In-Situ CCA Testing via Equivalent Circuit Voltage Measurement
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Solution Overview
Problem
Existing methods for testing the cold-cranking ampere (CCA) of lead-acid batteries require high-power resistors and can adversely affect battery life, and are not suitable for in-situ testing without removing the battery from vehicles, posing challenges in efficiency and practicality.
Innovation Solution
A charger system comprising a battery equivalent circuit, signal drive circuits, and load circuits with triodes and switching tubes, which calculates battery internal resistance using voltage differences and resistor values to determine CCA without high current discharge, allowing for in-situ testing without harming the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-power resistors are used for CCA testing, then the CCA value can be measured, but the battery life is adversely affected
Solution Approach 1:
The patent introduces an intermediary measurement approach by using voltage measurement across a known resistor to indirectly calculate the battery's internal resistance and CCA value, rather than directly applying high current through power resistors. This mediator method (voltage measurement and calculation) allows accurate CCA testing without the harmful effects of high-current discharge on battery life.
2Measurement precision
If standard CCA testing method is used, then CCA value can be obtained, but a number of high-power resistors need to be configured
Solution Approach 1:
The patent creates a simplified equivalent circuit model that copies the essential electrical characteristics of the battery system without requiring the full-power testing infrastructure. By measuring voltage across a small known resistor and calculating the results, the system replicates the CCA measurement function without needing actual high-power resistors, thereby reducing device complexity while maintaining measurement accuracy.
3Ease of operation
If in-situ testing is required, then practicality is improved, but the battery cannot be removed from vehicle for testing
Solution Approach 1:
The patent enables the battery to test itself while remaining installed in the vehicle by utilizing the vehicle's existing electrical system components (such as the alternator and wiring harness) as part of the measurement circuit. The testing device connects to the battery terminals and uses the vehicle's own electrical infrastructure to provide the measurement conditions, allowing reliable in-situ CCA testing without removing the battery.
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 solution reduces hardware costs, preserves battery life, and enables intuitive data display, allowing for in-situ testing and recommendations for battery maintenance or repair, enhancing practicality and flexibility.
Implementation Method 1
a battery equivalent circuit, comprising a battery internal resistance R0 and an electromotive force E connected in series
Implementation Method 2
a first triode (Q3), an emitter electrode of the first triode (Q3) is grounded, and a collector electrode thereof is connected to a control terminal of a first switching tube (Q1)
Data Source
AI summary
A charger system for battery starting current test, comprising: a battery equivalent circuit comprising a battery internal resistance R0 and an electromotive force E connected in series, two ends of the battery equivalent circuit are connected to a first signal and a second signal, respectively; a signal drive circuit, comprising a first DC output signal and a second DC output signal, and a first load circuit and a second load circuit configured between the first DC output signal and the second DC output signal, each load circuit is connected to the battery equivalent circuit and controlled by a first drive signal and a second drive signal; an intermediate resistor R28, configured between the signal drive circuit and the battery equivalent circuit. This invention uses the above technical solution to test the internal resistance of the battery, and find out the CCA value of the battery via the internal resistance correspondingly.