Abstract:
An apparatus for entering information into a battery tester/charger is provided. It includes a bar code reader, a controller that is used to receive information from the bar code reader wherein the controller controls a battery tester/charger. In addition, a method for entering information into a battery tester/charger is provided. The method comprises reading a bar code and inputting information into a controller for the battery tester charger based on the bar code. An additional method of recording information about a battery is provided. The method comprises printing information on a bar code reflecting information about the battery and associating the bar code with the battery.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to entering information into a battery tester charger. More particularly, the present invention relates to entering battery information into a battery tester charger using a bar code reader.  
         BACKGROUND OF THE INVENTION  
         [0002]    Rechargeable batteries are an important source of clean portable power in a wide variety of electrical applications, including automobiles, boats and electric vehicles. Lead-acid batteries are one form of rechargeable battery that are commonly used to start engines, propel electric vehicles, and to act as a source of back-up power when an external supply of electricity is interrupted. While not particularly energy efficient, due to the weight of lead in comparison to other metals, the technology of lead-acid batteries is mature. As a result, the batteries are cheap, reliable, and readily produced and thus, continue to constitute a substantial portion of the rechargeable batteries being produced today.  
           [0003]    The ability of lead-acid batteries to deliver large amounts of electrical power is well known, particularly when associated with the starting and powering of motor vehicles. Because the lead-acid batteries can be depleted of power overtime, such as when they are not in use over a period of time, or when a light in a car is left on for an extended period of time, they need to be recharged and tested. A number of battery testers and chargers have thus been developed to charge and test the lead-acid battery.  
           [0004]    Most conventional battery charger/tester are equipped to provide multiple charging rates for charging different size batteries. The multiple charging rates are achieved by varying the charging voltage at the battery terminals, generally by changing the transformer primary/secondary winding ratio. An operator manually selects the rate at which the battery should be charged and also the duration of the charge cycle if the charger is equipped with a timer function.  
           [0005]    Many defects found in lead-acid batteries and other types of batteries are the result of poor recharging control in conventional chargers. For example, an operator may undercharge or overcharge the battery at a very high rate resulting in the deterioration of the battery. Overcharging a battery wastes energy, reduces the life of the battery, and may permanently damage the battery. Additionally, conventional battery chargers can also include testers with the appropriate gauges in order to determine the current state of charge in a battery, how long and at what rate a particular battery should be charged, whether it is safe to charge the battery, and whether the battery is capable of accepting a charge.  
           [0006]    Once the battery charger/tester is in operation, the operator must return to check the status of the battery to ensure that the battery is charging properly. Because conventional battery requires actual visual inspection of the gauges, the operator can waste valuable time and money to inspect all the batteries that are currently being charged instead of generating money by working on other projects.  
           [0007]    During the charging period of the battery, temperature of the battery is an indicator as to how successfully the battery is accepting the charge. Different batteries accept the charge in a number of different ways. For example, some batteries heat up beyond a normal range. Anything beyond this normal range is an indication that the battery is not accepting the charge in an efficient manner. There is a need for a battery/charge tester to include a temperature sensing device, which monitors the device throughout the entire processing charging and testing process. There is a further need to provide the collected temperature data back to the charger to enable it to adjust the charge/test rate of the battery based upon this data.  
           [0008]    Information regarding batteries may be useful when servicing batteries and for a number of other reasons. For example, charger/tester chargers used at commercial servicing locations often encounter a wide variety of different batteries. Different batteries may require different techniques for charging or testing. For example, different charge rates, different charging times and other parameters may vary by battery. Because different batteries may require certain servicing techniques, it is useful to be able to quickly identify a certain battery so that various servicing parameters may be changed according to a specific need.  
           [0009]    Furthermore, other types of information such as warranty information, service history and the like is desirable to be known at a service facility so that specific problems can be identified when servicing an individual unit. Warranty information such as length of warranty, and identification of individual purchaser may be useful for a variety of reasons, including how to charge a customer having their battery serviced.  
           [0010]    As with any commercial endeavor, efficiency is important. Valuable time may be lost entering data into a battery tester/charger using cumbersome techniques. Therefore, a fast and error resistant way of entering information is desired. In addition, for future servicing, it may be desirable to record a history of service done and associated with a battery so when the battery is serviced in the future, it can be determined what work was done on the battery. Therefore, it is desirable to provide a way of quickly and efficiently summarizing work done on a battery in order to speed and improve future servicing.  
         SUMMARY OF THE INVENTION  
         [0011]    It is therefore a feature and advantage of the present invention to provide a fast and accurate way to enter information into a battery tester charger.  
           [0012]    It is another feature and advantage of the present invention to provide a way of recording information about a battery in a way that information can quickly be inputted into a battery tester charger.  
           [0013]    The above and other features and advantages are achieved through the use of a novel apparatus and method as herein disclosed.  
           [0014]    In accordance with one embodiment of the present invention, an apparatus for entering information into a battery tester charger is provided. The apparatus includes a bar code reader, a controller configured to receive information from the bar code reader, wherein the controller controls a battery tester charger.  
