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1 Exercise 4 Bttery Chrging Methods EXERCISE OBJECTIVE When you hve completed this exercise, you will be fmilir with the different chrging methods nd chrge-control techniques commonly used when chrging Ni-MI btteries. You will be ble to evlute which one is best suited to given sitution, depending on different fctors such s the chrge current rte, chrge durtion, chrge input, nd mbient temperture. DISCUSSION OUTLINE The Discussion of this exercise covers the following points: Chrge-control techniques Timed chrge Voltge drop (-V) Voltge plteu (0V) Temperture cutoff (TCO) Rte of temperture increse (T /t) Chrge-control technique nd cycle life Chrging methods Low-rte chrge Quick chrge Fst chrge Trickle chrge Three-step chrge DISCUSSION Chrge-control techniques The role of chrge control when chrging Ni-MI btteries using constnt current is to ensure tht the bttery hs reched full cpcity when the chrge is terminted, s well s to limit overchrge nd prevent excessive bttery tempertures. To this end, number of techniques for chrge control (chrge termintion) hve been developed for Ni-MI btteries, ech using different mens of determining when the chrge is complete. Depending on the chrge conditions (e.g., chrge rte, chrge input, mbient temperture), certin techniques re more efficient thn others. The five techniques most commonly used for chrge control of Ni-MI btteries re discussed below. Timed chrge The timed-chrge technique consists of terminting the chrge of Ni-MI bttery fter predetermined mount of time. This method should only be used t low chrge rtes to void excessive overchrge of the bttery. It is often used in conjunction with other chrge-control techniques in wht is clled topping chrge. This topping chrge is pplied to the bttery fter nother chrgecontrol technique termintes the initil chrge, to ensure tht the bttery is fully chrged. Festo Didctic

2 Exercise 4 Bttery Chrging Methods Discussion Voltge drop (-V) The voltge drop (-V) technique consists of monitoring the bttery voltge during chrge nd terminting the chrge when the voltge begins to drop, s shown in Figure 28. A drop of 10 mv per cell is generlly ccepted. Cution must be exercised when using the voltge drop method to chrge Ni-MI btteries becuse the decrese in voltge observed t the end of the cycle is not lwys obvious nd often lmost impossible to detect, especilly t low chrge rtes (0.3 or less). 0V Voltge (V) -V Voltge (V) Temperture (T ) T /t TCO Temperture (T ) Rte of temperture chnge (T /T) Rte of chnge (T /t) Chrge time, t Figure 28. Comprison of chrge-control techniques: TCO, T /t, nd V. Voltge plteu (0V) The voltge plteu (0V) technique is vrition on the voltge drop technique tht overcomes the difficulty of observing voltge drop t the end of the chrge of Ni-MI btteries. With the voltge plteu technique, the chrge is terminted when the vrition in voltge is equl to 0 V, insted of witing for the voltge to drop s in the voltge drop technique (see Figure 28). The voltge plteu technique thus hs the benefit of reducing the risks of overchrge. The disdvntge, however, is tht chrge termintion my occur before optiml bttery cpcity is reched. Temperture cutoff (TCO) The temperture cutoff (TCO) technique monitors the rise of bttery temperture during chrge nd termintes the chrge when the bttery reches certin predetermined cutoff temperture indicting the beginning of overchrge, s shown in Figure 28. The optiml temperture t which bttery chrge should be terminted, however, is difficult to determine precisely s it depends on severl 52 Fes t o Di dc t i c

