Battery Charging Method Preventing Electrolyte Loss
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Solution Overview
Problem
Conventional battery charging profiles for lead-acid batteries in UPS systems often result in reduced backup time and premature failure due to charge starvation, sulphation, and electrolyte loss, especially when charging is intermittently interrupted before sufficient de-sulphation occurs.
Innovation Solution
A method and system for charging batteries that involves monitoring charge during discharge cycles, recharging with a constant voltage or current, and transitioning to a standby mode when the charge exceeds the discharge amount, using a controller to manage the charging process and prevent overcharging, thereby maintaining the battery in a state that prevents self-discharge without electrolyte evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional charge profiles are used to charge flooded cell lead-acid batteries, then the charging process is simple and follows standard manufacturer recommendations, but the battery experiences charge starvation, sulphation, and electrolyte loss leading to reduced backup time and shortened life span
Solution Approach 1:
The charging system dynamically adjusts the charging profile based on real-time battery state monitoring. The controller transitions between different charging stages (bulk, absorption, float) and modifies parameters such as voltage and current based on battery voltage, current, and temperature measurements, rather than following a fixed conventional profile
Solution Approach 2:
The system implements continuous feedback monitoring of battery parameters (voltage, current, temperature) and uses this information to adjust the charging process. The controller monitors charge/discharge cycles and modifies the charging profile in response to battery state changes, preventing sulphation and electrolyte loss while extending battery life
2Loss of substance
If the battery is charged using float region voltage from the beginning, then electrolyte evaporation is limited, but the charging is slow and it takes an unacceptably long time to attain adequate de-sulphation
Solution Approach 1:
The charging process is divided into distinct stages: bulk charging at higher voltage for rapid charge delivery, absorption charging at reduced voltage for de-sulphation, and float charging at minimal voltage to prevent electrolyte evaporation. The system segments the charging profile temporally and applies appropriate voltage levels to each stage, achieving both fast charging and electrolyte conservation
Solution Approach 2:
The system performs preliminary bulk charging at higher voltage levels to rapidly restore battery charge and initiate de-sulphation processes before transitioning to lower voltage float charging. This preliminary high-voltage action enables faster charging while the subsequent float stage prevents electrolyte evaporation
3Adaptability or versatility
If intermittent charging occurs due to unpredictable power outages, then the UPS provides backup power during blackouts, but the battery experiences charge starvation and increased internal resistance leading to reduced backup time
Solution Approach 1:
The system automatically monitors its own charging state and detects when charging has been interrupted. It self-corrects by extending the charging duration and adjusting the profile in subsequent cycles to compensate for incomplete charging, ensuring the battery reaches full charge despite intermittent power availability
Solution Approach 2:
The system ensures continuous effective charging by monitoring charge delivery and extending charging cycles until the battery is fully charged, even across multiple interruptible power cycles. The controller tracks cumulative charge delivered and maintains charging action until the battery reaches its charge target, preventing charge starvation
4Reliability
If the battery is over-charged to compensate for intermittent charging interruptions, then sufficient charge is delivered, but electrolyte drying occurs causing premature battery failure
Solution Approach 1:
The controller continuously monitors battery voltage, current, and temperature to detect the battery's charging state. It uses this feedback to automatically adjust or terminate charging when the battery reaches full charge, preventing over-charging and electrolyte drying while ensuring sufficient charge delivery
Solution Approach 2:
The system changes charging parameters (voltage, current) based on battery state and environmental conditions. It adjusts the charging profile dynamically, reducing voltage and current as the battery approaches full charge, and accounts for temperature effects to prevent over-charging and electrolyte loss
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach extends battery life by reducing internal resistance, preventing electrolyte loss, and maintaining charge capacity over multiple cycles, thereby improving backup time and reducing the risk of battery failure.
Implementation Method 1
A battery is used to provide backup power for a critical load during blackout or brownout conditions
Implementation Method 2
flooded cell lead-acid batteries that are used to provide back-up power
Data Source
AI summary
Disclosed are methods for charging batteries utilizing a charge balance approach, and charger systems using those methods. In one example, a method for charging a battery includes monitoring an amount of charge released by the battery while in a discharge state, recording the amount of charge released while in the discharge state, applying a voltage which results in current in reverse direction to the battery at a first voltage level for a time sufficient to introduce an amount of charge substantially equal to the recorded amount of charge released by the battery while in the discharge state, and maintaining the battery in a stand-by mode by applying a voltage which results in current in reverse direction to the battery at a second voltage level, the second voltage level being in a range sufficient to prevent self-discharge of the battery and insufficient to induce evaporation of electrolyte in the battery.