Abstract:
An automatic battery fluid level monitoring system is provided. The automatic monitoring system includes a fluid consumption algorithm, programmed into a microprocessor based motor controller, connected through a communications link to a microprocessor based battery charger. The battery charger is electrically connected to a flooded type battery as well as a power connection such as being plugged into an outlet, the electrical connection from an alternator, or the like. Once the fluid consumption algorithm indicates that the fluid level is too low, a battery fluid indicator is activated utilizing a visual and/or audio display. After the battery is refilled, a fluid added reset is triggered, which deactivates the battery fluid indicator. Additional embodiments include utilizing a wired or wireless connection to a remote fleet management system, as well as alternative vehicle performance rules wherein the vehicle performance parameters can be purposefully altered to effect the ongoing performance of the vehicle.

Description:
BACKGROUND 
     Technical Field 
       [0001]    The present disclosure relates to systems relating to flooded lead acid or other similar type batteries. 
       State of the Art 
       [0002]    Much of today&#39;s machinery, especially machinery that requires or produces power, such as automobiles, golf carts, and the like, utilize a battery as an essential part of its systems. Flooded lead-acid batteries, which “flood” the plates with some form of electrolytic fluid such as water and acid, are the most prevalent type of battery used. 
         [0003]    One of the inherent problems associated with flooded type batteries, is that during the charging phase of the battery&#39;s cycle, the fluid evaporates and passes as vapor though valves in the battery casing to relieve the pressure that is building up within the battery. This “out gassing” of the battery causes the fluid level within the battery to slowly drop. When the fluid level drops below certain levels it exposes the plates within to air. Not keeping the plates fully submerged within the electrolytic fluid decreases the battery&#39;s efficiency and life span. 
         [0004]    It would therefore be advantageous to provide a system which would provide an accurate indication of the fluid levels within the battery and alert the operator or technician of the vehicle to take appropriate measures. 
       SUMMARY 
       [0005]    The present disclosure relates to systems relating to flooded lead acid or other similar type batteries. 
         [0006]    An aspect of the present disclosure includes a battery fluid level monitoring system comprising a battery having an internal fluid and a fluid level monitoring system in operative communication with the battery, wherein the fluid level monitoring system calculates consumption of the internal fluid based on a parameter, the fluid level monitoring system determines a level of the internal fluid based on the consumption and compares the level with a predetermined level, and when the level of the internal fluid is equal to or less than the predetermined level, the fluid monitoring system communicates a warning. 
         [0007]    Another aspect of the present disclosure includes a method of producing an automatic battery fluid level monitoring system comprised of calculating consumption of the internal fluid of a flooded type battery based on a parameter, comparing the level of the internal fluid based on the consumption with a predetermined level, and communicating a warning when the level of the internal fluid is equal to or less than the predetermined level. 
         [0008]    The foregoing and other features, advantages, and construction of the present disclosure will be more readily apparent and fully appreciated from the following more detailed description of the particular embodiments, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members: 
           [0010]      FIG. 1  is an illustrative embodiment of an automatic fluid level monitoring system for the electrolyte fluid levels of flooded type battery in accordance with the present disclosure; and 
           [0011]      FIG. 2  is a flowchart of an algorithm employed by the microprocessor based motor controller which controls the automatic monitoring system for the electrolyte fluid levels of flooded type battery in accordance with the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0012]    A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures listed above. Although certain embodiments are shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present disclosure will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of embodiments of the present disclosure. 
         [0013]    As a preface to the detailed description, it should be noted that, as used in this specification and the appended claims, the singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise. 
         [0014]    The drawings depict illustrative embodiments of a fluid level monitoring system  10  for a battery  24 , such as a flooded lead acid battery. These embodiments may each comprise various structural and functional components that complement one another to provide the unique functionality and performance of the battery fluid level monitoring system  10 , the particular structure and function of which will be described in greater detail herein. 