3 Exercise 4 Bttery Chrging Methods Discussion fctors such s the mbient temperture, bttery design, nd chrge rte. For exmple, bttery in low mbient temperture is likely to be overchrged when the cutoff temperture is reched, wheres bttery in wrm mbient temperture my not be fully chrged when the cutoff temperture is reched. Becuse of this, the TCO technique is generlly used in conjunction with nother chrge-control technique to terminte the chrge in cse this other technique fils to do so. Rte of temperture increse (T /t) The bbrevition for the rte of temperture increse chrge-control technique (T /t) cn lso be written without using Greek letters: dt /dt. The rte-of-temperture increse (T /t) technique monitors the increse in bttery temperture during chrge in reltion to time, nd termintes the chrge when certin rte of increse is reched (see Figure 28). The T /t technique is more relible thn the temperture cutoff technique becuse it does not depend on mbient temperture vritions. Chrge-control technique nd cycle life Figure 21 in Exercise 3 showed tht the use of the pproprite chrge-control technique hs beneficil effect on Ni-MI bttery cycle life. The longest cycle life for Ni-MI btteries is usully obtined using the rte-of-temperture increse (T /t) technique becuse it llows the chrge to terminte t chrgeinput levels tht re close to the bttery s nominl cpcity (120% or less). In contrst, when the TCO technique is used for chrge control, the chrge generlly termintes t chrge input levels of % nd the bttery is thus llowed to rech firly high tempertures. This generlly results in shorter cycle life. Chrging methods A number of different methods hve been developed to chrge Ni-MI btteries using constnt current. The five most importnt chrging methods re: low-rte chrge (bout 15 hours), quick chrge (4-5 hours), fst chrge (bout 1 hour), trickle chrge, nd 3-step chrge. Low-rte chrge The low-rte chrge method consists of chrging the Ni-MI bttery t current rte of bout 0.1 during long period of time (pproximtely 15 hours for fully dischrged bttery). At this low current rte, the production of gs occurring when the bttery reches full chrge does not exceed the oxygen-recombintion rte, thereby voiding severe dmge to the bttery. This chrging method is often used in conjunction with the timed-chrge control technique to terminte the chrge t chrge input of up to 150%. This method works best t mbient tempertures rnging from 15 C (59 F) to 30 C (86 F). The low-rte chrge is the lest efficient of the different chrging method s most of the energy supplied to the bttery towrd the end of the chrge cycle is not used to return the ctive mterils of the bttery to the high-energy stte, but rther is lost in the production of het nd other unwnted rections. Festo Didctic

4 Exercise 4 Bttery Chrging Methods Discussion Quick chrge The quick chrge method uses slightly higher current rte (bout 0.3 ) to chrge Ni-MI btteries in reduced mount of time (bout 4 to 5 hours). This method is commonly used to chrge Ni-MI btteries, since they cn be chrged efficiently nd sfely t reltively high chrge rtes. The timed-chrge technique cn be used to terminte the chrge with the quick-chrge method. However, other chrge-control techniques (e.g., temperture cutoff t 50 C or 122 F nd voltge drop) must be used in conjunction with the timed-chrge technique to minimize bttery overchrge nd void excessive tempertures. This is highly recommended when the bttery being chrged ws not fully dischrged. Fst chrge The fst chrge method consists of chrging Ni-MI bttery t n even higher current rte (between 0.5 nd 1 ), thus reducing the chrge time to bout n hour or two. In order to limit the extent of overchrge nd void excessive bttery tempertures, it is necessry to use chrge-control technique other thn the timed-chrge to terminte the chrge. The voltge drop (-V) technique cn be used to terminte fst chrge. However, the best results re obtined by using the rte-of-temperture increse (T /t) technique bcked by temperture cutoff (TCO). Figure 29 shows tht the fst chrge method yields the longest cycle life when the chrge is terminted using the rte-of-temperture increse (T /t) technique. This technique cn sense when the bttery hs reched full cpcity erlier thn the voltge drop (-V) technique, thus reducing the negtive effect of bttery overchrge nd excessive tempertures on cycle life. T /t) Cpcity (%) -V Number of cycles Figure 29. Cpcity versus number of cycles of Ni-MI bttery when using vrious chrgecontrol techniques to end the chrge cycle t fst chrge rte. Trickle chrge The trickle chrge method consists of chrging Ni-MI bttery t low current rte tht replces the bttery cpcity loss due to self-dischrge, in order to mintin the bttery in fully chrged condition. This method works best t chrge rtes between 0.03 nd 0.05, nd t n mbient temperture rnge between 10 C (50 F) nd 35 C (95 F). The trickle chrge method is often used to compenste for the reltively high self-dischrge rte of Ni-MI btteries nd 54 Fes t o Di dc t i c

5 Exercise 4 Bttery Chrging Methods Procedure Outline mintin them t full cpcity during long storge periods (such s in sttionry bttery pplictions). Three-step chrge The three-step chrge method is combintion of severl of the previous chrge methods. It consists of first chrging Ni-MI bttery t fst current rte of bout 1, using the T /t technique to terminte the chrge t chrge input of up to 120%. A topping chrge (timed chrge of 30 to 60 minutes t current rte of 0.1 ) is then pplied to the bttery in order to mximize its reltive cpcity. Finlly, current rte between 0.02 nd 0.05 is supplied to the bttery (trickle chrge) s mintennce chrge to ensure tht it remins in fully chrged stte. The complete chrge process is bcked by temperture cutoff (TCO) tht ensures the bttery temperture does not exceed 60 C (140 F). PROCEDURE OUTLINE The Procedure is divided into the following sections: Set up nd connections Full bttery dischrge Bttery chrge t 0.5C 5 using the dt /dt chrge-control technique Slow bttery chrge using low-rte, constnt-current chrging method (OPTIONAL) Three-step chrge (OPTIONAL) PROCEDURE High voltges re present in this lbortory exercise. Do not mke or modify ny bnn jck connections with the power on unless otherwise specified. Set up nd connections In this section, you will set up nd connect the equipment. All exercises should idelly be performed t n mbient temperture between 20 C (68 F) nd 25 C (77 F). 1. Refer to the Equipment Utiliztion Chrt in Appendix A to obtin the list of equipment required to perform this exercise. Instll the equipment required in the Worksttion. 2. Mke sure the min power switch on the Four-Qudrnt Dynmometer/ Power Supply is set to the O (off) position, then connect its Power Input to n c power outlet. 3. Connect the USB port of the Four-Qudrnt Dynmometer/ Power Supply to USB port of the host computer. Festo Didctic