           [0015]    In accordance with another embodiment of the present invention, an apparatus for entering information into a battery tester charger is provided. The apparatus includes: means for reading a bar code; means for controlling the battery tester charger and configured to receive information from the means for reading a bar code.  
           [0016]    A method for entering information into a battery tester charger is provided. The method includes: reading a bar code; imputing information into a controller for the battery tester charger based on the bar code.  
           [0017]    A method of recording information about a battery is provided. The method includes: printing information on a bar code reflecting information about the battery and associating the bar code with the battery  
           [0018]    There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
           [0019]    In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
           [0020]    As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    [0021]FIG. 1 is a hardware block diagram of an embodiment of the current invention.  
         [0022]    [0022]FIG. 2 is a hardware block diagram.  
         [0023]    [0023]FIG. 3 is a diagram of the process for applying a load to an open circuit in accordance with a preferred embodiment of the present invention.  
         [0024]    [0024]FIG. 4 is a flowchart of the process for testing and charging partially charged batteries in accordance with a preferred embodiment of the present invention.  
         [0025]    [0025]FIG. 5 is a flowchart of the process for testing and charging discharged batteries in accordance with a preferred embodiment of the present invention.  
         [0026]    [0026]FIG. 6 is a front view of a display and keyboard of one embodiment of the current invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0027]    [0027]FIG. 1 is an embodiment of the current invention. The battery charger/tester  100  (“charger  100 ”) can include a power source  110  that provides a 120V (volts) AC (alternating current) to the charger  100 . A circuit breaker  112  is provided to prevent damage that can be caused by a sudden power surge or a short in the system. A power switch  114  is linked to the power source  110  to enable the operator to turn the charger  100  on or off.  
         [0028]    A power transformer  116  is provided to step down both the voltage and current to a level that enables the charger  100  to charge and/or test a battery. In a preferred embodiment, the power source  110  supplies the charger  100  with 120V AC. The power transformer  116  reduces the 120V AC to approximately 20-25V AC, which is optimal for charging the battery. Two lines  118 ,  120  from the power transformer  116  are inputted into a rectifier  124  and a third line  122  is directly coupled to the negative clamp  238 . The lines  118 ,  120  pulse alternately through a full-wave rectifier  124  at a cycle of 60 Hz. The diodes of the rectifier  124  convert the positive AC voltage to DC (direct current) power supply. The third line  122  provides a return path for the negative voltage of outputs  118 ,  120  to return to the transformer  116 .  
         [0029]    A silicon control rectifier (SCR)  126  or thyristor is included in the preferred embodiment to regulate the output from the rectifier  124  to the battery. Exiting from the rectifier  124  is a pulsed positive sine waveform with peak voltages and current. The sine waveform results in varying voltages and current being outputted from the rectifier  124 . The SCR  126  essentially operates as a switch allowing certain voltages and/or current to pass to the battery.  
         [0030]    The operator can choose either a voltage or a current or both to charge the battery. This selection is called a set-point. This set-point is then transmitted to a FPGA  142  (field programmable gate array, discussed below), which then determines at which point in the sine wave to allow voltage to pass through to the battery. This point in the sine wave is related to the set-point as chosen by the operator. The set-point, depending on the selection of the operator, is situated on the sine wave by starting from the end of the sine wave and working in a rearward direction. Once the set-point is located on the sine wave, the voltage underneath the sine wave is allowed to pass through. Therefore, the set-point voltage is a mean value of a range of voltages.  
         [0031]    For example, if the operator decides to charge the battery at 12V, this set-point of 12V is entered into the charger  100 . The set-point is transmitted to the FPGA  142 , which then determines at which point in the sine wave to allow the voltage or current to pass through to the battery. The 12V set-point in this example permits voltages larger than and less than 12V to pass through to the battery. The mean of the voltages distributed to the battery will approximately equal twelve volts.  
         [0032]    The SCR  126  operates essentially as a switch and allows current or voltage to pass to the battery at a set-point fixed by the operator. The SCR  126  can operate based on either voltage or current or a combination thereof. The SCR  126  is normally switched off until it receives a signal from an I/O control (input/output)  134 . The voltage or current exiting from the rectifier  124  is transmitted to an ADC (analog-to-digital converter)  136 . The ADC  136  in turn transmits the voltage or current information to a linked CPLD (computer programmable logic device)  140 , which is linked to the FPGA  142 . The FPGA  142 , simulating as a processor, determines the operability of the SCR  126  by comparing the previously programmed set-point value with the output value of the rectifier  124 . If the output value of the rectifier  124  is equal or greater than the set-point of the SCR  126 , then the FPGA  142  instructs the I/O control  134  to send a signal to the SCR  126  to allow the output voltage or current to pass to the battery. For example, if the operator desires a minimum current of 20 amps, the SCR  126  will allow a current equal to or exceeding 20 amps to pass to the battery.  