         [0015]    Referring to the drawings,  FIG. 1  depicts an illustrative embodiment of a battery fluid level monitoring system  10 . Embodiments of the battery fluid level monitoring system  10  may comprise a microprocessor-based motor controller  16 , a battery fluid consumption software program  12 , and microprocessor-based battery charger  22 , a communications link  18  operatively coupling the motor controller  16  and the battery charger  22  to one another, and a battery  24 , such as a battery pack or the like. 
         [0016]    Embodiments of the monitoring system  10  may comprise a micro-processor based motor controller  16 . The controller  16  may comprise a microprocessor  14 . The microprocessor  14  may provide the computational and logical control processing capabilities that empower the controller  16  to govern the operational aspects of the propulsion system (not depicted) of an electric device, such as a motor of an electric vehicle  8 . The controller  16  may be capable of controlling, operating, monitoring, governing, or otherwise directing the operational aspects of the vehicle  8 , including for example, but not limited thereto, the operations of the propulsion mechanism to propel the vehicle  8 , the operations of on-board software, the operations of a GPS unit (not depicted), the operations of a visual display unit (VDU)  31 , the operations of a wireless transceiver  34 , the operations of the battery charger  22 , the operations of one or more status indicators  27  and  29  of the vehicle  8 , and the charging and discharging of the battery  24 . During operation of the vehicle  8 , the controller  16  may be configured to direct power from the battery  24  to the propulsion mechanism to facilitate the movement of the vehicle  8 , in response to user inputs, such as, for example, the user depressing the pedal of the accelerator. In other words, based on user input received and processed by the controller  16 , the battery  24  may be directed by the controller  16  to deliver electrical energy to the propulsion mechanism, such as the motor, to operate the motor and drive the vehicle  8 . 
         [0017]    Embodiments of the monitoring system  10  may comprise the controller  16  having memory for storage capabilities, such as one or more hard drives, solid state drives, and/or RAM or the like. The controller  16  may thereby be configured to store therein a software program  12  containing an algorithm that is accessible to and utilized by the microprocessor  14 . The algorithm may be a battery fluid consumption algorithm, capable of computing the consumption of a fluid within a battery  24  over a duration of time and/or after charging based on one or more parameters. The controller  16  may therefore be in operative communication with the battery  24  to sense, tally, or otherwise measure, these parameters described herein. 
         [0018]    Embodiments of the monitoring system  10  may comprise battery charger  22 . The battery charger  22  may be a microprocessor-based, high-frequency, solid state device, capable of electrically coupling a power source  26  to a battery  24  for the purpose of recharging the battery  24 . The battery charger  22  may further comprise a microprocessor or controller  20  configured to control and govern the operational aspects of the charger  22 , including, but not limited to, the execution of the on-board software, the storing of charging and operational information in a memory, the real-time monitoring of changes in voltage in the battery  24  to deliver the appropriate charge to the battery  24 , and the modification of the charge cycle depending on the needs of the battery  24  and the instruction received from the motor controller  16  through the communications link  18 , to be described in greater detail herein. 
         [0019]    Embodiments of the monitoring system  10  may comprise a battery  24 . The battery  24  may be a battery system having a single battery, a bank of batteries, a bank of batteries with a dedicated controller, or the like. For example, the battery  24  may be configured as a 48 V 100 Ah battery, or other similar battery. Embodiments of the monitoring system  10  may comprise the battery  24  being a power source for an electric-powered device. Embodiments of the monitoring system  10  may comprise the battery  24  being part of a vehicle  8 , such as a golf cart, utility vehicle, forklift, passenger vehicle or the like. The battery  24  may serve as the sole source of power to propel the vehicle  8 , as in a traction battery pack for golf carts and utility vehicles, while in others the battery  24  may function as a supplemental power source, as with a hybrid drive. 