6 Exercise 4 Bttery Chrging Methods Procedure 4. Turn the Four-Qudrnt Dynmometer/Power Supply on, then set the Operting Mode switch to Power Supply. 5. Turn the host computer on, then strt the LVDAC-EMS softwre. In the LVDAC-EMS Strt-Up window, mke sure the Four-Qudrnt Dynmometer/Power Supply is detected. Select the network voltge nd frequency tht correspond to the voltge nd frequency of the locl c power network, then click the OK button to close the LVDAC-EMS Strt-Up window. 6. Connect one bttery in the Ni-MI Btteries module to the Four-Qudrnt Dynmometer/Power Supply s shown in Figure 30. Mke sure tht the bttery is fully chrged by performing the Bttery stte-of-chrge evlution section described in the procedure of Exercise 1. Connect the thermistor inputs of the Four-Qudrnt Dynmometer/Power Supply to the thermistor of the Ni-MI bttery to be dischrged (without connecting the series resistor). Four-Qudrnt Dynmometer/Power Supply * * 12 V Ni-MH bttery N (*) Meter in the Four-Qudrnt Dynmometer/Power Supply window of LVDAC-EMS Figure 30. Ni-MI bttery connected to the Four-Qudrnt Dynmometer/Power Supply operting s bttery dischrger. Full bttery dischrge In this section, you will fully dischrge bttery of the Ni-MI Btteries module t dischrge rte of 1 (2 A). During the dischrge cycle, you will observe the bttery voltge, current, temperture, nd relesed energy. This dischrge cycle is necessry to observe the behvior of the bttery during the chrge cycle in the next prts of the exercise. 7. In LVDAC-EMS, open the Four-Qudrnt Dynmometer/Power Supply window nd mke the following settings: Set the Function prmeter to Bttery Dischrger. 56 Fes t o Di dc t i c

7 Exercise 4 Bttery Chrging Methods Procedure Set the Dischrge Current prmeter to 2 A (1 ). Set the Dischrge Durtion prmeter to 60 min. Set the Cutoff Voltge prmeter to 10.0 V (vlue recommended by the bttery mnufcturer). Also, reset the Energy Meter to mke sure tht the mount of energy dischrged from the bttery is currently equl to 0.00 Wh. The setting of the dischrge durtion corresponds to the time required to remove pproximtely 100% of the energy contined in fully chrged bttery when dischrging t rte of 1. Depending on the ctul stte of chrge of the bttery, the dischrge will terminte when the cutoff voltge is reched or t the end of the dischrge durtion. 8. In LVDAC-EMS, open the Dt Tble window. Set the timer to mke 480 records with n intervl of 30 seconds between ech record. This setting corresponds to 240-minute period of observtion, providing enough time to record the prmeters during the bttery dischrge, the puse time required to cool the bttery, nd the subsequent bttery chrge. Set the Dt Tble to record the voltge, current, energy, nd temperture indicted by the meters in the Four-Qudrnt Dynmometer/Power Supply window, nd the time ssocited with ech record. 9. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Bttery Dischrger, then immeditely strt the timer in the Dt Tble window to begin recording dt. 10. About 15 minutes fter the bttery dischrge begn, mesure the bttery voltge using n externl multimeter. Compre the voltge mesured with the multimeter with tht indicted by the voltmeter on the Four-Qudrnt Dynmometer/Power Supply. If the vlues differ, correct the cutoff voltge of the Bttery Dischrger ccordingly. For exmple, if the module voltmeter underestimtes the bttery voltge by 0.3 V, reduce the cutoff voltge to 9.7 V to ensure the dischrge termintes when the bttery voltge is ctully 10.0 V. 11. As soon s the Bttery Dischrger stops the chrge (either becuse the dischrge durtion hs elpsed or the cutoff voltge is reched), remove the Ni-MI Btteries module from the worksttion (without removing the connections to the bttery nd thermistor) in order to ventilte the Ni-MH bttery pck inside the module until its temperture decreses to less thn 26 C (79 F). If vilble, use fn to speed up the process. This step is necessry to return the bttery temperture to ner mbient temperture s soon s possible nd proceed with the next section. Do not stop the timer in the Dt Tble window t the end of the dischrge cycle. Festo Didctic

