Invented by Don Karner, Frank Fleming, Ulf Krohn, Christer Lindkvist, Electric Applications Inc, Northstar Battery Co LLC

The market for systems and methods for determining crank health of a battery has been growing rapidly in recent years. As the demand for electric vehicles (EVs) and renewable energy storage systems continues to rise, the need for efficient and reliable battery diagnostics becomes increasingly important. The crank health of a battery refers to its ability to deliver a high current for a short period, typically during engine start-up in traditional vehicles or power demand spikes in EVs. It is a critical factor in determining the overall performance and lifespan of a battery. Therefore, accurate and timely assessment of crank health is crucial for ensuring optimal battery performance and preventing unexpected failures. Traditionally, battery health diagnostics have relied on simple voltage measurements or load testing. However, these methods often fail to provide a comprehensive understanding of a battery’s true condition, especially in the case of EVs and other high-performance applications. This has led to the development of advanced systems and methods that offer more precise and reliable crank health analysis. One of the key advancements in this market is the use of impedance spectroscopy, a technique that measures the electrical response of a battery to different frequencies of alternating current. By analyzing the impedance spectrum, these systems can accurately assess the internal resistance and capacity of a battery, providing valuable insights into its crank health. This technology is particularly useful for detecting early signs of battery degradation and predicting potential failures before they occur. Another emerging trend in the market is the integration of artificial intelligence (AI) and machine learning algorithms into battery diagnostics systems. These intelligent systems can analyze large amounts of battery data, including voltage, current, temperature, and other parameters, to identify patterns and anomalies that may indicate crank health issues. By continuously learning from real-time data, these systems can improve their diagnostic accuracy over time and provide proactive maintenance recommendations. The market for systems and methods for determining crank health of a battery is not limited to automotive applications. It also extends to various industries that rely on energy storage systems, such as renewable energy, telecommunications, and backup power. In these sectors, battery reliability and performance are critical for ensuring uninterrupted operations and reducing downtime. The increasing adoption of electric vehicles and the growing demand for renewable energy storage are the primary drivers behind the market’s growth. According to a report by MarketsandMarkets, the global battery diagnostics market is expected to reach $4.5 billion by 2025, with a compound annual growth rate (CAGR) of 5.93% during the forecast period. Key players in this market include battery manufacturers, diagnostic equipment suppliers, and software developers. Companies like AVL, Midtronics, and Nuvation Engineering are at the forefront of developing innovative diagnostic solutions for battery health assessment. These companies are investing heavily in research and development to improve the accuracy, speed, and ease of use of their diagnostic systems. In conclusion, the market for systems and methods for determining crank health of a battery is witnessing significant growth due to the increasing demand for electric vehicles and renewable energy storage systems. Advanced technologies like impedance spectroscopy and AI-driven diagnostics are revolutionizing battery health assessment, enabling proactive maintenance and improving overall performance. As the market continues to evolve, we can expect further advancements in battery diagnostics, leading to more efficient and reliable energy storage solutions.

The Electric Applications Inc, Northstar Battery Co LLC invention works as follows

The method may include: receiving battery temperature data, representing a temperature of the battery at a time of cranking the internal combustion engine; receiving voltage data monitored from a battery, determining an instantaneous minimum voltage of battery during the time of cranking an internal combustion motor; and determining a capability of battery to crank an interior combustion engine based on battery temperature data and an instantaneous minimum voltage of battery. The method can include receiving battery data representing the temperature of the engine at the time the engine is cranked; receiving voltage data from the engine, determining the minimum voltage instantaneously of the engine during cranking; and determining the capability of the engine to be cranked based on battery temperature and the minimum voltage instantaneously.

Background for Systems and Methods for Determining Crank Health of a Battery

Lead acid energy storage devices have been widely used for over 100 years in many different applications. These energy storage devices were monitored in some cases to determine the condition of energy storage devices. These monitoring techniques are usually complex and expensive enough to limit their usage and the amount of data they can provide, especially in remote applications with low value. There are generally not enough data available about the performance of an energy storage device during its lifetime. In addition, in limited numbers, certain energy storage devices can be coupled with sensors to collect information about the energy system. However, this is not common in large systems or for devices that are geographically distributed. The limited data collected via monitoring prior to the invention is often insufficient for analysis, notification, and determinations. Similar limitations exist for non-lead-acid energy storage devices. These batteries are used in new mobile applications, but their power and high energy levels do not allow them to be monitored by traditional systems. “New devices, systems, and methods of monitoring energy storage (and batteries, in particular) are still desirable. For example, they can provide new opportunities for managing energy storage devices in remote and/or diverse geographic locations.