         [0020]    Embodiments of the monitoring system  10  may further comprise the battery charger  22  being positioned internally to the vehicle  8  with a direct current (DC) cable  28  coupled between the battery charger  22  and the battery  24 , as exemplarily depicted in  FIG. 1 . As such, the battery charger  22  may be integral with the vehicle  8 . In such embodiments, when the battery  24  needs to be recharged, a plug  29  at the end of the AC cable  26  may be inserted into a corresponding plug port  31  on the vehicle  8  to thereby supply power from the power source  26  to the vehicle  8 , and in particular to the battery  24  on the vehicle  8 . In alternative embodiments of the monitoring system  10 , the battery charger  22  may be positioned externally to the vehicle  8  to thus be separate and independent from the vehicle  8 , but yet maintain the functionality of the battery charger  22  described herein once coupled to the vehicle  8  to recharge the battery  24 . 
         [0021]    Embodiments of the monitoring system  10  may further comprise a communications link  18  that may operatively couple the motor controller  16  to the battery charger  22 . The communications link  18  may be configured to allow the motor controller  16  and the battery charger  22  to communicate one with another, to transfer data, instructions, directives, and/or signals to one another to influence the behavior and operational aspects of one another, to be described herein. 
         [0022]    Embodiments of the monitoring system  10  may comprise the controller  16  being configured to govern one or more of the operational aspects of the vehicle  8  based on inputs received by the controller  16  from such components as, for example, the battery  24 , the battery charger  22 , software program  12 , and/or the reset  32 . The controller  16  may be configured to receive and/or send electrical and data communication to one or more of the wireless transceiver  34 , the VDU  31 , the audible indicator  27 , the visible indicator  29 , the reset  32 , the software program  12 , and/or the motor  33 , as described herein and as schematically depicted in  FIG. 1 , to control and govern the operational aspects thereof. Indeed, one or more communication buses may be configured between component parts of the system  10 , as needed, to provide adequate communication capability therebetween, as described herein. 
         [0023]    Embodiments of the battery monitoring system  10  may further comprise a visual display unit (VDU)  31 . The VDU  31  may be an electronic display device, such as an LCD or OLED screen or the like, to display information about the vehicle  8 , the battery  24 , the battery charger  22 , and/or other operational aspects of the vehicle  8 , including a GPS location and the like. The VDU  31  may be utilized to display messages or other information regarding the current status, proper use, or operational features of the vehicle  8 , the battery  24 , or the like. The VDU  31  may also be an input device, such as a user interface, for a user to utilize to access, control, and/or manipulate the various components of the vehicle  8  or the battery monitoring system  10 . For example, the VDU  31  may be a touch screen display or other user-interactive display that may provide access to the computer program  12  and other internal controls. 
         [0024]    Further in example, the VDU  31  may be configured to govern and/or utilize a communication control device, such as a wireless transceiver  34 . The wireless transceiver  34  may be configured to communicate a wireless communication signal to a remote or third party  50 , to be described in greater detail herein. For example, using the capability of the VDU  31 , a wireless communication signal may be sent by a user thereof via a web server, a wireless network, Bluetooth, Wi-Fi, a cellular or mobile network, and/or other wireless communication means by the wireless transceiver  31  to the remote or third party  50  to provide information to the third party  50  about a particular vehicle  8  and its operational status, including historical status and real-time status of the various components of the vehicle, including the battery  16 . 
         [0025]    Embodiments of the battery monitoring system  10  may further comprise one or more status indicators configured to communicate one or more operational aspects of the battery charger  22 , the battery  16 , and/or the vehicle  8  to the third party  50 , such as an operator, attendant, computer terminal, fleet manager, and/or user. For example, when the controller  16  of the vehicle  8  determines by the algorithm or software program  12  that the fluid level of the battery  24  is at or below acceptable levels or predetermined acceptable levels, the controller  16  may instruct an audible indicator  27  on the vehicle  8  to sound an audible signal to alert the third party  50  that fluid should be added to the battery  24 . The audible indicator  27  may be a buzzer, beeper, or other audible device capable of making an audible noise/alert, such as a speaker. 