8 Exercise 4 Bttery Chrging Methods Procedure 12. While the Ni-MI bttery is being ventilted, record the energy supplied by the bttery (indicted by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window) during the dischrge cycle. Energy supplied during dischrge: 13. Clculte the dischrge cpcity (in Ah) of the Ni-MI bttery using the dischrge durtion mesured during the dischrge cycle. Dischrge durtion: Dischrge cpcity: h Ah Bttery chrge t 0.5C 5 using the dt /dt chrge-control technique In this section, you will determine the rte of temperture increse needed to stop chrging cycle t the beginning of the plteu in the bump observed in the voltge profile t the end of chrge cycle. You will then chrge the fully dischrged bttery of the Ni-MI Btteries module t chrge rte of 0.5 (1 A), using the dt /dt chrge-control technique set to the clculted rte of temperture increse bcked by the temperture cutoff chrge-control technique. During the chrge cycle, you will record the bttery voltge, current, nd temperture, s well s the energy returned to the bttery. You will then clculte the chrge efficiency nd plot the voltge nd temperture profiles of the Ni-MI bttery mesured throughout the exercise section. You will compre the chrge input supplied to the bttery during chrge cycle t 0.5 terminted using the dt /dt technique to the chrge input supplied to the bttery during chrge cycle t 0.5 terminted using the TCO technique. 14. Determine the rte of temperture increse needed to stop the chrge t the beginning of the plteu in the bump observed in the voltge profile t the end of chrge cycle using the Ni-MI bttery temperture profile t chrge rte of 0.5 obtined in Exercise 3. To do so, determine the time t the beginning of the plteu in the bump of the voltge profile, then record the bttery temperture 1 minute before the beginning of the plteu nd 1 minute fter the beginning of the plteu. Clculte the difference between the two tempertures nd divide the result by two in order to obtin the rte of temperture increse t the beginning of the voltge plteu in the bump in the voltge profile. Time t the beginning of the voltge plteu: min Temperture 1 minute before: Temperture 1 minute fter: Rte of temperture increse dt /dt: C ( F) C ( F) C/min ( F/min) 15. Before proceeding with the next step, wit for the bttery temperture indicted by the Temperture Meter in LVDAC-EMS to drop 58 Fes t o Di dc t i c

9 Exercise 4 Bttery Chrging Methods Procedure below 26 C (79 F). When the temperture of the Ni-MI bttery hs decresed below 26 C (79 F), put the Ni-MI Btteries module bck into the worksttion nd stop ny externl ventiltion. From now on, the Ni-MI Bttery Chrger (Constnt- Current Chrge with dt /dt nd TCO) function is referred to s the Ni-MI Bttery Chrger for brevity purposes. 16. In the Four-Qudrnt Dynmometer/Power Supply window, mke the following settings: Set the Function prmeter to Ni-MI Bttery Chrger (Constnt- Current Chrge with dt /dt nd TCO). When the Ni-MI Bttery Chrger (Constnt-Current Chrge with dt /dt nd TCO) function is selected, the Four-Qudrnt Dynmometer/Power Supply opertes s Ni-MI bttery chrger using the following prmeters to chieve chrge control: chrge current, dt /dt, nd TCO. Set the Chrge Current prmeter to 1 A (0.5 ). Set the dt /dt prmeter to the vlue you clculted in step 14. Set the TCO prmeter to 50 C (122 F). Do not reset the Energy Meter. In this exercise, the dt /dt vlue should be reched before the TCO temperture is ttined. However, in the event the rte of temperture increse method fils to work, TCO of 50 C (122 F) hs been set in order to prevent excessive bttery overchrge. 17. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Ni-MI Bttery Chrger, then immeditely strt the timer in the Dt Tble window to begin recording dt. Let the bttery chrge until the Ni-MI Bttery Chrger utomticlly stops the chrge (when the dt /dt or TCO vlue is reched). This should tke pproximtely 120 minutes. When the chrge is terminted, immeditely stop the timer in the Dt Tble window to stop recording dt, then sve the recorded dt. 18. Does the energy vlue displyed by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window show tht the energy returned to the bttery during the chrge t 0.5 with dt /dt nd TCO exceeds the energy supplied by the bttery during the dischrge? Yes No Record the mount of energy returned to the bttery during the chrge cycle. Energy returned to the bttery during chrge: Wh 19. Clculte the chrge efficiency (in %) of the chrge cycle using the mount of energy supplied during the dischrge recorded in step 12 nd the mount Festo Didctic

