharge process with safe discharge and also aid in recovering batteries that may have been weakened or discharged too much. The electromagnetic switch (1128) is designed for quick and efficient switching, enabling it to switch between different modes and settings rapidly while maintaining safe and reliable operation.

[0053] (A.5} High-power load (1130}: The load (1130) in the NiMH-DU is designed to create a high load on the battery during the discharging process, which helps to simulate the actual operating conditions of the battery in real- world applications such as hybrid vehicles. However, it is important to note that this high load (1130) is applied with safe discharge to prevent any damage to the battery.

[0054] Referring to figure 1C, the NiMH diagnostic unit (110) further includes:[B.l ] Data Analysis and Interface system (114): In the NiMH-DU, there is a data analysis and interface setup (1142) that utilizes a mini computer and touch screen display. This setup (1142) is used to analyze and present the data collected throughout the battery diagnostic process. The minicomputer runs algorithms and software to interpret the data collected from the voltage and Current measurement circuits (1122, 1124), and displays the results on the touch screen for easy interpretation. The system (114) is designed to save the data collected in the device for future reference and analysis. This allows for historical tracking of battery performance over time and helps to identify any trends or changes in battery behavior that may require attention.

[0055] [C.l -C.2] Data collection and control center (116): With the NiMH-DU, the data collection and control center (116) enables users to remotely access and control the device through a LAN connection (1162), either via an Ethernet cable or wirelessly through a local server (1164). This feature is particularly useful for managing and diagnosing batteries in large-scale applications.

[0056] In addition, the data collection and control center (116) collects data using specially configured flash memory, either after the battery diagnosis process or at any time. This feature allows for easy storage and retrieval of data for future analysis and comparison with other batteries. The flash memory can also be used to store important diagnostic information and other relevant data for the battery being tested.

[0057] In accordance with an embodiment of the present invention, the apparatus (100) may further include a storage module may be understood as a local storage (such as SSD, eMMC, Flash, SD card, etc.) or a cloud-based storage. In any manner, the storage module is envisaged to be capable of providing the data to the respective processing module, when the data is queried appropriately using applicable security and other data transfer protocols. In one embodiment, the storage module may be configured with prestored data of the various conditions of NiMH batteries, along with respective specification and capacity.

[0058] Figure 2 illustrates an exemplary method of operation of the apparatus (100), in accordance with an embodiment of the present invention. The invention of the EXELX Battery Recovery system including Battery Diagnostics Unit (NiMHDU) lies in its ability to effectively recoverNiMH battery modules, as demonstrated by its successful implementation in several hybrid vehicles. This innovative technology utilizes a combination of advanced data analytics, intelligent user platforms, microcontroller-based management, automation systems, and advanced power protection and control circuits to enable efficient and effective battery recovery.

[0059] The flowchart for the operation of the NiMH battery module regenerative process can be explained as follows:

[0060] Start: The operation begins at Stage 1, which is the recharge of the module using a (CC) loop.

[0061] CC Loop: The module is recharged using a constant current until it reaches a certain charge level.

[0062] Check Module: After the CC loop, the module is checked using a NiMH diagnostic unit to evaluate its condition and performance.

[0063] Recovery Performance Criteria: Based on the diagnostic results, the recovery performance of the module is assessed.

[0064] Performance < 30%: If the recovery performance is less than 30%, the module is considered unsuitable for its original application. Instead, it is assigned for repurposing in other applications.

[0065] Performance > 40%: If the recovery performance exceeds 40%, the module proceeds to Stage 2 for further processing.

[0066] Stage 2: In this stage, the module undergoes a recharge using a Constant Voltage (CV) method and goes through a regenerative cycle loop ten times.

[0067] Regenerative Cycle Loop: To improve its performance, the module is subjected to regenerative cycles, which involve discharging and recharging processes.

[0068] NIMH Diagnostic Check: After the regenerative cycle loop, the module is again checked using the NiMH diagnostic unit to evaluate its performance.

[0069] Performance > 40%: The process is considered completed if the module's performance is now above 40%. The module can be reintegrated into its original application, such as a NiMH hybrid battery vehicle.

[0070] Performance between 30% and 40%: If recovery falls between 30% and 40%, the process repeats both Stage 1 and Stage 2. This allows the module to experience additional recharge and regenerative cycles to improve performance.

[0071] Loop: The process continues to loop back to Stages 1 and 2 until the recovery performance falls below 30% or exceeds 40%.

[0072] By tailoring the charging algorithms to the battery's specific parameters, such as voltage and current, EXELX technology optimizes the recovery process for each battery module or block.

