Modular Battery Tester with Segmented Load Modules
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Solution Overview
Problem
Current portable battery testers lack the capability to apply significant, configurable heavy loads necessary for detecting incipient battery problems like internal shorts, and existing devices are often bulky, non-portable, and limited to short-term, fixed load applications.
Innovation Solution
A modular, portable battery tester system utilizing high-resistivity, large-gauge resistance wire configured in a unique manner with a switch and cooling fans to apply user-selectable heavy loads, allowing for configurable load settings and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heavy-load testers use large resistance elements to apply significant battery load, then the battery testing capability is improved, but the device size increases and portability is reduced
Solution Approach 1:
The heavy-load testing capability is divided into separate modular load modules that can be detached from the main tester unit. The tester includes a controller and connection interface, while the load modules contain the high-power resistance elements. This allows the main unit to remain portable while heavy-load functionality is available when needed through module attachment.
Solution Approach 2:
The resistance elements are arranged in a three-dimensional configuration within the load modules, utilizing vertical stacking and multi-layer arrangements. This maximizes the power density and load capability within a compact volume, reducing the overall device footprint while maintaining heavy-load capability.
2Measurement precision
If heavy-load testers apply significant battery load for extended periods, then detection precision is improved, but heat generation increases and requires cooling
Solution Approach 1:
Cooling fans are introduced as intermediary components between the heat-generating resistance elements and the surrounding environment. These fans actively remove heat from the load modules during heavy-load testing, enabling extended test durations without excessive temperature buildup, thus maintaining measurement precision.
Solution Approach 2:
The cooling system utilizes phase change of cooling air (heating and expanding as it passes through the resistance elements, then cooling and contracting) to efficiently transfer heat away from the load modules. This allows sustained heavy-load operation by continuously cycling air through the thermal management system.
3Device complexity
If moderate-load testers use simple voltmeter design, then device complexity is reduced, but testing capability is limited and cannot perform battery condition analysis
Solution Approach 1:
The tester is designed with multiple functions integrated into a single device: voltmeter capability for basic measurements, controller for managing test sequences, and interface for connecting various load modules. This multi-functional design enables both simple voltage monitoring and comprehensive battery condition analysis with heavy-load testing.
Solution Approach 2:
The tester includes a configurable control system that can dynamically adjust test parameters based on battery characteristics. The controller manages variable load applications, timing sequences, and analysis algorithms, transforming a static voltmeter into an adaptive diagnostic tool capable of performing comprehensive battery condition assessment.
4Device complexity
If fixed load design is used in testers, then device complexity is reduced, but adaptability to different battery types is limited
Solution Approach 1:
The load system is segmented into multiple discrete load modules with different resistance values and power ratings. Each module can be independently selected and attached to the tester based on the specific battery being tested, providing adaptability without requiring complex internal switching or reconfiguration mechanisms.
Solution Approach 2:
The tester enables parameter changes by allowing users to select different load modules with varying electrical characteristics. The control system automatically adjusts test parameters based on the connected module's specifications, providing configurability for different battery types and test requirements while keeping individual modules relatively simple in design.
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
Enables the detection of battery issues with heavy loads in a portable, user-configurable format, suitable for various vehicle and equipment applications, improving diagnostic capabilities and safety through efficient heat management.
Implementation Method 1
Preferred embodiments of the present invention use resistance wire, configured in a unique manner, to provide a heavy load to the battery under test while advantageously dissipating heat
Implementation Method 2
a switch and at least one cooling fan
Data Source
AI summary
A modular heavy load battery test system is provided. The system includes a heavy load module and a battery tester. The heavy load module includes a housing, first and second lengths of high-resistivity, large-gauge wire arranged on respective upper and lower surfaces of a heat-resistant support plate, a switch and at least one cooling fan. The battery tester includes a housing, a microcontroller and a set of battery charging wires. The microcontroller selects the configuration of the first and second wires and provides the control signal to the heavy load module, while the switch selectively connects the first and second wires to the battery tester based upon the control signal.