10 Exercise 4 Bttery Chrging Methods Procedure of energy returned to the bttery during the chrge cycle recorded in the previous step. Chrge efficiency: % 20. Export your recorded dt to spredsheet ppliction nd crete seprte plots for the voltge nd temperture profiles of the Ni-MI bttery t chrge rte of 0.5. It is suggested tht you include the dt tble nd the grph plotted in this exercise in your lb report. 21. Record the chrge durtion of the chrge cycle t 0.5 with dt /dt chrge termintion, then clculte the chrge input (percentge of the bttery s nominl cpcity) tht hs been returned to the bttery during the chrge cycle. Chrge durtion: h Chrge input: % 22. Compre the chrge input supplied to the bttery by chrge cycle t 0.5 with dt /dt chrge termintion to the chrge input supplied to the bttery by chrge cycle t 0.5 with TCO chrge termintion recorded in Exercise 3. Which chrge-control technique mximizes the cycle life of Ni-MI bttery? Which chrge-control technique mximizes the bttery cpcity? Explin why. 60 Fes t o Di dc t i c

11 Exercise 4 Bttery Chrging Methods Procedure Slow bttery chrge using low-rte, constnt-current chrging method (OPTIONAL) Since the slow chrge method lsts bout 15 hours, it cnnot be performed within norml lb session. For this reson, it is considered optionl. In this section, you will fully dischrge one of the btteries in the Ni-MI Btteries module. During the dischrge cycle, you will observe the bttery voltge, current, temperture, nd relesed energy. You will then chrge the bttery using the slow chrge method. During the chrge cycle, you will observe the bttery voltge, current, nd temperture, s well s the energy returned to the bttery. You will then clculte the chrge efficiency nd plot the voltge nd temperture profiles of the Ni-MI bttery mesured throughout this section. You will compre the chrge efficiency of the chrge cycle nd the chrge input supplied to the bttery obtined for ech of the three chrging methods studied thus fr: chrge cycle t 0.5 with TCO, chrge cycle t 0.5 with dt /dt nd TCO, nd timed chrge cycle t 0.1 with TCO. Finlly, you will determine if the slow chrge method is good chrging method for Ni-MI btteries. 23. Connect fully chrged bttery of the Ni-MI Btteries module to the Four- Qudrnt Dynmometer/Power Supply. Mke sure tht the bttery is fully chrged by performing the Bttery stte-of-chrge evlution section described in the procedure of Exercise 1. Connect the thermistor inputs of the Four-Qudrnt Dynmometer/Power Supply to the thermistor of the Ni-MI bttery to be dischrged (without connecting the series resistor). 24. In the Four-Qudrnt Dynmometer/Power Supply window, mke the following settings: Set the Function prmeter to Bttery Dischrger. Set the Dischrge Current prmeter to 2 A (1 ). Set the Dischrge Durtion prmeter to 60 min. Set the Cutoff Voltge prmeter to 10.0 V (vlue recommended by the bttery mnufcturer). Also, reset the Energy Meter to mke sure tht the mount of energy dischrged from the bttery is currently equl to 0.00 Wh. The setting of the dischrge durtion corresponds to the time required to fully dischrge Ni-MI bttery when dischrging t rte of 1. Depending on the ctul stte of chrge of the bttery, the dischrge will terminte when the cutoff voltge is reched or t the end of the dischrge durtion. 25. In LVDAC-EMS, open the Dt Tble window. Set the timer to mke 600 records with n intervl of 2 minutes between ech record. This setting corresponds to 1200-minute period of observtion, providing Festo Didctic