         [0026]    Embodiments of the battery monitoring system  10  may comprise the audible indicator  27  being an indicator that is customarily used on golf carts and other utility vehicles to indicate the vehicle  8  is in reverse mode. For example, when a transmission control or other equivalent directional control of the vehicle  8  is placed into a reverse setting, the controller  16  may be configured to actuate the audible indicator  27  to generate a beep, buzz, or similar sound. The controller  16  can be configured to actuate the same audible indicator  27  when the fluid levels in the battery  24  are at or below a predetermined level or amount. The audible indicator  27  may be an additional indicator, but need not be as the existing audible indicator of the vehicle  8  may be used. Moreover, as suggested, the same audible sound may be used to indicate both charging and reverse mode, but embodiments of the charging system  10  may include different audible sounds, different audible sound patterns, and/or different audible sound tones being generated for reverse and for charging, to thereby distinguish therebetween. Further still, the controller  16  may be configured to instruct the VDU  31  and/or the on-board speakers of the vehicle  8  to be the audible indicator  27  to generate the audible alert for low levels of battery fluid in the battery  24 . 
         [0027]    In addition or in the alternative, the battery monitoring system  10  may further comprise a visual indicator  29  to communicate an operational status of the battery charger  22 , the battery  16 , and/or the vehicle  8  to the third party  50 , such as an operator, attendant, remote fleet manager, remote computer terminal, and/or user. For example, although the audible indicator  27  has been herein described in association with battery fluid level status, the visual indicator  29  may be used to additionally or alternatively communicate battery fluid level status to the third party  50 . That is, the visual indicator  29  may be used separately from the audible indicator  27  or as a supplement to the audible indicator  27 . For example, embodiments of the battery monitoring system  10  may comprise the controller  16 , in response to the determination by the algorithm or software program  12  that the internal fluid in the battery  24  is below acceptable minimum levels, instructing the visible indicator  29  to turn on or otherwise illuminate. Further in example, embodiments of the battery monitoring system  10  may comprise the controller  16 , in response to the determination by the algorithm or software program  12  that the internal fluid in the battery  24  is below acceptable minimum levels, utilizing the VDU  31  to visually indicate to the third party  50  one or more operational aspects of the battery charger  22 , the battery, or the vehicle  8  itself. The controller  16  may instruct the VDU  31  to display an acknowledge button or icon, even digital, that may permit the third part  50  to silence the audible indicator  27 . The controller  16  may further provide instructions to the third party  50  as to what additional steps, if any, may need to be taken to ensure proper internal fluid levels within the battery  24 . 
         [0028]    Embodiments of the monitoring system  10  may further comprise at least a software program  12 , mentioned above, that has one or more computer programs or algorithms, which are executed and run by the microprocessor, that are configured to measure, calculate, analyze, gauge, compare, estimate, or otherwise determine, battery fluid levels within the battery  24  based on one or more parameters. The parameters may be, for example, a duration of time the battery  24  is in a discharging state, a duration of time the battery  24  is in a charging state, a duration of time the battery  24  is in a stand-by state, a duration of time the battery  24  is in a storage state, a duration of time the battery  24  is in an off-gassing state during charge, or any combination of the foregoing. These durations of time may be measured by a timer (not depicted) configured within the battery charger  22  and/or motor controller  16 . Additional parameters, such as, temperature, pressure, charge rate, discharge rate, and the like may also be measured and/or sensed by the system  10 , the battery charger  22  and/or the motor controller  16 . The parameters may be, for example, an accumulated amount of time the battery  24  has spent in one or more charge cycles or discharge cycles, or the accumulated amount of time for any of the parameters described herein, such as the amount of time the battery  24  spends in the any of the phases of charging, including the gassing phase. The parameters may be, for example, a predetermined initial level of internal fluid in the battery  24 , as well as a predetermined minimum level of internal fluid in the battery  24  that is acceptable for the battery  24  to continue to be used without damaging the battery  24 . 