         [0033]    A current sensor  128  is provided at the output of the SCR  126  to monitor or sense the current exiting from the rectifier  124  and the SCR  126 . The current from the rectifier  124  is relayed to the ADC  136 , which like the voltage is fed to the CPLD  140  and then onto the FPGA  142 . The FPGA  142  verifies if the current from the rectifier  124  is equal to or exceeds the current set-point value. The output from the current sensor  128  is connected to the battery clamps  238 ,  240 .  
         [0034]    [0034]FIG. 2 illustrates a battery tester charger  200  according to one embodiment of the invention. A battery  202  having a positive terminal  234  and a negative terminal  236  may be attached to the battery tester charger  200  via a positive clamp  240  and a negative clamp  238  located at an end of the respective positive and negative cables  230 ,  232 .  
         [0035]    In a preferred embodiment, the battery tester charger  200  can determine whether the connections between the battery  202  and the clamps  238 ,  240  are acceptable. A connection test may be performed at either the positive  240  or the negative clamp  238  connection by applying the connection test to the positive components  230 ,  240  or negative components  232 ,  238  of the battery tester charger  200 . Of course, applying the connection test to both components will test both the positive and negative connections. The connection test may be performed by comparing the voltage in the battery cables  230 ,  232  upstream from the connection of the clamps  238 ,  240 , and the voltage at the connection of the clamps  238 ,  240 . Voltage loss due to cable resistances  208 ,  210  may be considered and subtracted from the difference in voltage at the clamps  238 ,  240  and the upstream position. Additional differences in voltage between the upstream position and the connections of the clamps  238 ,  240  may be caused by clamp connection resistances  206 ,  204 .  
         [0036]    The testing of the battery connections can be applied to either the positive or negative components to test the connections individually or can be applied to both components to test both connections. The external battery cables  230 ,  232  are attached to the respective terminals  234 ,  236  of the battery  202  via the respective clamps  240 ,  238 . Standard clamps, such as alligator clamps, may be used.  
         [0037]    A portion  237 ,  239  (FIG. 1) of each clamp  238 ,  240  is isolated from the remainder of the clamps  238 ,  240  and the associated cables  232 ,  230 . Portions  237 ,  239  can be isolated from the remainder of the clamps  238 ,  240  by a non-conductive element. The cables  232 ,  230  can carry a large current, either to the battery  202  when charging or from the battery when the battery is in use. The isolated portions  237 ,  239  may be connected to another device to determine the voltage at terminals  234 ,  236 . For example, the isolated portions  237 ,  239  may be attached to high impedance wires  226 ,  224  to differential operational amplifiers  214 ,  212  (opp. amp) as shown in FIG. 2. Alternately, in some optional embodiments, as shown in FIG. 1, the high impedance wires  226 ,  224  may be attached to the ADC  136 .  
         [0038]    The battery connections may be tested to determine the resistances  206 ,  204  associated with the connection when the battery  202  is charged by a current source  110  or exposed to a heavy load  144 . Whether the battery  202  is charging or in use, large current will flow through the cables  230 ,  232  and clamps  240 ,  238 . A sensor  220 ,  222  in the battery charger tester  200  senses the voltage upstream from the clamps  240 ,  238  and the battery terminals  234 ,  236  connections and inputs a signal representative of the voltage to opp amps  214 ,  212  or optionally to ADC  136 . For example, in some optional embodiments of the invention, the voltage may be sensed upstream from the current sense  128  in both cables  230 ,  232  as shown in FIG. 1. As mentioned above, voltage is sensed in the isolated portions  237 ,  239  and compared to the voltage sensed upstream. The cable resistances  208 ,  210  are known, and the portion of the voltage difference between the voltage in the isolated portions  237 ,  239  and the voltage at the upstream position is accounted for by the cable resistances  208 ,  210 . The remaining voltage difference between the voltage measured at the isolated portions  237 ,  239  and the upstream positions is due to the resistances in the clamps  240 ,  238  and terminal  234 ,  236  connections. In optional embodiments of the invention, cable resistances  208 ,  210  and the associated difference in voltage due to cable resistances  208 ,  210 , may be neglected or approximated.  
         [0039]    The resistance of the connections  206 ,  204  can be analyzed using Ohm&#39;s law, V=IR, where V stands for voltage, I stands for current, and R stands for resistance. Simple algebraic manipulation yields R=V/I. The unknown connection resistances  206 ,  204  associated with the connection can be expressed in terms of known parameters of current and voltage, thus the resistances  206 ,  204  can be determined.  
         [0040]    Once the connection resistances  206 ,  204  are determined, each connection can be evaluated to determine whether the connection is acceptable or not. In one embodiment, a method is provided and compares the connection resistances  206 ,  204  against a pre-determined acceptable and non-acceptable range of connection resistance. Based on the comparison, the operator can determine whether the connection is acceptable or not.  
         [0041]    In an alternative embodiment, a method is provided to compare the voltage differences between the isolated portions  237 ,  239  and the voltage in the cables  230 ,  232  at the upstream positions. If the difference in voltage between the two locations is negligible, then the connection is likely to be acceptable. Optionally, the difference in voltage due to cable resistances  208 ,  210  may be subtracted from the voltage difference or otherwise accounted for in determining whether the connections are acceptable or not. If the voltage difference is higher than a predetermined maximum amount, then the connection between the battery terminal  234  and the clamp  140  will likely be unacceptable.  