12 Exercise 4 Bttery Chrging Methods Procedure enough time to record the prmeters during the bttery dischrge, the puse time required to cool the bttery, nd the subsequent bttery chrge. Set the Dt Tble to record the voltge, current, energy, nd temperture indicted by the meters in the Four-Qudrnt Dynmometer/Power Supply window, nd the time ssocited with ech record. 26. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Bttery Dischrger then immeditely strt the timer in the Dt Tble window to begin recording dt. 27. About 15 minutes fter the bttery dischrge begn, mesure the bttery voltge using n externl multimeter. Compre the voltge mesured with the multimeter with tht indicted by the voltmeter on the Four-Qudrnt Dynmometer/Power Supply. If the vlues differ, correct the cutoff voltge of the Bttery Dischrger ccordingly. For exmple, if the module voltmeter underestimtes the bttery voltge by 0.3 V, reduce the cutoff voltge to 9.7 V to ensure the dischrge termintes when the bttery voltge is ctully 10.0 V. 28. As soon s the Bttery Dischrger stops the chrge (either becuse the dischrge durtion hs elpsed or the cutoff voltge is reched), remove the Ni-MI Btteries module from the worksttion (without removing the connections to the bttery nd thermistor) in order to ventilte the Ni-MH bttery pck inside the module until its temperture decreses to less thn 26 C (79 F). If vilble, use fn to speed up the process. This step is necessry to return the bttery temperture to ner mbient temperture s soon s possible nd proceed with the next section. Do not stop the timer in the Dt Tble window t the end of the dischrge cycle. 29. While the Ni-MI Btteries module is being ventilted, record the energy supplied by the bttery (indicted by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window) during the dischrge cycle. Energy supplied during dischrge: 30. Clculte the dischrge cpcity (in Ah) of the Ni-MI bttery using the dischrge durtion mesured during the dischrge cycle. Dischrge durtion: Dischrge cpcity: h Ah 31. Before proceeding with the next step, wit for the bttery temperture indicted by the Temperture Meter in LVDAC-EMS to drop below 26 C (79 F). When the temperture of the Ni-MI bttery hs 62 Fes t o Di dc t i c

13 Exercise 4 Bttery Chrging Methods Procedure decresed below 26 C (79 F), put the Ni-MI Btteries module bck into the worksttion nd stop ny externl ventiltion. 32. In the Four-Qudrnt Dynmometer/Power Supply window, mke the following settings: From now on, the Ni-MI Bttery Chrger (Constnt- Current Timed Chrge with TCO) function is referred to s the Ni-MI Bttery Chrger for brevity purposes. Set the Function prmeter to Ni-MI Bttery Chrger (Constnt- Current Timed Chrge with TCO). Set Chrge Current prmeter to 0.2 A (0.1 ). Set the Chrge Durtion prmeter to 15 hours. Set the TCO prmeter to 50 C (122 F). Do not reset the Energy Meter. Since the chrge current is low, the bttery temperture should not rise up to the TCO temperture. The chrge should therefore be terminted t the end of the timed chrge of 15 hours. 33. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Ni-MI Bttery Chrger. Let the bttery chrge until the Ni-MI Bttery Chrger utomticlly stops the chrge. When the chrge is terminted, immeditely stop the timer in the Dt Tble window to stop recording dt, then sve the recorded dt. 34. Does the energy vlue displyed by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window show tht the energy returned to the bttery during the slow chrge t 0.1 equls or exceeds the energy supplied by the bttery during the dischrge? Yes No Record the mount of energy returned to the bttery during the chrge cycle. Energy returned to the bttery during chrge: Wh 35. Clculte the chrge efficiency (in %) of the chrge cycle using the mount of energy supplied during the dischrge recorded in step 29 nd the mount of energy returned to the bttery during the chrge cycle recorded in the previous step. Chrge efficiency: % Festo Didctic

14 Exercise 4 Bttery Chrging Methods Procedure 36. Compre the chrge efficiency obtined for ech of the three different chrging methods you hve used so fr: chrge cycle t 0.5 with TCO (step 18 of Exercise 3), chrge cycle t 0.5 with dt /dt nd TCO (step 19 of this exercise), nd timed chrge cycle t 0.1 with TCO (previous step). Briefly explin the mening behind ech clculted chrge efficiency. 37. Export your recorded dt to spredsheet ppliction nd crete seprte plots for the voltge nd temperture profiles of the Ni-MI bttery t chrge rte of 0.5. It is suggested tht you include the dt tble nd the grph plotted in this exercise in your lb report. 38. Record the chrge durtion of the chrge cycle t 0.1, then clculte the chrge input (percentge of the bttery s nominl cpcity) tht hs been returned to the bttery during the chrge cycle. Chrge durtion: h Chrge input: % 39. Compre the chrge inputs obtined for ech of the three different chrging methods you hve used so fr: chrge cycle t 0.5 with TCO (step 23 of Exercise 3), chrge cycle t 0.5 with dt /dt nd TCO (step 21 of this exercise), nd timed chrge cycle t 0.1 with TCO (previous step). Which chrge input is better for the bttery life? 64 Fes t o Di dc t i c

