Battery Test Attachment
Encyclopedia of radio electronics and electrical engineering / Chargers, batteries, galvanic cells
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Often, during the mass operation of batteries, for example, in industry or service centers, special devices are used to charge and test them - analyzers, which can be very conditionally divided into two groups: universal, allowing you to work with batteries and rechargeable batteries, and non-universal, serving only completely certain batteries. Unlike the former, the cost of non-universal analyzers is much less, and if only specific batteries are in operation, then the use of a specialized device is fully justified.
The author happened to work with a similar device from Motorola TDN9431B for charging nickel-cadmium batteries with a capacity of 1,2 Ah, consisting of six batteries, at one of the portable radio repair shops. Numerous tests have shown that the battery is often inoperable - self-discharge increases, capacity decreases - due to the failure of one or two batteries. By replacing faulty batteries, you can extend the "life" of the battery.
Unfortunately, the TDN9431B analyzer does not allow you to test individual batteries. I propose a prefix to the analyzer, which expands its capabilities. With its help, it was possible to assemble fully functional batteries from faulty batteries, which were then operated for several years.
The attachment diagram is shown in the figure.
Transistor VT1 and resistors R8, R9 perform the function of a controlled voltage source. Since the analyzer allows testing only batteries containing four or more nickel-cadmium batteries, a voltage drop is created on resistors R8, R9, simulating the "missing" (in our case - four) batteries.
Op-amp DA1 performs the function of a voltage amplifier of the tested battery G1 with a gain of about four. A voltage source control unit is assembled on the DA2 op amp.
The controlled voltage source is fed from an unstabilized source on the mains transformer T1, rectifier VD2-VD5 and filter capacitor C2. The supply voltage of the op-amp is stabilized by the simplest stabilizer VD1R10.
The device is connected to one of the analyzer compartments, and the tested battery is connected to connectors X1 and X2 of the attachment. The battery parameters are displayed on the analyzer display, and it should be remembered that the true voltage is five times less than the readings.
The mains transformer must be designed for a power of at least 24 watts. On the regulating transistor VT1, a power of about 7,5 W is released, so it should be installed on a heat sink with an area of 110 cm2. Resistors R8, R9 - C5-16V or C5-16MV.
The attachment can be used with almost any non-universal analyzer. You may have to recalculate the resistance of resistors R8, R9 for a different number of batteries in the battery. As an example, we present the calculation of device parameters for our case.
We calculate the drop across resistors R8, R9 based on the minimum and maximum voltage on the battery:
where N is the number of batteries to be replaced. We select the maximum charging current of 0,6 A and calculate the resistance of resistors R8 and R9:
Power dissipated by resistors R8 and R9:
Author: S.Labuzov, Gomel, Belarus
See other articles Section Chargers, batteries, galvanic cells.
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