Patent Publication Number: US-2007096689-A1

Title: Battery analysis system and method

Description:
BACKGROUND OF THE INVENTION  
      Notebook or laptop computers and other types of portable computing devices utilize an internal battery to enable self-powered use of the computing device (i.e., independent of an electrical outlet and/or other type of external power source). When a consumer and/or user of the computing device perceives a problem associated with the battery, a replacement battery is either purchased by the user or a warranty replacement battery is sought (e.g., if the battery is still under warranty). However, working batteries are many times unnecessarily replaced as the battery is either functioning properly or simply requires re-calibration, thereby resulting in the consumer and/or the battery vendor incurring additional and unnecessary costs. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in connection with the accompanying drawings in which:  
       FIG. 1  is a diagram illustrating an embodiment of a battery analysis system in accordance with the present invention;  
       FIG. 2  is a flow diagram illustrating an embodiment of a battery analysis method in accordance with the present invention;  
       FIG. 3  is a flow diagram illustrating another embodiment of a battery analysis method in accordance with the present invention;  
       FIG. 4  is a flow diagram illustrating another embodiment of a battery analysis method in accordance with the present invention;  
       FIG. 5  is a flow diagram illustrating another embodiment of a battery  
       FIG. 6  is a flow diagram illustrating yet another embodiment of a battery analysis method in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS  
      The preferred embodiments of the present invention and the advantages thereof are best understood by referring to  FIGS. 1-6  of the drawings, like numerals being used for like and corresponding parts of the various drawings.  
       FIG. 1  is a diagram illustrating an embodiment of a battery analysis system  10  in accordance with the present invention. In the embodiment illustrated in  FIG. 1 , analysis system  10  is illustrated as being disposed within a computer device  12  for analyzing and/or otherwise determining whether a battery  14  is defective and/or otherwise needs replacement. Computer device  12  may comprise any type of computer device such as, but not limited to, a laptop or notebook computer, tablet computer, personal digital assistant, or any other type of computer device capable of being battery powered. In the embodiment illustrated in  FIG. 1 , battery  14  is illustrated as being part and/or otherwise forming a part of computer device  12  (e.g., an internal battery  14 ). However, it should be understood that battery  14  may comprise an external battery (e.g., a travel battery, secondary battery, or other type of external battery). In the embodiment illustrated in  FIG. 1 , analysis system  10  is illustrated as being disposed within and/or otherwise forming a part of computer device  12 . However, it should be understood that analysis system  10  may be otherwise located relative to computer device  12 . For example, in the embodiment illustrated in  FIG. 1 , analysis system  10  may be located remote from computer device  12 , illustrated generally by  16 , and configured to communicate and/or otherwise interface with battery  14  via a communication network  18  (e.g., the internet, an Intranet, a local area network (LAN), a wide area network (WAN), or other type or wired and/or wireless communications network). For ease of description, only analysis system  10  is described below; however, it should be understood that system  16  may be similarly configured for remote use thereof. Further, it should be understood that embodiments of the present invention are not limited to having a single system  10  or  16  (e.g., computer device  12  may be configured having an internal system  10  and also be configured to enable remote access thereto by system  16 ).  
      In the embodiment illustrated in  FIG. 1 , analysis system  10  comprises a processor  20  and a memory  22 . Processor  20  may be a discrete processor element forming a part of analysis system  10  and/or analysis system  10  may utilize another processing element disposed on computer device  12 . In the illustrated embodiment, analysis system  10  comprises a test module  24 . Test module  24  may comprise hardware, software, or a combination of hardware and software. In the embodiment illustrated in  FIG. 1 , test module  24  is illustrated as being stored in memory  22  so as to be accessible and executable by processor  20 . However, it should be understood that test module  24  may be otherwise located, even remotely from computer device  12 . In operation, test module  24  accesses various information from battery  14  and analyzes such information to determine whether battery  14  is defective and/or otherwise needs replacement. Preferably, computer device  12  is operating using a power source other than the analyzed battery  14  (e.g., external alternating current (AC) outlet or AC adapter) when running analysis system  10  to facilitate accurate readings from battery  14 . It should be understood that a determination that battery  14  is defective and/or otherwise needs replacement may be based on results of an analysis performed after a re-calibration of battery  14  and/or before a re-calibration of battery  14 .  
      In the embodiment illustrated in  FIG. 1 , battery  14  comprises a microprocessor  30  and one or more memory registers  32 . Memory registers  32  comprise information stored by microprocessor  30  associated with various preset and/or operating parameters of battery  14 . For example, information stored in registers  32  may comprise information preset and/or stored in battery  14  prior to a first customer use of battery  14  (e.g., default values, design values and/or other types of information stored in registers  32  prior to battery  14  leaving a factory) and/or information monitored, logged, and/or otherwise stored by microprocessor  30  during operation of battery  14  (e.g., during the use of battery  14  by with computer device  12 ).  