15 Exercise 4 Bttery Chrging Methods Procedure 40. Is the slow chrge good chrging method for Ni-MI btteries, considering the time required for full chrge cycle, the chrge efficiency, nd the chrge input? Why? Yes No Three-step chrge (OPTIONAL) This section is optionl but cn be performed during norml lb session. In this section, you will fully dischrge one of the btteries in the Ni-MI Btteries module. During the dischrge cycle, you will observe the bttery voltge, current, temperture, nd relesed energy. You will then chrge the bttery using the three-step chrge method. During the chrge cycle, you will observe the bttery voltge, current, nd temperture, s well s the energy returned to the bttery. You will then clculte the chrge efficiency nd plot the voltge nd temperture profiles of the Ni-MI bttery mesured throughout this section. You will compre the chrge efficiency of the chrge cycle nd the chrge input supplied to the bttery obtined for the three-step chrge method to the chrge efficiency nd chrge input obtined for the other chrging methods studied so fr. Finlly, you will determine if the three-step chrge method is good chrging method for Ni-MI btteries. 41. Connect fully chrged bttery of the Ni-MI Btteries module to the Four- Qudrnt Dynmometer/Power Supply. Mke sure tht the bttery is fully chrged by performing the Bttery stte-of-chrge evlution section described in the procedure of Exercise 1. Connect the thermistor inputs of the Four-Qudrnt Dynmometer/Power Supply to the thermistor of the Ni-MI bttery to be dischrged (without connecting the series resistor). 42. In the Four-Qudrnt Dynmometer/Power Supply window, mke the following settings: Set the Function prmeter to Bttery Dischrger. Set the Dischrge Current prmeter to 2 A ( ). Set the Dischrge Durtion prmeter to 60 min. Set the Cutoff Voltge prmeter to 10.0 V (vlue recommended by the bttery mnufcturer). Also, reset the Energy Meter to mke sure tht the mount of energy dischrged from the bttery is currently equl to 0.00 Wh. Festo Didctic

16 Exercise 4 Bttery Chrging Methods Procedure The setting of the dischrge durtion corresponds to the time required to fully dischrge Ni-MI bttery when dischrging t rte of 1. Depending on the ctul stte of chrge of the bttery, the dischrge will terminte when the cutoff voltge is reched or t the end of the dischrge durtion. 43. In LVDAC-EMS, open the Dt Tble window. Set the timer to mke 600 records with n intervl of 30 seconds between ech record. This setting corresponds to 300-minute period of observtion, providing enough time to record the prmeters during the bttery dischrge, the puse time required to cool the bttery, nd the subsequent bttery chrge. Set the Dt Tble to record the voltge, current, energy, nd temperture indicted by the meters in the Four-Qudrnt Dynmometer/Power Supply window, nd the time ssocited with ech record. 44. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Bttery Dischrger then immeditely strt the timer in the Dt Tble window to begin recording dt. 45. About 15 minutes fter the bttery dischrge begn, mesure the bttery voltge using n externl multimeter. Compre the voltge mesured with the multimeter with tht indicted by the voltmeter on the Four-Qudrnt Dynmometer/Power Supply. If the vlues differ, correct the cutoff voltge of the Bttery Dischrger ccordingly. For exmple, if the module voltmeter underestimtes the bttery voltge by 0.3 V, reduce the cutoff voltge to 9.7 V to ensure the dischrge termintes when the bttery voltge is ctully 10.0 V. 46. As soon s the Bttery Dischrger stops the chrge (either becuse the dischrge durtion hs elpsed or the cutoff voltge is reched), remove the Ni-MI Btteries module from the worksttion (without removing the connections to the bttery nd thermistor) in order to ventilte the Ni-MH bttery pck inside the module until its temperture decreses to less thn 26 C (79 F). If vilble, use fn to speed up the process. This step is necessry to return the bttery temperture to ner mbient temperture s soon s possible nd proceed with the next section. Do not stop the timer in the Dt Tble window t the end of the dischrge cycle. 47. While the Ni-MI Btteries module is being ventilted, record the energy supplied by the bttery (indicted by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window) during the dischrge cycle. Energy supplied during dischrge: 66 Fes t o Di dc t i c