         [0042]    If the connection is not acceptable, the battery tester charger  200  can alert or notify the operator. In some embodiments, the battery tester charger  200  may alert the operator as to which connection (positive or negative) is unacceptable or whether both are unacceptable. In some embodiments, the battery tester charger  200  may alert the operator that the connection(s) are acceptable. The operator may be alerted by a variety of ways such as, an indicator light, a message on a display screen, an audible signal, or other ways that are disclosed herein. Because the operator is warned that a connection is not acceptable, the operator may take corrective measures to improve the connection, such as cleaning or replacing the terminals  234 ,  236  or clamps  240 ,  238 .  
         [0043]    Referring to FIG. 1, in the preferred embodiment of the invention, a Sabre Battery Test procedure is used as a heavy load test to analyze the condition of the battery. The heavy load test is applied with a heavy load  144  that includes a solenoid switch  146 . The solenoid switch  146  is operated by the FPGA  142  through the I/O control  134  via the CPLD  140 . The solenoid switch  146  in the heavy load test ensures that a high load amperage test can be efficiently and safely transmitted to the battery. One detraction in incorporating the solenoid switch  146  with the heavy load test is that it is not possible to make an exact determination of when the heavy load  144  is started or ended. This results from the mechanics of the solenoid switch  146  in that when the switch is turned off or on, it does not occur immediately. Therefore, there is a delay that fluctuates due to the mechanics of the solenoid switch  146  which makes exact testing and charging more difficult. One of ordinary skill in the art will recognize that the solenoid  146  can be replaced with electronic switching devices, such as transistors, in an alternate embodiment. However, cost considerations drive the design of the preferred embodiment and a mechanical solenoid switch  146  was selected.  
         [0044]    The preferred embodiment analyzes the charge-state of a given type of battery, determines whether the battery is defective and, if not, charges the battery at its most optimum charge rate up to its maximum allowed charging volts. Furthermore, the preferred embodiment executes its analysis, determination, and charging in the safest and most optimal time possible.  
         [0045]    In operation, the heavy load test is shown in the Sabre Test Timing Diagram  300  in FIG. 3. The Sabre Battery Test requires a first applied load  302  to be placed on an open circuit  304 . A battery voltage reading (“LVA 15 ”)  306  can be taken at the end of the first applied load  302 , which is approximately fifteen seconds after the first load  302  is applied and released. A bounce back voltage measurement (“Rv”)  308  is taken approximately twenty seconds after the first applied load  302  is turned off. A second applied load  310  is then placed on the open circuit  304  and maintained for approximately fifteen seconds. Another battery voltage reading (“LVB 15 ”)  312  is taken at the end of the second applied load  310 .  
         [0046]    Heavy load tests are highly accurate for testing charged batteries. If the battery to be tested is partially charged, then the test accurately determines whether the battery is defective. A person skilled in the art will recognize that any heavy load test procedure that is suitable for testing the condition of the battery may be used. Additionally, load as used herein can also be a charge.  
         [0047]    If the condition of the battery is such that the battery can be recharged, a preferred embodiment of the invention can calculate a set time to charge the battery. If LVB 15   312  is less than 4.0 V, the set time, i.e., maximum charge time, equals approximately forty-five minutes. If LVB 15   312  is equal to or greater than 4.0 V, the set charge time is calculated as follows:  
         [0048]    Set time=(12.5−Vss) * 56.25 minutes  
         [0049]    Where,  
         [0050]    Vss=bounce back voltage (“Rv”) if 11.7V&lt;=Rv&lt;=12.5V  
         [0051]    Vss=12.5V if Rv&gt;12.5 V  
         [0052]    Vss=11.7V if Rv&lt;11.7 V  
         [0053]    By applying the heavy load test and monitoring the bounce back voltage, the charger  100  calculates the state of charge of the battery and the set time required to charge the battery while maintaining an optimum charge rate. The charger  100  controls the optimum charge rate by precisely controlling the charging voltage throughout the charging cycle.  
         [0054]    If the battery condition can be charged, as determined by the heavy load test (e.g., Sabre Battery Test), further testing and charging will be performed. If the battery condition is determined to be faulty, then testing is terminated and the battery can be discarded. Therefore, the operator does not waste time and effort to charge the defective battery.  
         [0055]    If the battery condition is determined to be functional, additional testing and charging are performed, as depicted in FIG. 4. The first step in this testing is to determine whether the bounce back voltage is greater than 12.6 volts  400 . The bounce back voltage is a measure of the state of battery charge. If the bounce back voltage is determined to be greater than 12.6 volts, the battery tester/charger will perform a micro-load test  162 . If the bounce back voltage is equal to or less than 12.6 volts, the charger  100  is activated  402  to charge the battery for a set time  404 .  