         [0029]    Using one or more of these parameters as inputs, the software program  12  may be able to calculate or determine the amount of internal fluid that escapes from the battery  24  in the form of vapor or gas. The program  12  may calculate, estimate, gauge, compute, or otherwise determine the amount of internal fluid that escapes from the battery  24  in the form of vapor or gas, as a function of the time that the battery is being charged or as a function of a specific phase of the charge, including the gassing phase. Indeed, the software program  12  may calculate a theoretical loss, or consumption, of internal fluid within the battery  24  based on the parameters measured and received. Once the program  12  has calculated or estimated the amount of fluid lost or consumed, the program  12  may estimate the new, or current, level of internal fluid within the battery  24  by subtracting the calculated lost or consumed amount from the previous known amount to arrive at the current estimated amount remaining or current fluid level. The program  12  may then compare the new, or current, level of internal fluid to the predetermined acceptable minimum level to determine if the current level is above, at, or below the predetermined minimum level. The program  12  may then instruct the controller  16  to take appropriate actions based on the determination and comparison, to be described in greater detail. 
         [0030]    Embodiments of the battery monitoring system  10  may further comprise the software program  12  and algorithm utilizing the accumulated time the battery  24  spends in the gassing phase of the charge cycle. Due to the fact that variables such as temperature and pressure are known, or can readily be determined by the system  10  through appropriate sensors (not depicted), the amount of fluid escaping from the battery  24  in the form of vapor or gas can be calculated as a function of the accumulated time that the battery  24  has been and/or is being charged. In other words, the algorithm can count the amount of time that the battery has been and/or is in the “gassing phase” during the charging cycle and predict the theoretical amount of internal fluid consumed. Thereby, the algorithm may calculate the amount of internal fluid left in the battery casing of the battery  24  at any given time. 
         [0031]    Embodiments of the battery monitoring system  10  may further comprise the software program  12  and algorithm storing and referencing tabulated values of a minimum safe level, or volume, of electrolyte fluid for each particular battery type and size. Minimum safe levels of electrolyte fluid in each battery  24  may be based on the prescribed or theoretical volume of the fluid within the battery casing. The minimum safe level may be the lowest level the fluid can attain and still cover the lead plates completely without allowing them to be exposed to air. This minimum safe level may be calculated by subtracting the volume of space above the plates from the overall volume of the fluid within the battery  24  at its maximum filled level. The minimum safe level can be recalibrated individually for different types of batteries, or generalized to all similar battery types with a margin of error added. Once a minimum fluid level is established, the minimum fluid level may be set as a parameter within the algorithm. 
         [0032]    Embodiments of the battery monitoring system  10  may further comprise the controller  16  being configured to take appropriate action and govern operational aspects of the charger  22 , battery  24 , and/or vehicle  8  according to the calculated, measured, and/or estimated fluid levels of the internal fluid level of the battery  24 . For example, the controller  16  may be configured to sound an audible alert by way of the audible indicator  27  and/or display a visual alert by way of the visible indicator  29  should the internal fluid levels of the battery  24  fall below the predetermined levels. Moreover, the motor controller  16  may also be configured display an audible and/or visual alert by way of the VDU  31 , such as for example a digital battery watering visual reminder icon should the internal fluid levels of the battery  24  fall below the predetermined levels. Again, these fluid levels may be calculated or theoretical fluid levels based on the calculations of the program  12 , and even the algorithms contained therein. 
         [0033]    Embodiments of the battery monitoring system  10  may further comprise the controller  16  being configured to take appropriate action and govern operational aspects of the program  12 , charger  22 , battery  24 , and/or vehicle  8  according to the electrical connectivity between the battery  24  and the charger  22 . For example, as mentioned herein, the motor controller  16  may be configured to monitor the battery  24  and/or the battery charger  22  to detect an electrical connection between the charger  22  and the battery  24 . In other words, the controller  16  may monitor whether or not the battery  24  is plugged into the charger  22 , which would establish an electrical connection therebetween. Indeed, embodiments of the battery monitoring system  10  may comprise the controller  16  and the program  12  working together to detect the initial charging connection between the battery  24  and the charger  22  to thereafter execute the steps of the program  12 , which is discussed in greater detail herein. 