[0073] Overall, the EXELX Battery Recovery system for NiMH batteries offers significant improvements over existing charging systems and prolongs the lifespan of NiMH batteries. Its advanced monitoring and safety features make it an ideal choice for anyone looking to extend the life of their NiMH batteries and ensure safe and reliable operation and maintenance of their Hybrid electric vehicle.

[0074] The invention of NiMH-DU is to diagnose and manage the discharging process of modules of NiMH batteries, particularly NiMH batteries used in hybrid vehicles. One of the main innovations of the NiMH-DU is its ability to diagnose the state of NiMH battery Module in integrated units without the need to separate the cells from each other. This is a difficult task due to the presence of many variables caused by the cells being connected in a series manner.

[0075] The NiMH-DU diagnostic process is accurate and identical to the car, making it an essential tool in treating cells. Moreover, this diagnostic process is battery-friendly, making it a reliable and safe option for battery maintenance. Improper discharging can lead to damage, reduced lifespan, or even safety hazards, and managing the discharging process helps to prevent such issues and ensure that the batteries are properly treated, extending their lifespan and keeping them in good condition. Also includes a data analysis and interface system, consisting of a mini computer and a touch screen display, used to analyze and display the data collected during the battery diagnosis process. The system is designed to save the data collected in the device for future reference and analysis, allowing for historical tracking of battery performance over time and helps to identify any trends or changes in battery behavior that may require attention.

[0076] The NiMH-DU can be controlled wirelessly via a local server, allowing for remote access and control of the device. Additionally, it can collect data using specially configured flash memory after diagnosis or at any time, that can effectively diagnose and manage the discharging process of batteries, making them an essential tool for battery maintenance and extending their lifespan.

[0077] Working ExampleThis innovative technology as operationally explained in Figure 2, utilizes a combination of advanced data analytics, intelligent user platforms, microcontroller-based management,automation systems, and advanced power protection and control circuits to enable efficient and effective battery recovery.