         [0056]    While the battery is being charged  402 , the current is monitored. If the charge is greater than five amps  406 , the charger  100  continues to charge for the set time. If the current is less than or equal to five amps  406 , the charger  100  continues to charge the battery for a minimum of at least five minutes  408 .  
         [0057]    Once the set time or five minutes of charging  408  is reached, the charger  100  turns off  410 . A heavy load test is applied to the battery for at least ten seconds followed by the heavy load  144  being removed for at least twenty seconds  410 . The previous application and removal of the heavy load  144  is important to condition the battery by stabilizing the battery voltage. Another heavy load test  412  is then performed on the battery.  
         [0058]    The charger  100  then determines from the heavy load test  412  if the battery is good  414 . If the battery is determined to be faulty or bad  416 , the testing is terminated and the battery is discarded. If the battery is determined to be functional  414 , or if the bounce back voltage is greater than 12.6 volts, the cold cranking amps (“CCA”) are measured using a micro-load test  418 .  
         [0059]    In the preferred embodiment, the micro-load test  418  is performed after the battery is determined to be functional by the heavy load test  412 . This microload test  418  is performed by applying a smaller load (approximately twenty to sixty amps) for a preset duration (approximately 250 milliseconds to one second) and measuring the CCA  420  after the micro-load  162  is removed. If the measured CCA is greater than 70% of the rated CCA  420  of the battery, then the battery is good and the charge is completed  424 , then the cycle ends at  426 . If the measured CCA is less than 70% of the rated CCA  420  of the battery, then it is bad battery  422  and will be discarded. It should be recognized that other micro-load tests could be substituted for the micro-load test  418  described above. For example, a dual micro-load test can also be used.  
         [0060]    If the condition of the battery can not be determined from the heavy load test  412 , the charger  100  will charge the battery and retest it in accordance with the method depicted in FIG. 5. For re-testing, the charger  100  is activated  500 . The charger  100  charges the battery for approximately one-minute  502 . The battery voltage is read after one-minute  504 . If the battery voltage  504  is less than one volt after one minute then the battery is bad. The charger  100  is turned off and the battery will be discarded  506 .  
         [0061]    If the voltage  504  is equal to or exceeds one volt after one minute of charging, the charger  100  will continue to charge for approximately nine minutes  508 . During the nine minutes of charging, the charging current is recorded or read at one-minute intervals to determine if the charging current exceeds three amps  510 . If the charging current is equal to or does not exceed three amps, the battery is determined to be bad  512  and the charger  100  is turned off and the battery is discarded.  
         [0062]    If the charger&#39;s  100  current does exceed three amps, the charger will continue to charge for the set period of time as calculated above  514 . The charger  100  will apply the heavy load  144  to the battery for a period of ten seconds to condition the battery and then removed the heavy load for a period of twenty seconds  516  for the battery voltage to stabilize. The heavy load test (e.g., Sabre Battery Test) is then performed  518 .  
         [0063]    The charger  100  then determines whether the battery is good  520 . If the battery is determined to be bad  522 , it is discarded. If the battery is determined to be functional  520 , the CCA is then measured using the micro-load test  524 . The measured CCA is then compared to the rated CCA for the battery  526 . In the preferred embodiment of the invention, if the measured CCA is less than or equal to approximately seventy percent of the rated CCA for the battery  526 , then the battery is determined to be bad  528  and is discarded. If the measured CCA  526  is greater than approximately seventy percent of the CCA, then the battery is determined to be good  530  and the charge is completed  532 .  
         [0064]    Referring to FIG. 1, the preferred embodiment contains an infrared temperature sensor  164 , which aids in monitoring both the charger  100  and the battery being charged. The infrared temperature sensor  164  ensures that both the battery and charger  100  are maintained are safe levels. In the preferred embodiment, the infrared sensor  164  is contained within a housing. The housing is placed over the charging battery for safety reasons especially in the instance that, while charging, the battery unexpectedly explodes. The housing aids in containing the surrounding areas from the contaminants of the exploded battery.  
         [0065]    The infrared temperature sensor  164  is placed within the housing to monitor the temperature of a charging battery. While charging a battery, heat is discharged or dissipated from the battery. However, excessive heat is an indication that the battery is being charged at an excessive rate. In the preferred embodiment, the infrared temperature sensor  164  is linked to the ADC  136 , essentially an input to the ADC  136 , which relays the information to the CPLD  140 , which then relays it to the FPGA  142 . The FPGA  142 , with the help of the infrared temperature sensor  164 , can monitor the temperature of the battery and relay the information, including any problems to the operator. The infrared temperature sensor  164  is aimed at the battery to ensure that the temperature of the battery is being monitored throughout the charging process. For example, if the battery being charged contains a short, the battery will heat excessively in a short period of time. The feedback from the infrared temperature sensor  164  can be used to alert the operator of the problem so that the operator can take the appropriate action.  
         [0066]    A gel battery can heat excessively during charging and therefore, the charging current is applied in relation to the heat detected. For this type of battery, a temperature is fixed after which point the charging current is reduced. By monitoring the temperature and adjusting the current in view thereof, the charging time is reduced. The temperature and charging current are proportionally related in specific types of batteries (e.g. gel). Thus, by monitoring the temperature and the charging current, the gel battery or other batteries can be charged efficiently, and explosions can be prevented during charging.  