         [0034]    Embodiments of the battery monitoring system  10  may comprise other means by which the system  10  and the controller  16  may communicate the status of the low fluid levels within the battery  24  to the third party  50 . For example, embodiments of the battery monitoring system  10  may comprise the controller  16  communicating a battery fluid level warning to a remote party  50  or third party, which may be a user, a display, a computer terminal, an internet-enabled device, a base station, a fleet manager, a maintenance station, or the like. The system  10  may comprise a wireless transceiver  34  in communication with the controller  16  that can be configured to wirelessly connect to a communications network, web server, or other internet-enabled devices, and/or the internet through WiFi, cellular modem, Bluetooth, or other similar wireless technology. As such, the controller  16  may be configured to direct the wireless communication with the third party  50 , even in real-time, regarding the status of fluid levels within the battery  24 . For example, if and when the system  10  determines the battery fluid levels are below acceptable minimum levels, the controller  16  and the wireless transceiver  34  may function to wirelessly transmit a signal or communication, such as an alert, e-mail, text message, social media post, or the like, to the third party  50 . The communication may include such information as site name, site location, site identification, vehicle number, and time of detection, for example, so that the operator can attend to the specific vehicle in question. 
         [0035]    Embodiments of the battery monitoring system  10  may further comprise a reset  32 , wherein once the audio or visual warning is acknowledged and the battery  24  has been refilled with water, even distilled or deionized water, the battery monitoring system  10  may be reset to allow the algorithm to restart and calculate the fluid level accurately over again. The reset  32  may reset the timer used by the algorithm to determine the fluid loss or consumption and may reset the initial battery fluid levels. The reset  32  may be a manually operated control configured on the vehicle  8  or on the VDU  31  that once pressed by the user, may reset the system  10 . Alternatively, the reset  32  may be remotely actuated by the third party  50  sending a command to the controller  16  via the transceiver  34  to reset the parameters utilized by the algorithm to calculate battery fluid levels. 
         [0036]    However, if the warning signals sent from the controller  16  are ignored and the internal fluid levels are not filled or the fluid level reset  32  has not been triggered, at least within a minimum time frame, additional protocols can be put into place (a minimum time frame may include the number of times the warning has repeatedly signaled without reset, an actual specified amount of time (hours, days, or weeks), a certain number of charge cycles that the battery is subjected to without the system being filled and reset, or any other parameter that is deemed to be appropriate). For example, the controller  16  may be configured to purposefully alter performance parameters or characteristics of the vehicle  8  should the low internal fluid level warnings be ignored or go untreated. Such performance alternations, i.e., diminished power and performance, may serve to remind, compel, motivate, or otherwise urge, a user of the need to refill the internal fluid levels of the battery  24  to avoid irreversible damage to the battery  24 . For example, the controller  16  may alter such vehicle performance parameters as reducing vehicle speed, enunciating a reverse buzzer, or possibly even preventing vehicle use until the low battery fluid is acknowledged and addressed. The controller  16  may be configured to control and/or limit the power available from the battery  24  to the motor  33  to reduce the power delivered to the drive system of the vehicle  8 , thus reducing vehicle speed and acceleration. In addition, the controller  16  may be configured, through the software program  12  or other software configuration, to reduce or otherwise limit the top speed available to the vehicle  8  or the maximum acceleration of the vehicle  8 . In addition, the controller  16  may actuate, even repeatedly, the audible indicators  27  and/or visible indicators  29  to attract the attention of, or even annoy, the user, operator, controller, fleet manager or any other entity that might be able to address the low battery fluid levels so that the user, operator, etc. can see to it that the battery fluid levels are attended to and filled. Should the warning signals sent from the controller  16  regarding the low internal battery fluid levels continue to be ignored, such that the internal fluid levels are not filled and the fluid level reset  32  is not triggered within a maximum allotted measurement of time, charge cycles, or repeated warnings, the controller  16  may be configured to cut off the power available from the battery  24  to the motor  33  to eliminate the power delivered to the drive system of the vehicle  8 , thus preventing operation of the vehicle  8  until the internal battery fluids are addressed. 