[0078] Work Operational Details:NiMH Recovery Process is shown in a screenshot of a user interface of the present apparatus in figure 3A, in an exemplary embodiment of the present invention.As shown in figure 3A, the system utilizes a microcontroller-based charging algorithm that analyzes the battery's parameters to determine the optimal charging parameters.NiMH Recovery stages example:StartVolt: 6.2080998 I: 0.0 AH: 0.0ResumeVolt: 6.2080998 I: 0.0 AH: 0.0Volt: 6.4898 I: 0.4965 AH: 0.0Volt: 7.073 I: 0.9528 AH: 0.013165499384714497Volt: 7.1015 I: 0.9479 AH: 0.015180419110516706Volt: 7.1287999 I: 0.9052 AH: 0.017148921283278197Volt: 7.1392999 I: 0.8938 AH: 0.0190684548657404Volt: 7.1355 I: 0.9102 AH: 0.020965978820184864SkipVolt: 7.1465998 I: 0.8908 AH: 0.02248816279366943WaitingVolt: 6.7419 I: 0.0 AH: 0.02287366639299525SkipVolt: 6.7588 I: 0.0 AH: 0.02287366639299525Volt: 6.7588 I: 0.0 AH: 0.02287366639299525Volt: 7.0546999 I: 0.7843 AH: 0.023502274323390585Volt: 7.0960999 I: 0.7863 AH: 0.025175312097887193Volt: 7.1110001 1: 0.79 AH: 0.026855429646333053Volt: 7.1145 I: 0.7685 AH: 0.028540592750900314Volt: 7.1401 1: 0.7943 AH: 0.03019650865531629WaitingVolt: 6.7915001 1: 0.0 AH: 0.03053791464538706Volt: 6.8302999 I: 0.0 AH: 0.03053791464538706Volt: 6.8263998 I: 0.0 AH: 0.03053791464538706Volt: 7.0423999 I: 0.6762 AH: 0.0311025417236487Volt: 7.0665002 I: 0.6751 AH: 0.03253360911459392Volt: 7.0777998 I: 0.6687 AH: 0.033986568041311366Volt: 7.0749002 I: 0.6511 AH: 0.03541832857794232Volt: 7.0784998 I: 0.6798 AH: 0.03541832857794232WaitingVolt: 6.8035002 I: 0.0 AH: 0.03600470321892368Volt: 6.8557 I: 0.0 AH: 0.03600470321892368Volt: 6.8569999 I: 0.0 AH: 0.03600470321892368Start chargingVolt: 7.1715999 I: 0.8833 AH: 0.03666547275629309Volt: 7.1894002 I: 0.8694 AH: 0.03857068795283635StopVolt: 7.1985998 I: 0.8559 AH: 0.04006179286836253Volt: 7.4545002 I: 0.335 AH: 0.09760966502695616Volt: 7.4601002 I: 0.3248 AH: 0.09838303537326391SkipVolt: 7.4552999 I: 0.333 AH: 0.09913064992022516Waiting,Volt: 7.1058998 I: 0.0 AH: 0.09928814628672601SkipVolt: 7.2087002 I: 0.0 AH: 0.09928814628672601Start chargingVolt: 7.4288998 I: 0.3645 AH: 0.09957033446519906Volt: 7.4301 1: 0.3736 AH: 0.10039361944209205Volt: 7.5630999 I: 0.7086 AH: 0.10121942927049929Volt: 7.3674002 I: 0.4224 AH: 0.10265026282623743Volt: 7.3787999 I: 0.4132 AH: 0.10365816885375978Volt: 7.3751998 I: 0.4206 AH: 0.1046242636116412Volt: 7.3979001 1: 0.3823 AH: 0.10559430904964608Volt: 7.3978 I: 0.3891 AH: 0.10649604939036238Start chargingStopVolt: 7.4035001 1: 0.3852 AH: 0.00016337852042913438Start chargingVolt: 7.5634999 I: 0.9126 AH: 0.0007612437624865108Volt: 7.5844998 I: 0.9101 AH: 0.0026974978817303976Volt: 7.6114001 1: 0.931 AH: 0.004658258600069417Volt: 7.6087999 I: 0.886 AH: 0.006584948826505077Volt: 7.6271 1: 0.9168 AH: 0.008529362757941085Volt: 7.6321001 1: 0.9177 AH: 0.010480382881270513Volt: 7.6381998 I: 0.9188 AH: 0.012426253703302807Volt: 7.6420002 I: 0.9113 AH: 0.014383146902845964Volt: 7.6355 I: 0.9116 AH: 0.01632808659295241Volt: 7.6619 I: 0.9152 AH: 0.0182790155932241Volt: 7.2315998 I: 0.0 AH: 0.01866108400882615Volt: 7.5675001 1: 0.7084 AH: 0.02675767521473435Volt: 7.5667 I: 0.6996 AH: 0.028278108144243568Volt: 7.5770001 1: 0.6844 AH: 0.028878725774089505Volt: 7.2445998 I: 0.0 AH: 0.02918006399450038Volt: 7.3582001 1: 0.0 AH: 0.02918006399450038Volt: 7.3645 I: 0.0 AH: 0.02918006399450038Start chargingVolt: 7.5118999 I: 0.5997 AH: 0.029693221188657824Volt: 7.5054002 I: 0.573 AH: 0.030978332489093156StopVolt: 7.5072999 I: 0.5955 AH: 0.03223361765265466Volt: 7.5072999 I: 0.5955 AH: 0.03326272801001868FinishedVolt: 7.5072999 I: 0.5955 AH: 0.03326272801001868Start chargingVolt: 7.7035999 I: 0.9413 AH: 0.0008163112904230752StopVolt: 7.665 I: 0.9 AH: 0.0020395497591959104Volt: 7.3105998 I: 0.0 AH: 0.0020395497591959104Volt: 7.8499999 I: 0.0 AH: 1.597833052918788Volt: 7.8499999 I: 0.0 AH: 1.597833052918788Volt: 7.8495998 I: 0.0 AH: 1.597833052918788Volt: 7.8312998 I: 0.0 AH: 1.597833052918788Volt: 7.8311 1: 0.0 AH: 1.597833052918788Volt: 7.8309002 I: 0.0 AH: 1.597833052918788FinishedVolt: 7.8309002 I: 0.0 AH: 1.597833052918788

[0079] Now, the exemplary NiMH Diagnostic Process has been shown in figure 3B, in accordance with an embodiment of the present invention. Figure 3B shows illustrates the Intelligent Monitoring and Protection aspects of the system.The system incorporates comprehensive monitoring sensors to gather real-time data on battery voltage, and current.