         [0067]    In another embodiment, the infrared temperature sensor  164  can be aimed at the charger  100  only or in combination with the battery. By monitoring the charger  100 , any excessive temperature generated by the charger can be relayed to the operator, thus appropriate actions can be taken to avoid overheating and damaging the charger.  
         [0068]    One of ordinary skill in the art recognizes that the temperature sensor  164  can be located in a number of different locations, either located in the charger  100  or linked to the charger  100 . The location of the infrared temperature sensor  164  is not limited to a housing. Additionally, temperature sensors are needed most when the battery is charging. Therefore, monitoring the temperature of the battery and/or the charger can help to prevent battery explosions.  
         [0069]    In a preferred embodiment, a conventional processor is replaced by a dynamic FPGA  142 . The use of the FPGA  142  allows a designer to make changes to the charger  100  without having to replace the processor. Changes to a mounted conventional processor requires remounting and reconfiguration of the charger  100  design, which in turn requires more design hours and additional costs. With the use of the FPGA  142 , the designer is allowed to make changes on the fly without remounting or tireless reconfiguration of the initial design.  
         [0070]    The FPGA  142  is configured and arranged to operate as a conventional processor. In the preferred embodiment, the FPGA  142  controls and processes a number of different functions of the charger  100 . One such function is the operation of the micro and heavy load tests  418 ,  412 . These tests are downloaded and stored into a memory device  144 . It can also be stored in a RAM device  146 . Once stored in these memory devices  144 ,  146 , the code is downloaded into the FPGA  142  and executed. Upon execution of the code, the FPGA  142  begins to operate various controls of the charger  100 , such as the solenoid switch  146  on the heavy load  144 , and the SCR  126  for current and voltage control. Additionally, data can be inputted into the FPGA  142  through the input device  148 , such as a keypad. The FPGA  142  can transmit to and receive information from an output display  150 , a serial port  154 , such as a printer port, a second serial port  152 , such as an infrared bar code reader, a module port  156  that can accept various communication modules, or any other device that can communicate with the FPGA.  
         [0071]    Upon start-up or boot-up of the charger  100 , an image of a soft-core microprocessor is loaded from the memory (i.e. flash  144 , RAM  146 , etc.) into the FPGA  142 . Therefore, there is an image of the FPGA  142  resides in the memory. Additionally, upon start-up, the CPLD  140  takes control of the data and address bus and clocks the FPGA  142  image from memory into the FPGA  142 . As stated previously, this allows for redesign of the processor and the board without the need for remounting a processor. All that is necessary for a design change is to upload a new FPGA image into the memory device. Additionally, any new tests or operating parameters that is required by the operator can be easily upload into the FPGA  142  and executed. The preferred embodiment uses flash memory  144  to accomplish this function.  
         [0072]    The output display  150  can be an integrated display or a remote display that relays information, such as data gathered from the charging and testing of the battery, and menu information. Additionally, the display  150  can notify the operator of any problems that have been detected. The serial port  154  in the preferred embodiment are standard RS-232 serial ports for connecting a device, such as a printer. One of ordinary skill in the art will recognize that the RS-232 can be replaced with an RS-432, an infrared serial port or a wireless radio frequency port, such as BLUETOOTH™, or any other similar device.  
         [0073]    In some embodiments of the current invention, a bar code port  152  is provided. The bar code port  152  may serve to operably connect a bar code reader (not shown) to the FPGA  142  or a microprocessor. In some embodiments, the bar code port  152  may be a conventional component, such as an RS-232. The bar code reader may be, for example, a conventional optical bar code reader, such as a gun or a wand type reader.  
         [0074]    The operator swipes or aims the bar code reader on a bar code that is associated with the particular battery to be charged or tested and reads the bar code. The bar code itself may be affixed to the battery at the time of manufacture, purchase, or service. The bar code may contain information, or point to information stored in a database. The database may be located within the FPGA  142 , the storage media  168  (below) or located remotely and accessed electronically. Examples of remotely located databases include data based accessible by the Internet, Ethernet, or other remote memory storage facility.  
         [0075]    The bar code may provide a variety of information regarding the battery. For example, the bar code may provide information regarding the battery type (e.g. gel, flooded lead acid, deep cycle), the battery rating (cold cranking amps), maintenance information, serial number, lot number, warranty information, and a manufacture date code. This data can be used to select parameters for the test or charge cycle. The data provided by the bar code is not limited to the examples given.  
         [0076]    In some embodiments, the printer port  154  may print bar code labels that may be attached or otherwise associated with the battery and provide updated information. The updated information may include, among other things, service dates, service procedures, and warranty information (e.g. time left on warranty, who was the original purchaser, what types of service are and are not warranted, etc.) The printed label may then be read by the bar code reader in subsequent tests or charge cycles.  