         [0037]    The controller  16  may also be configured to purposefully alter the charging mode of the battery charger  22  should the internal battery fluid, as estimated by the algorithm, fall below the predetermined minimum fluid level. The controller  16  may be configured to limit the battery charger  22  to a lower charge voltage (for example, 13.2 volts instead of 13.6 volts while charging a 12-volt battery) in order to reduce the amount of out gassing or off gassing that occurs within the battery  24  during charging, thereby reducing the amount of fluid loss or consumption. 
         [0038]    With reference to  FIG. 2 , embodiments of the battery fluid level monitoring system  10  may further compromise a method of monitoring the internal fluid level of the battery  24 . The method may comprise filling a battery  24  to its maximum internal fluid level. The method may further comprise the program  12  storing this predetermined maximum level of internal fluid for the battery  24  in the controller  16 . The method may further comprise the program  12  adjusting a theoretical or calculated level of internal fluid based on a calculated or estimated amount of internal fluid lost due to the actual and measured amount of time the battery  24  spends in one or more phases of a charge cycle. For example, the program  12  may calculate the amount of internal fluid lost as a factor of real time the battery  24  has spent in one or more phases of the charge cycle. Using the calculated amount of fluid lost, the program  12  may theoretically adjust the maximum level of internal fluid within the storage of the controller  16  to thereby arrive at a current, real-time estimated level of internal battery fluid. The method may comprise the program  12  storing this current, real-time estimated fluid level and comparing the current, real-time estimated fluid level against a predetermined safe internal fluid level. The method may comprise the program  12  instructing the controller  16  to take particular actions based on this comparison. 
         [0039]    With further reference to  FIG. 2 , embodiments of the method of monitoring the internal fluid level of the battery  24  may comprise monitoring an electrical connection between the battery  24  and the charger  22  to initiate the program  12 , as depicted in step  40 . For example, upon the controller  16  sensing or detecting the electrical coupling of the battery  24  and the charger  22 , the program  12  may be initiated. Once the program  12  is initiated, the method may comprise comparing a current, real-time estimated internal fluid level of the battery  24  to a predetermined safe level of internal fluid for the battery  23 , as depicted in step  42 . Once compared, the program  12  may instruct the controller  16  to take one or more appropriate actions. 
         [0040]    For example, should the estimated or calculated internal fluid level be above the predetermined safe level, the controller  16  may instruct the charger  22 , through the communications link  18 , to perform a normal charge of the battery  24 , as depicted in step  44 . That is, the charger  22  may charge the battery  24  at the normal voltage at which the charger  22  normally or typically charges the battery  24 . As the charger  22  charges the battery  24  in a normal mode, the program  12  may calculate the estimated and theoretical internal fluid lost from the battery casing during the charging of the battery  24  based on the time the battery  24  spends in one or more stages of the charge cycle, say for example the off-gassing stage. Thereafter, the program  12  may instruct the controller  16  to increment the battery fluid usage total by the theoretical amount lost during the latest charge of the battery  24 , as depicted in step  52 . 
         [0041]    On the other hand, should the estimated or calculated internal fluid level be below the predetermined safe level in step  42 , the program  12  may instruct the controller  16  to communicate, as depicted in step  46 , a fluid level warning to a remote party  50  or third party, which may be a user, a display, a computer terminal, an internet-enabled device, a base station, a fleet manager, a maintenance station, or the like. In addition, the program  12  may instruct the controller  16  to activate, as a warning indicator, one or both of the audible indicator  27  and the visible indicator  29  to alert users, operators, or the like to the problem of the low internal fluid levels of the battery  24 . 