      In the embodiment illustrated in  FIG. 1 , memory registers  32  comprise a design voltage register  34 , a temperature register  36 , cell voltage register(s)  38 , a cycle count register  40 , status register(s)  42  and capacity register(s)  44 . As discussed above, information stored in memory registers  32  may comprise information acquired and/or otherwise collected during use of battery  14  and/or information pre-stored before in battery  14 . For example, in some embodiments of the present invention, design voltage register  34  comprises information associated with a designed voltage level of battery  14 , temperature register  36  comprises information associated with recorded operating temperatures of battery  14  (e.g., a minimum and/or maximum recorded operating temperature), cell voltage register(s)  38  comprise cell voltage levels for each cell  38   1 - 38   n  of battery  14 , cycle count register  40  comprises information associated with a quantity of recharged cycles of battery  14 , status register(s)  42  comprise information associated with various status alarm bits or indicators, and capacity register(s)  44  comprise information associated with charge capacities of battery  14 . For example, in the embodiment illustrated in  FIG. 1 , status register(s)  42  comprise an overtemp register  46  having information associated with an over-temperature condition of battery  14 , and a terminate discharge register  48  having information associated with discharging of battery  14 . Additionally, in the embodiment illustrated in  FIG. 1 , capacity register(s)  44  comprise a design capacity register  49  having information associated with designed charge capacity of battery  14 , and a last-learned capacity register  50  having information associated with a last-determined and/or stored charge capacity level of battery  14 . However, it should be understood that battery  14  may comprise other types of memory registers  32  and/or related information usable by analysis system  10  to determine whether battery  14  is defective.  
      In operation, test module  24  reads information from various memory registers  32  of battery  14  to determine whether battery  14  is defective and/or otherwise needs replacement. For example, in some embodiments of the present invention, test module  24  reads information from various memory registers  32  and compares the read values to predetermined thresholds and/or predetermined ranges of values. In the embodiment illustrated in  FIG. 1 , a database  52  has battery parameter data  54 . Battery parameter data  54  comprises information associated with values read from memory registers  32  and/or predetermined values used to analyze and/or evaluate the read register values to determine whether battery  14  is defective and/or otherwise needs replacement.  
      In the embodiment illustrated in  FIG. 1 , battery parameter data  54  comprises design voltage values  60 , cell voltage values  62 , temperature values  64 , terminal values  66 , capacity values  68 , cycle values  70  and status values  72 . Design voltage values  60  comprises a register value  80  representing a design voltage value read from design voltage register  34 , and predetermined design voltage value(s)  82  representing preset and/or default design voltage value(s) of battery  14  used to analyze and/or evaluate the read register value  80  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement. In the embodiment illustrated in  FIG. 1 , cell voltage values  62  comprise register value(s)  86  representing cell voltage value(s) read from register(s)  38   1 - 38   n  for each cell of battery  14 , and predetermined cell voltage value(s)  88  representing predetermined threshold and/or ranges of cell voltage values used to analyze and/or evaluate the read register value(s)  86  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement.  
      In the embodiment illustrated in  FIG. 1 , temperature values  64  comprise a register value  90  representing a temperature register value read from temperature register  36 , and predetermined temperature values  92  representing predetermined threshold and/or ranges of temperature values used to analyze and/or evaluate the read register value  90  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement. Terminal values  66  comprise information associated with a terminal voltage level  96  and a terminal current level  98  at a power supply terminal of battery  14 . For example, terminal value  66  represent actual voltage and current values  96  and  98 , respectively, measured at a power supply terminal of battery  14 . Terminal values  66  also comprises predetermined terminal values  99  representing predetermined threshold and/or ranges of terminal voltage and/or current values used to analyze and/or evaluate the determined value(s)  96  and/or  98  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement. Capacity values  68  comprise a design capacity register value  100  representing a design capacity register value read from design capacity register  49 , a last-learned capacity register value  102  representing a last-learned capacity value read from last-learned capacity register  50 , and predetermined capacity values  104  representing predetermined threshold and/or ranges of values used to analyze and/or evaluate the read register values  100  and/or  102  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement.  
      Cycle values  70  comprises a cycle count register value  110  representing a cycle count value read from cycle count register  40 , and predetermined cycle count values  112  representing a predetermined threshold and/or range of values used to analyze and/or evaluate the read register value  110  and/or otherwise used in combination with other read register values and/or predetermined values to determine whether battery  14  is defective and/or otherwise needs replacement. Status values  72  comprise an overtemp status register alarm value  120  representing an alarm and/or bit value read from overtemp register  46 , a terminate discharge register alarm value  122  representing an alarm and/or bit value read from terminate discharge register  48 , and predetermined status values  124  used in combination with overtemp status register alarm value  120  and/or terminate discharge register alarm value  122  to determine whether battery  14  is defective and/or otherwise needs replacement.  