[0080] An onboard microcontroller processes this data, constantly assessing the battery's condition and performance. In case of any abnormalities or potential risks (e.g., overheating, overvoltage, or excessive discharge), the system triggers protective measures such as automatic shutdown or user notifications.ERR - 1 ExampleStart SW8.00 2.556 0.0000 0 0.007.92 2.634 0.0428 0 0.667.86 2.625 0.0857 1 1.327.82 2.613 0.1284 2 1.987.79 2.601 0.1709 3 2.630.00 0.000 0.1709 3 2.63ERR -001ERR -2 ExampleStart SW7.39 2.515 0.0126 0 0.197.36 2.520 0.0537 1 0.837.33 2.516 0.0947 2 1.467.31 2.508 0.1357 3 2.097.30 2.502 0.1765 4 2.727.28 2.495 0.2173 5 3.347.26 2.489 0.2579 6 3.977.25 2.483 0.2985 7 4.597.23 2.477 0.3389 8 5.217.21 2.470 0.3792 9 5.837.20 0.000 0.3792 9 5.83ERR -002Test 1Start SW7.46 2.453 0.0000 0 0.007.33 2.508 0.0409 0 0.637.24 2.485 0.0816 1 1.267.20 2.475 0.1222 2 1.887.12 2.445 0.1623 3 2.507.08 2.430 0.2020 4 3.117.05 2.415 0.2415 5 3.727.00 2.397 0.2808 6 4.326.96 2.380 0.3197 7 4.926.92 2.364 0.3584 8 5.516.88 2.347 0.3968 9 6.106.88 2.350 0.4351 10 6.696.83 2.330 0.4733 11 7.286.78 2.309 0.5111 12 7.866.72 2.285 0.5486 13 8.446.65 2.257 0.5856 14 9.016.58 2.229 0.6222 15 9.576.51 2.201 0.6583 16 10.136.45 2.173 0.6939 17 10.68Drop Battery - voltage= 6.40

[0081] The present invention offers a number of advantages. One of the most significant advantages of the present invention is that it can save a significant amount of money for the consumers. Instead of replacing their NiMH batteries (which was the traditional practice), consumers may use the charger to restore the lost capacity, extending their longevity and reducingthe need for replacements. This is especially advantageous for those who rely on NiMH batteries for business or hobbies since it may save them time and money in the long term.

[0082] Another advantage of the apparatus of the present invention is that it is environmentally friendly. It is possible to minimize the amount of waste created by battery replacements by recovering the capacity of NiMH batteries, which can positively influence the environment. This is becoming more crucial as more people become aware of the need to minimize their carbon footprint and safeguard the environment.

[0083] As previously explained, the present invention is equipped with sensors that detect the current and voltage of the battery module and block during the loop of the charging process. This information is used to adjust the charging and discharging rate and prevent overcharging or undercharging, which can cause damage to the battery. In addition to its monitoring capabilities, it includes safety features such as short-circuit protection, voltage drop and reverse polarity protection. These features help prevent accidents and ensure the safe operation of the battery charging system.

[0084] Since it is a low-cost, environmentally friendly option for extending the life of NiMH batteries and reducing the need for replacements, the present invention has the potential to transform the battery market. As more people become aware of the benefits of this technology, it will more traction in the future and will become more readily acceptable globally.

[0085] In general, the word “module,” as used herein, refers to logic embodied in hardware or firmware, or to a collection of software instructions, written in a programming language, such as, for example, Java, C, or assembly. One or more software instructions in the modules may be embedded in firmware, such as an EPROM. It will be appreciated that modules may comprised connected logic units, such as gates and flip-flops, and may comprise programmable units, such as programmable gate arrays or processors. The modules described herein may be implemented as either software and / or hardware modules and may be stored in any type of computer-readable medium or other computer storage device.

[0086] Further, while one or more operations have been described as being performed by or otherwise related to certain modules, devices or entities, the operations may be performed by or otherwise related to any module, device or entity. As such, any function or operation that has been described as being performed by a module could alternatively be performed by a different server, by the cloud computing platform, or a combination thereof. It should be understood that thetechniques of the present disclosure might be implemented using a variety of technologies. For example, the methods described herein may be implemented by a series of computer executable instructions residing on a suitable computer readable medium. Suitable computer readable media may include volatile (e.g., RAM) and / or non-volatile (e.g., ROM, disk) memory, carrier waves and transmission media. Exemplary carrier waves may take the form of electrical, electromagnetic or optical signals conveying digital data steams along a local network or a publicly accessible network such as the Internet.

[0087] It should also be understood that, unless specifically stated otherwise as apparent from the following discussion, it is appreciated that throughout the description, discussions utilizing terms such as "controlling" or "obtaining" or "computing" or "storing" or "receiving" or "determining" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that processes and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.

[0088] Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claim.