         [0042]    Embodiments of the method may comprise the controller  16  tracking the amount of time the battery fluid level warning has been active, or even the number of times the battery fluid level warning has been repeatedly activated, and comparing these measured values to a predetermined value, as depicted in step  48 . For example, these measured values may be, for example, the number of times the warning has repeatedly signaled without reset, an actual specified amount of time (hours, days, or weeks), a certain number of charge cycles that the battery is subjected to without the system being filled and reset, or any other parameter that is deemed to be appropriate. Should the measured values of the warning be less than the corresponding predetermined value, the program  12  may instruct the controller  16  to increment the battery fluid usage total by the theoretical amount lost during the latest charge of the battery  24 , as depicted in step  52 . On the other hand, should the measured values of the warning be greater than the corresponding predetermined value, the program  12  and/or the controller  16  may begin to implement safe charging cycles for the charger  22  and the battery  24 , as well as begin to alter the performance parameters of the vehicle  8 , as depicted in step  50 . The safe charging cycle and the altered performance parameters have been described herein. Once the safe charging cycle(s) and the altered performance parameters have been initiated or set in place, the program  12  may instruct the controller  16  to increment the battery fluid usage total by the theoretical amount lost during the latest charge of the battery  24 , as depicted in step  52 . 
         [0043]    Once the battery fluid usage level has been incremented, as heretofore described, so as to arrive at a new and updated calculated/estimated internal fluid level, the method may comprise comparing the new and updated calculated/estimated internal fluid level of the battery  24  to the predetermined safe level of internal fluid for the battery  23 , as depicted in step  54 . Once compared, the program  12  may instruct the controller  16  to take one or more appropriate actions. 
         [0044]    For example, should the new and updated internal fluid level be below the predetermined safe level, the program  12  may instruct the controller  16  to merely display the battery fluid level warning, as depicted in step  56 , without yet having had to communicate the warning, as depicted in step  46 . Such may be the case when the step  56  is the first or initial time the program  12  instructs the controller  16  to send a warning of any kind. However, as described above, should the warning be ignored or if the initial comparison of the calculated internal fluid levels be below the predetermined level, as determined by the step  42 , the program  12  may instruct the controller  16  to communicate the warning, as described herein with regard to step  46 . After the battery fluid level warning has been displayed, according to the step  56 , the program  12  may instruct the controller  16  to determine whether the system is reset. Under the condition an operator, user, or the like fills the internal fluid levels of the battery  24  back to the maximum internal fluid level, the operator, user, or the like may operate the reset to reset the system back to initial status. Resetting the system may remove the safe charge restrictions as well as the restrictive performance parameters of the vehicle. Once the system  10  is reset and the restrictions are lifted, the system  10 , the controller  16 , and/or the program  12  may await the electrical coupling of the charger  22  to the battery  24 , as depicted in the step  40 , that will charge the battery  24  once again and begin the operations of the system  10  once anew. However, if the system  10  is not reset, the program  12  may instruct the controller  16  to await another electrical coupling event between the charger  22  and the  24 , as depicted in the step  40 , so that the program can determine that the calculated battery fluid level is still below the predetermined threshold, according to the step  42 , so that the program  12  and the controller  16  may communicate the battery fluid level warning to the remote party  50  and/or to the audible and visible indicators  27  and  29  on the vehicle itself, according to the step  46 . And, under a worst case scenario, wherein the battery fluid level warning is ignored beyond the maximum permitted values, the program  12  and the controller  16  may shut down the vehicle, according to the step  50 . 
         [0045]    While this disclosure has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the present disclosure as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure, as required by the following claims. The claims provide the scope of the coverage of the present disclosure and should not be limited to the specific examples provided herein.