      In some embodiments of the present invention, test module  24  reads design voltage register  34  to obtain design voltage register value  80  and uses predetermined design voltage values  82  to automatically determine a quantity of cells in battery  14 . For example, in some embodiments of the present invention, predetermined design voltage values  82  comprise a predetermined and/or preset range of values generally associated with batteries having different cell counts (e.g., a different value range for each of a three-cell battery, four-cell battery, etc., to determine a quantity of cells in battery  14 ). Thus, for example, in some embodiments of the present invention, for a three-cell battery  14 , design voltage register value  80  should generally fall between 10,800 millivolts (mV) and 11,100 mV, and for a four-cell battery, design voltage register value  80  should fall between 14,400 mV and 14,800 mV. It should be understood that other predetermined ranges of design voltage values  82  may be provided and/or otherwise used. Thus, test module  24  is configured to automatically determine a quantity of cells of battery  14  based on which predetermined design voltage value  82  range the read design voltage register value  80  falls. Further, if the read design voltage register value  80  does not fall within any predetermined design voltage value  82  ranges, test module  24  identifies battery  14  as being defective (e.g., indicating a corrupt design voltage register  34  and/or other anomaly generally associated with a defective battery  14 ).  
      In some embodiments of the present invention, test module  24  reads cell voltage register(s)  38  to determine cell voltage values for each cell of battery  14 . For example, in some embodiments of the present invention, test module  24  reads cell voltage registers  38  for each cell  38   1 - 38   n  and stores the register values as cell voltage register value(s)  86 . Test module  24  evaluates the read cell voltage register values  86  and determines a maximum spread and/or difference between maximum and minimum cell voltage register values  86  read from cell voltage register(s)  38  corresponding to cells  38   1 - 38   n . In some embodiments of the present invention, predetermined cell voltage values  88  comprise a maximum threshold capacity difference value between cells  38   1 - 38   n . For example, if the maximum spread and/or difference between a maximum cell voltage register value  86  and a minimum cell voltage register value  86  read from cell voltage registers  38  exceeds a predetermined cell voltage threshold value  88  (e.g., 50 mV), test module  24  identifies battery  14  as defective (e.g., indicating a faulty battery cell, corrupt register  38 , and/or other anomaly generally associated with a defective battery condition).  
      In some embodiments of the present invention, test module  24  reads temperature register value  90  from temperature register  36  and evaluates temperature register value  90  against predetermined temperature values  92 . For example, in some embodiments of the present invention, predetermined temperature values  92  comprise predetermined minimum and/or maximum threshold values. Thus, for example, if temperature register value  90  falls below a predetermined minimum threshold temperature value  92  and/or exceeds a predetermined maximum threshold temperature value  92 , test module  24  identifies battery  14  as defective (e.g., as a result of a possible thermistor disconnection, corrupt register, and/or other anomaly generally associated with a defective battery condition). In some embodiments of the present invention, test module  24  reads overtemp status register alarm value  120  and terminate discharge register alarm value  122  from overtemp register  46  and terminate discharge register  48 , respectively, to determine whether alarm bits have been set in overtemp register  46  and/or terminate discharge register  48 , respectively. If the alarm bits of status registers  42  have been set and/or otherwise correspond to predetermined status values  124  representing an alarm set or error log condition in status registers  42 , test module  24  identifies battery  14  as defective (e.g., resulting from an overtemp condition, corrupt register, and/or other anomaly generally associated with a defective battery condition).  
      In some embodiments of the present invention, test module  24  reads terminal voltage value  96  and/or terminal current value  98  representing actual voltage and current values located at a power supply terminal of battery  14 , respectively, and evaluates terminal voltage value  96  and/or terminal current value  98  to predetermined terminal values  99  and/or other read register values and/or information. For example, in some embodiments of the present invention, based at least on a determination of a quantity of cells of battery  14  (e.g., based on design voltage register value  80  read from design voltage register  34 ), test module  24  evaluates the terminal voltage value  96  and terminal current value  98  to determine if battery  14  is defective. For example, if battery  14  comprises four cells and terminal voltage value  96  is less than a predetermined terminal voltage level value  99  for a four-cell battery  14  (e.g., 11 mV for a four-cell battery  14 ) but terminal current value  98  is greater than a predetermined terminal current level value  99  (e.g., 500 mA), test module  24  identifies battery  14  as defective (e.g., indicating that battery  14  is not charging properly and/or generally indicating another anomaly generally associated with a defective battery condition).  