The method may include: receiving battery temperature data, representing a temperature of the battery at a time of cranking the internal combustion engine; receiving voltage data monitored from battery; determining an instantaneous minimum voltage of battery during the time of cranking internal combustion engine. The method can include: receiving battery data representing the temperature of the engine at the time the engine is cranking; receiving voltage data from the engine; determining the minimum voltage instantaneously of the engine during cranking; and determining the capability of the engine to crank based on battery temperature and the minimum voltage instantaneously.

The method may include: detecting a crank event based on monitoring battery voltage; sensing a battery temperature (a Crank Temperature) and the battery voltage (a Crank Voltage) during the crank event; storing the stored data for each of these parameters. The method can include: detecting an event by monitoring battery voltage, sensing battery temperature (a “Crank Temperature”) and battery voltage (a “Crank Voltage”) during the event, storing CrankTemperature and CrankVoltage for the event and determining crank health based upon analysis of changes to the CrankTemperature and CrankVoltage.

The method may include: detecting a crank event based on monitoring battery voltage; sensing a battery temperature (a Crank Temperature) and the battery voltage (a Crank Voltage) during the crank event; and determining the crank health of a battery based on the Crank Temperature and/or a predicted future. The method can include: detecting an event by monitoring battery voltage, sensing the battery temperature (a “Crank Temperature”) and battery voltage (a “Crank Voltage”) during the event, and determining the battery crank health based on the CrankTemperature and CrankVoltage.

The contents of this section were intended as an introduction to the disclosure and not to limit any claim.

The detailed description includes the best mode as an illustration. These embodiments have been described in enough detail for those in the know to be able to apply the principles of this disclosure. However, other embodiments can be realized, and logical, chemical, mechanical and/or electric changes may be made, without departing the spirit and scope. The detailed description is only for illustration purposes and does not limit the scope of the present disclosure. The steps in the method descriptions can be performed in any order.

For the sake of conciseness, it is possible that certain sub-components and other aspects of a system will not be described herein in detail. In a practical system such as a battery monitoring device, there may be many functional or physical relationships that are different or added. These functional blocks can be realized using any number of components that are configured to perform specific functions.

The principles of the disclosure can improve battery operation, by removing monitoring components like a current-sensing device that can drain the battery prematurely. A battery monitoring circuit can be embedded into the battery during manufacture so that it can monitor the battery from its first day until it’s recycled or disposed. The principles of this disclosure also improve the operation of computing devices such as mobile communications devices and/or battery monitors in many ways. For example, reducing memory usage by a circuit monitor via compact storage in a matrix-like database reduces manufacturing cost, operating current draw and extends the operational life of the circuit monitor.

In addition, the principles of this disclosure can improve the operation and/or performance of devices that are coupled with and/or associated to a battery. For example, a cell radio base station or an electric forklift.

Yet, further, the application of principles in the present disclosure can transform and change real-world objects. As an example, a charging algorithm causes lead sulfate to be converted into lead, sulfuric acid, and lead oxide in a monobloc of lead-acid batteries. This transforms a partially-depleted battery to a fully-charged battery. As part of an example algorithm, monoblocs within a warehouse can be physically moved, recharged or removed or replaced. This creates a new configuration of monoblocs.

It will be understood that there are other ways to monitor, maintain, or use energy storage devices. The systems and methods disclosed herein are not intended to preempt such techniques or fields, but instead represent specific advancements that offer technical improvements, cost and time savings, environmental benefits and improved battery life. It will also be noted that the systems and methods described herein provide these desirable benefits, while at the same eliminating a costly component, which drains power, of previous monitoring systems. This is a current-sensor. In other words, the various examples of systems and methods are not configured with a current sensing device and/or any information that can be derived from it, which is in stark contrast to almost all previous approaches.

In an exemplary embodiment, there is a battery monitoring circuit disclosed. The battery monitor circuit can be configured to record and/or wirelessly or wired communicate certain information about and/or from a cell, such as date/time, temperature and voltage information.

In an exemplary embodiment, monoblocs are energy storage devices that include at least one cell of an electrochemical nature, and in most cases a plurality. The term “battery” is used in this document. It can refer to a monobloc or a group of monoblocs electrically connected together in parallel and/or series. A “battery” In other literature, a “battery” is a collection of monoblocs electrically connected together in parallel or series. A battery can have a positive and negative terminal. In addition, in different exemplary embodiments a battery can have a number of positive and/or negative terminals. In one exemplary embodiment, the battery monitor circuit can be embedded or positioned inside a housing of a cell and is connected to the battery terminals by a wired connector. In another example, a circuit for monitoring a power source is attached to a cell, such as by attaching it to the outside of the battery housing, and connecting the terminals to the battery via a wired connector.