Claims

CLAIMS1. An apparatus (100) for regeneration of Nickel-metal Hydride (NiMH) batteries, the apparatus (100) comprising: an NiMH-Recovery module (102) for a recovery of NiHM batteries, the NiHM recovery module (102) including: a data analytics system (104) configured to determine an optimal approach or method for recovering and treating the battery; and an advanced power protection and power system (108) configured to protect against problems selected from reverse polarity, over-current, over-voltage, and short circuits, as well as adjust the output voltage and output current; a management board (106) configured to measure the voltage and current with a high accuracy and control a controllable power supply (1084) via a control signal; a battery docking station (1086) adapted to house NiHM batteries for recovery and treatment; a user interface (1022) configured to enable a user to choose, locally or remotely, a specification of the NiHM battery to be recovered along with a desired method or approach for recovery; and an NiMH-Diagnostic unit (110) connected with the NiHM recovery module (102), the NiHM diagnostic unit (110) including: a Data Acquisition and Control System (112) configured to: measure voltage and current from the module of the battery, as well as manage a discharging process of the battery; collect data to analyze and diagnose the battery's condition; adjust or stop the discharging process in case battery’s condition is deteriorating; a data analysis and interface system (114) adapted to analyze and present the data collected throughout the battery diagnostic process, and display analytical results to the user while also enabling historical tracking of battery’s performance; a data collection and control center (116) configured to enable local or remote access of the apparatus (100) to the user, using wired or wireless connections.

2. The apparatus (100) as claimed in claim 1, wherein the optimal approach for recovering and treating the NiHM batteries involves subjecting the NiHM battery through a series of charge and discharge cycles that are meticulously controlled in different combinations dependingupon a capacity of the NiHM battery, to prevent the NiHM battery from being damaged or overcharged, in order to break down crystal deposits and restore the NiHM battery's lost capacity.

3. The apparatus (100) as claimed in claim 1, wherein the data analytics system (104) of the NiHM recovery module (102) further comprises a microcontroller and a user interface; wherein the microcontroller is configured to analyze the received data to determine the optimal approach for recovering and treating the battery; wherein the user interface is configured to display the analyzed data, allow the user to monitor the battery recovery process, and select the appropriate charging algorithm for recovering the battery.

4. The apparatus (100) as claimed in claim 2, wherein the management board (106) further comprises a voltage and Current measurement circuit (1066) and an EXELX control circuit (1066), configured to measures the voltage and current with high accuracy and controls the controllable power supply (1084) via the control signal from the microcontroller.

5. The apparatus (100) as claimed in claim 1, wherein the advanced power protection and power system (108) further comprises a protection circuit (1082) and a controllable DC power supply (1084) with an electromagnetic switch (1086); wherein the protection circuit (1082) is configured to protect against problems selected from reverse polarity, over-current, over-voltage, and short circuits, while the controllable power supply (1084) is configured to be adjusted to the output voltage and current as CC or CV.

6. The apparatus (100) as claimed in claim 1, wherein the Data Acquisition and Control System (112) of the NiHM diagnostic unit (110) further comprises: a current measurement circuit (1122) configured to convert a current flowing through the NiHM battery into a voltage, which is then measured and processed by a high-accuracy current sensor to provide precise measurements of the current; wherein the current sensor then communicates the measured values to a microcontroller (1126) through a I2C interface, allowing the system to analyze and diagnose the battery's condition; a voltage measurement circuit (1124) configured to measure a voltage of the NiHM battery by utilizing the microcontroller's internal voltage reference; wherein the filtering components to remove any noise or interference in the signal, ensuring clean and precisemeasurements of the battery's voltage as well as circuit protection components to ensure the safety of both the battery and the apparatus (100); the microcontroller (1126) configured to process the analog signals from the current and voltage measurement circuits (1122, 1124) to convert them into digital signals as well as measure and analyze the battery's state to manage the discharging process safely and efficiently; an electromagnetic switch (1128) configured to: disconnect the NiHM battery if any faults occur during the discharging and diagnosis process, thereby preventing any harm to the battery or the device; manage the discharge process with safe discharge and aid in recovering batteries that may have been weakened or discharged too much, thereby assisting in extending a life of the NiHM battery; and a high-power load adapted to create a high load on the NiHM battery during the discharging process, which helps to simulate the actual operating conditions of the battery in real- world applications.

7. The apparatus (100) as claimed in claim 1, wherein the data analysis and interface system (114) further comprises a mini computer and a user interface; wherein the mini computer is adapted to run algorithms and software to interpret the data collected from the voltage and current measurement circuits, and display the results on the user interface for easy interpretation.

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