17 Exercise 4 Bttery Chrging Methods Procedure 48. Clculte the dischrge cpcity (in Ah) of the Ni-MI bttery using the dischrge durtion mesured during the dischrge cycle. Dischrge durtion: Dischrge cpcity: h Ah 49. Before proceeding with the next step, wit for the bttery temperture indicted by the Temperture Meter in LVDAC-EMS to drop below 26 C (79 F). When the temperture of the Ni-MI bttery hs decresed below 26 C (79 F), put the Ni-MI Btteries module bck into the worksttion nd stop ny externl ventiltion. From now on, the Ni-MI Bttery Chrger (3-Step Chrge with TCO) function is referred to s the Ni-MI Bttery Chrger for brevity purposes. 50. In the Four-Qudrnt Dynmometer/Power Supply window, modify the settings s follows: Set the Function prmeter to Ni-MI Bttery Chrger (3-Step Chrge with TCO). When the Ni-MI Bttery Chrger (3-Step Chrge with TCO) function is selected, the Four-Qudrnt Dynmometer/Power Supply opertes s Ni-MI bttery chrger whose operting prmeters re controlled by the bttery chrcteristics: TCO, chrge current during ech of the three steps, dt /dt to terminte the first step, nd chrge durtion to terminte the second step. Set the TCO prmeter to 50 C (122 F). Set the Step-1 Current prmeter to 2 A (1 ). Set the Step-1 dt /dt prmeter to 0.85 C/min (1.55 F/min). Set the Step-2 Current prmeter to 0.2 A (0.1 ). Set the Step-2 Durtion prmeter to 30 min. Set the Step-3 Current prmeter to 0.06 A (0.03 ). 51. In the Four-Qudrnt Dynmometer/Power Supply window, strt the Ni-MI Bttery Chrger, then immeditely strt the timer in the Dt Tble window to begin recording dt. Let the bttery chrge for 180 minutes (3 hours), then stop the chrge. Stop lso the timer in the Dt Tble window to stop recording dt, then sve the recorded dt. As the bttery is considered to be fully chrged fter the second step, the third step is only intended to mintin the full chrge of the bttery. The chrge should be stopped fter 180 minutes (3 hours), but could theoreticlly continue indefinitely. Festo Didctic

18 Exercise 4 Bttery Chrging Methods Procedure 52. Does the energy vlue displyed by the Energy Meter in the Four-Qudrnt Dynmometer/Power Supply window show tht the energy returned to the bttery during the three-step chrge exceeds the energy supplied by the bttery during the dischrge? Yes No Record the mount of energy returned to the bttery during the chrge cycle. Energy returned to the bttery during chrge: Wh 53. Clculte the chrge efficiency (in %) of the chrge cycle using the mount of energy supplied during the dischrge recorded in step 47 nd the mount of energy returned to the bttery during the chrge cycle recorded in the previous step. Chrge efficiency: % 54. How does the chrge efficiency of the three-step chrge method compre with the chrge efficiency obtined for the other chrging methods studied so fr? 55. Export your recorded dt to spredsheet ppliction nd crete seprte plots for the voltge nd temperture profiles of the Ni-MI bttery during full dischrge followed by three-step chrge. It is suggested tht you include the dt tble nd the grph plotted in this exercise in your lb report. 56. Record the chrge durtion during ech of the steps, then clculte the chrge input (percentge of the bttery s nominl cpcity) tht hs been returned to the bttery during the complete chrge cycle by dding the chrge input of ech step. Step 1 chrge durtion: h Step 1 chrge input: % Step 2 chrge durtion: h Step 2 chrge input: % 68 Fes t o Di dc t i c

19 Exercise 4 Bttery Chrging Methods Conclusion Step 3 chrge durtion: h Step 3 chrge input: % Totl chrge input: % 57. Is the three-step chrge good chrging method for Ni-MI btteries, considering the time required for full chrge cycle, the resulting chrge input, nd the control of the bttery temperture? Why? Yes No 58. Wht is the min distinction between the three-step chrging method nd the other chrging methods studied in this exercise? 59. Close LVDAC-EMS, then turn off ll the equipment. Disconnect ll leds nd return them to their storge loction. CONCLUSION In this exercise, you becme fmilir with the different chrging methods nd chrge-control techniques commonly used when chrging Ni-MI btteries. You were ble to evlute which one is best suited to given sitution, depending on different fctors such s the chrge current rte, chrge durtion, chrge input, nd mbient temperture. REVIEW QUESTIONS 1. Why is it recommended to use chrge-control technique when chrging Ni-MI bttery using high current rtes (0.3 nd more)? Festo Didctic

20 Exercise 4 Bttery Chrging Methods Review Questions 2. Wht is the difference between the voltge drop (-V) technique nd the voltge plteu (0V) technique nd which one is best suited for Ni-MI btteries? 3. Which chrge-control technique is the most pproprite for Ni-MI btteries with regrd to cycle life, nd why? 4. Which methods between the low-rte chrge, quick chrge, nd fst chrge re most commonly used to chrge Ni-MI btteries nd why? 70 Fes t o Di dc t i c

21 Exercise 4 Bttery Chrging Methods Review Questions 5. Describe the chrge cycle of Ni-MI bttery when using the three-step chrge method. Festo Didctic

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