In an embodiment, a battery monitor circuit comprises various electrical components, for example a voltage sensor, a temperature sensor, a processor for executing instructions, a memory for storing data and/or instructions, an antenna, and a transmitter/receiver/transceiver. A battery monitor circuit can also include, in some embodiments, an alarm clock. A battery monitor circuit can also include positioning components such as a GPS receiver circuit.

In certain embodiments, the battery monitor circuit can include a voltage sensing device with electrical connections wired to a cell, which is used for monitoring voltage between the positive and negative terminals (terminals) of a cell. The battery monitor circuit can also include a sensor to measure the temperature of the battery. The battery monitor circuit can include a processor that receives a monitored voltage from the voltage sensors, a monitored temp signal from the temperature sensors, processes the monitored voltage and monitored temp signal, generates voltage data and temperature information based on monitored voltage and monitored temperature signals, and executes other functions and instructions.

In various embodiments of the battery monitor circuit, a memory is used to store data. For example, voltage data or temperature data associated with a battery. The memory can also be used to store instructions that are executed by the processor or data and/or instruction received from an outside device. In one embodiment, voltage data is the voltage measured across the battery terminals, while temperature data is the temperature at a specific location within or on the battery. The battery monitor circuit can also include an antenna and transceiver for, for instance, wirelessly transmitting data such as voltage data and temperature data to a distant device and/or for receiving data or instructions. The battery monitor circuit can also include a wired link to the remote device or to the battery, such as for transmitting voltage and temperature data via the wired link to the remote device and/or receiving data. In an exemplary embodiment, a battery monitor circuit transmits voltage data and temperature data wirelessly to a remote device via the antenna. In another embodiment, the battery monitoring circuit transmits voltage and temperature data to the remote device via a wired link. In one embodiment, the battery monitoring circuit is located outside the battery and electrically connected to the batteries.

In one example, the battery monitor circuit can be created by coupling various components onto a circuitboard. The battery monitor circuit may also include a real-time time clock in an exemplary embodiment. The real-time time clock can be used to precisely time the collection of voltage data and temperature for a battery. The battery monitor may be placed inside the battery and configured for sensing an internal battery temperature. Alternatively, the circuit can be externally mounted to the cell and configured for sensing an external battery temperature. In a second exemplary embodiment, the battery monitor circuit can be positioned inside a monobloc in order to detect an internal temperature. In a further exemplary embodiment, the battery monitor circuit can be coupled to a single-block to detect an external temperature. The battery monitor circuit’s wired or wireless signals can be used to perform various useful actions, as described in the following paragraphs.

Referring to FIGS. In an exemplary embodiment of a battery 100, it may be comprised of a monobloc. In an exemplary embodiment the monobloc can be defined as a device for storing energy. The monobloc includes at least one cell electrochemical (not shown). In some embodiments the monobloc contains multiple electrochemical cell, such as to allow the monobloc to be configured with the desired voltage or current. In several exemplary embodiments the electrochemical cell is of lead-acid design. In one exemplary embodiment the lead-acid cells can be of any type. However, they are designed as absorbent glass mats (AGM). In a second exemplary embodiment, lead-acid cells are designed as gels. Another exemplary embodiment is the flooded type of design. It will be understood that the principles of this disclosure can be applied to a variety of battery chemistries including, but not limited, to Nickel-cadmium, Nickel Metal Hydride, Lithium Ion, Lithium Cobalt Oxide, Iron Phosphate, Manganese Oxide, NiCd, Nickel-cobalt Aluminum Oxide, Titanate, Rechargeable Alkaline and/or other chemistries.

The housing 110 of the battery 100 is possible. The battery 100 can be made with a monobloc sealed lead-acid energy case. The battery 100 can also include a positive and negative terminal. The sealed case can have openings that allow the positive terminal 101 or negative terminal 102 to pass through.

Referring to the FIGS. A battery 200 can be made up of a number of monoblocs that are electrically connected, such as batteries 100. Monoblocs within the battery 200 can be electrically linked in parallel or series. The battery 200 can include at least one monobloc string in an exemplary embodiment. In one exemplary embodiment, the battery 200 may include at least one string of monoblocs. In a different exemplary embodiment, the second string can comprise a plurality monoblocs that are electrically connected together. In the case of more than one monobloc string in the battery the first, second and/or other strings can be electrically interconnected in parallel. The positive terminal 201 of battery 200 and the negative terminal 202 may be connected by a series/parallel of monoblocs, for example to obtain a desired voltage or current characteristic for battery 200. In an exemplary embodiment, the battery 200 includes more than one monobloc. The battery 200 can also be referred herein as “a power domain”.

The battery 200 could have a housing or cabinet 210. The battery 200, for example, may include thermal and mechanical structures that protect the battery while providing a suitable operating environment.

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