         [0077]    The output display  150  and an input device  148  are illustrated in a preferred embodiment in FIG. 6. The display  150  and input device  148  can be located preferably on a common face of a cabinet of the charger  100 , although they alternatively can be located remote from each other and/or remote from the cabinet of the charger, if desired. The display  150  can include one or more LED&#39;s indicating states of the charger  100  or the battery during charging or testing. For example, LED  652  indicates that power is applied to the unit, LED  653  indicates a charge is being applied to the battery, LED  654  indicates a fault in the battery, and LED  655  indicates a good battery is detected. A segmented or dot matrix type, alphanumeric LCD display  656  may also be provided as part of the output display  150 . For example, as shown in FIG. 6, the display  656  can be a 4 by 20 backlit LCD display, having four rows each having twenty character columns. This permits display of a wide range of information relating to e.g., charging status, time, amount, etc, as well as display and selection from a menu of control functions. Thus, the display  150  can include either the alphanumeric display  656 , the LED&#39;s  652  to  655  or both. The two types of displays can be on a single panel or separate ones.  
         [0078]    Control functions may be inputted via at least one, preferably two and more preferably three or more functional buttons, such as up down buttons  658 , and a menu select button  660 . A ten key alphanumeric keypad  662  may also or alternatively be provided for input of numeric data, alphabetic data, and/or command selection. Each key can provide for entry of a number, one or more letters, and/or a function. Thus, the input device  151  can include the menu button  660 , the up down buttons  658 , the alphanumeric keypad  662 , or a combination thereof. These arrangements can be on a single panel or separate ones.  
         [0079]    For example, the key labeled GO may generally be used in the affirmative. It usually means continue on. It is also used to initiate menu prompts leading to the test/charge sequence. The key labeled CLEAR can generally be used in the negative. It is generally used to clear a value that is to be entered. It may also be used to break out of a process or back out of a menu sequence. The key labeled MENU can be used to initiate the function menu. It is also used to back out of a menu sequence. The ARROW KEYS can be used to navigate within the menus and display screens. If an arrow is displayed on the right of the display, the corresponding arrow key can be used to “move” the view to another part of the menu or screen. The arrow keys may also be used to increment or decrement a displayed value. The NUMBER KEYS can be used to communicate with the application in a number of ways. They can be used to indicate the selection on a menu. They can also be used to provide numerical and/or alphabetical input to an application parameter.  
         [0080]    The screen may include the ability to scroll through a set of menu items, such as for example, the following:  
                                                             a) Top level menu, (GO or MENU)           b) Function Menu:                1-Test Results           | 1-View results           | | 1-Print results           | | 2-Print engineering data           | 2-Print results           2-Setup           | 1-Set Clock           | 2-Set Language           | 3-Set Printer Port           | 4-Ethernet Setup           | 5-Save setup           3-Self Test           | 1-LCD Test           | 2-keypad Test           | 3-LED Test           | 4-Audio Test           | 5-Watchdog Test           | 6-Load Cycle Test           | 7-RAM test           | 8-Checksum application           | 9-Test Barcode Reader           4-Update S/W           5-Utility menu           | 1-print codes           | 2-upload data           6-Calibrate           | 1-Set DAC0           | 2-Set DAC1           | 3-Set Amps Offset           | 4-Set Amps Gain           | 5-Set Volts Offset           | 6-Set Volts Gain           | 7-TemperatureOffset           | 8-Manual Controls           | | 1-Test SCR           | | 2-Enable SCR load           | | 3-Enable Low Volts Charging           | | 4-Auto Charge Mode           | | 5-Heavy Load Test           | | 6-Micro Load test           | | 7-Manual Charge Mode           | | 8-Monitor Volts           | 9-Save Calibrations                      
 
         [0081]    This menu is by way of example only. Other features, commands, displays or inputs, for example may also be provided.  
         [0082]    Referring to FIG. 1 an additional smaller transformer  158  provides current and voltage to the I/O control  134  and a cooling fan  160 . The smaller transformer  158  provides a step down of both the voltage and current to a level that enables the I/O control  134  and a cooling fan  160  to operate. The cooling fan  160  helps to control the operating temperature of the charger  100 .  
         [0083]    The peripheral module port  156  can be constructed and arranged to receive an information relay device, such as an Ethernet wired module  166  and/or an Ethernet wireless module  164 . The Ethernet modules  164 ,  166  communicate at data rates of 10 Mbps (10Base-T Ethernet), 100 Mbps (Fast Ethernet), 1000 Mbps (Gigabit Ethernet), and other data rates. The Ethernet modules  164 ,  166  can relay information between the charger  100  and another device connected to the modules via a wire or wirelessly. The information relayed can include data from the result of the charging/testing of the battery, data of the battery&#39;s warranty information, data of the battery type (deep cycle, gel, etc.), data of battery make and model, data from previous charging/testing of the battery, firmware update, data from diagnostic or operating parameters of the charger  100 , maintenance data of the charger  100 , and any other data required by the operator.  
         [0084]    The peripheral module port  156  is in communication with the FPGA  142 . Information can be exchanged between the peripheral module port  156 , the Ethernet modules  164 ,  166 , and the FPGA  142 . The Ethernet modules  164 ,  166  can relay the information to and from a remote device, such as a network server, a printer, a personal computer, a workstation, a file server, a print server, other communication devices, such as a fax machine, a cellular/digital phone, a pager, a personal digital assistant, an email receiver, and a display. Through the use of the Ethernet modules  164 ,  166  any information, such as the information of the battery tested by the charger  100 , can be relayed to a printer server and printed. Thus, the charger  100  is not dependent on a stand-alone printer that may be down, and can print to any networked printer, thereby saving time and money to the operator.  
         [0085]    With the Ethernet module  164 ,  166 , information can also be stored remotely, such as on a workstation, a file server or other data storage device. For example, after the charger  100  concludes the charging/testing of the battery, the information from the test/charge can be relayed and stored on a networked personal computer. With the information stored on the networked personal computer, the information from any previous charge/test can be compared with the latest information, a report can be generated and forwarded to the appropriate personnel.  
         [0086]    If the chargers  100  (same or similar model) that are used by the operator are “networked” together, the chargers&#39; firmware can be updated simultaneously. Conventionally, to update firmware, a laptop is hooked up to the charger  100  and the new firmware is uploaded. Once the upload is completed, the operator then must go to the next charger  100  and repeat the process until all of the chargers  100  are updated with the new firmware. By being able to upload new firmware onto networked chargers  100 , the update process will be less time consuming, and thus cost-effective for the operator. By having the chargers  100  networked via the Ethernet modules  164 ,  166 , information from all the chargers  100  can be relayed and displayed to the operator. Because the chargers  100  can be networked, the operator does not have check each individual charger  100  to see if the charging and testing is completed and saves valuable time and money. Additionally, by being networked, the chargers  100  can be instructed to run diagnostics and other functions remotely without having to individually program each charger  100 .  
         [0087]    In another embodiment, a notification system is provided to notify the operator when there is a problem with the charger  100  or the battery or when the charging/testing is completed. Typically, the operator has to physically check the status of the charger  100  and often would have to return many times to see if the charging/testing is completed. With the charger  100  having an Ethernet connection modules  164 ,  166 , the status information can be relayed to a remote location, such as the network server or the personal computer, which can be programmed to notify the operator of any problems or the completion of the charging/testing. Because the operator can be notified of any problems, the operator can take appropriate measures, such as terminating the charging of the battery because charger  100  or the battery is overheating. By being notified of any problems, the operator can save money due to a decrease in electricity usage and decrease the possibility of an explosion due to overcharging the battery. Notification of the operator can be done with a personal computer that can notify the operator via another display, by pager, by fax, by email, by phone, by computer or by any means that will relay the requested information to the operator.  
         [0088]    In another embodiment of the invention, the peripheral module port  156  can be constructed and arranged to accept a removable data storage media  168  (“storage media”). Information can be exchanged between the peripheral module port  156 , the storage media  168 , and the FPGA  142 . The storage media  168  can be permanently fixed to the charger  100  to provide additional memory or can be removable, as required by the operator. The storage media  168  can transfer information to and from the charger  100 . The information can include data from the result of the charging/testing of the battery, the battery&#39;s warranty information, the battery type (deep cycle, gel, etc.), battery&#39;s make and model, data from previous charging/testing of the battery, firmware update, data from diagnostic or operating parameters of the charger  100 , maintenance data of the charger  100 , and any other data required by the operator.  
         [0089]    The storage media  168  can include, but not limited to floppy disc (including ZIP); tape drive cartridge (such as DAT); optical media (such as CD-ROM, DVD-ROM, etc.); flash memory (such as smart media, compact flash, PC card memory, memory sticks, flash SIMMs and DIMMS, etc.); magnetic based media, magneto optical; USB drives; or any other storage media that an operator can store or retrieve information from it. A person skilled in the art will recognize that any storage media can be used.  
         [0090]    One use of the storage media  168  is to update firmware, wherein the storage media can be programmed with the firmware update and loaded into the charger  100 . By using the user interface  148 , the operator can select the “update firmware” option from a menu that was previously provided to the charger  100 . The charger  100  is able to retrieve the new firmware and update the charger  100 . In another example, the operator can use the storage media  168  to store information regarding the battery that was charged/tested. The information can be downloaded into the storage media  168 , such as a compact flash card, and can be sent to the appropriate person. Additionally, the storage media  168  can contain information from the charging/testing result of a battery at another location and can be uploaded into the charger  100  and displayed to the operator. Alternatively, the information can be relayed via the Ethernet module to be viewed, stored, or printed at a remote location. The storage media  168  can also provide an image of a soft-core microprocessor to the FPGA  142  during start-up.  
         [0091]    The charger  100  can have more than one peripheral module port  156  so that a communication nodule, a storage media module, and an many other modules as needed can be onboard the charger. The peripheral module port  156  provides flexibility to the charger  100  and provides a port so that any new device can be added to the charger as needed by the operator.  
         [0092]    The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirits and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.