      In some embodiments of the present invention, test module  24  evaluates design capacity register value  100  read from design capacity register  49  and last-learned capacity register value  102  read from last-learned capacity register  50  with at least predetermined capacity values  104  to determine a condition of battery  14 . For example, in some embodiments of the present invention, predetermined capacity value  104  represents a predetermined value and/or threshold ratio of last-learned capacity register value  102  relative to design capacity register value  100 . Thus, for example, if a ratio of last-learned capacity register value  102  relative to design capacity register value  100  is greater than a predetermined value and/or threshold ratio value  104  (e.g., 110%), test module  24  identifies battery  14  as defective (.e.g., indicating a corrupt register, a problem reading last-learned capacity register values  102  and/or another anomaly generally associated with a defective battery condition).  
      In some embodiments of the present invention, test module  24  evaluates cycle count register value  110  read from cycle count register  40  with predetermined cycle count values  112  and/or other read register values and/or information to evaluate a condition of battery  14 . For example, in some embodiments of the present invention, test module  24  evaluates cycle count register value  110  in combination with design capacity register value  100  and last-learned capacity register value  102  to evaluate a condition of battery  14 . For example, if last-learned capacity register value  102  is less than half of design capacity register value  100  and cycle count register value  110  is less than a predetermined quantity of cycles indicated by value  112  (e.g., less than 300 charging cycles having been performed), test module  24  identifies battery  14  as defective (e.g., indicating an extremely low battery  14  capacity, a corrupt register, and/or another anomaly generally associated with a defective battery condition).  
      Thus, embodiments of the present invention evaluate one or more parameter values associated with battery  14  to automatically determine whether battery  14  is defective and/or otherwise needs replacement. It should be understood that in some embodiments of the present invention, test module  24  is configured to indicate a defective battery  14  based on a single analyzed item and/or a combination of analyzed items (e.g., using multiple analyzed items as a check or verification against other analyzed items). Further, in some embodiments of the present invention, test module is configured to display an indication of battery  14  defective status (e.g., display element or flashing light emitting diode (LED)). Test module  24  may be configured to initiate analysis of battery  14  automatically (e.g., corresponding to a predetermined schedule, upon each boot of computer device  12  using power supplied by battery  14  and/or each time power to computer device  12  is switched from an external source to battery  14 , or vice versa) or in response to a user request.  
       FIG. 2  is a flow diagram illustrating an embodiment of a battery analysis method  200  in accordance with the present invention. The method begins at block  202 , where test module  24  reads design voltage register value  80  from design voltage register  34 . At block  204 , test module  24  determines a quantity of cells in battery  14  based on design voltage register value  80 . For example, as discussed above, design voltage register value  80  may be compared to one or more predetermined design voltage range values  82 , based on which design voltage value range value  82  the design voltage register value  80  falls, battery  14  is determined to have a corresponding quantity of cells.  
      At block  206 , test module  24  reads cell voltage register values  86  from cell voltage registers  38  corresponding to each cell  38   1 - 38   n . At block  208 , test module  24  identifies minimum and maximum cell voltage register values  86  read from cell voltage registers  38 . At decisional block  210 , a determination is made whether a maximum difference and/or spread between the minimum and maximum read cell voltage register values  86  exceeds a predetermined maximum difference threshold cell voltage value  88 . If the difference between the minimum and maximum cell voltage register values  86  exceeds a predetermined maximum difference threshold cell voltage  88 , the method proceeds to block  212 , where test module  24  identifies battery  14  as defective. If the difference between the minimum and maximum cell voltage register values  86  does not exceed the predetermined maximum difference threshold cell voltage value  88 , the method ends.  
       FIG. 3  is a flow diagram illustrating another embodiment of a battery analysis method  300  in accordance with the present invention. The method begins at block  302 , where test module  24  reads temperature register value  90  from temperature register  36  of battery  14 . At block  304 , a determination is made whether temperature register value  90  exceeds a predetermined maximum temperature threshold value  92 . If temperature register value  90  exceeds a predetermined maximum temperature threshold value  92 , the method proceeds to block  308 , where test module  24  identifies battery  14  as defective. If temperature register value  90  does not exceed a predetermined maximum temperature threshold value  92 , the method proceeds to decisional step  306 , where a determination is made whether temperature register value of  90  falls below a predetermined temperature minimum threshold value  92 . If temperature register value  90  falls below a predetermined minimum threshold temperature value  92 , the method proceeds to block  308 , where test module  24  identifies battery  14  as defective. If temperature register value  90  does not fall below a predetermined temperature minimum threshold value  92 , the method ends.  
       FIG. 4  is a flow diagram illustrating another embodiment of a battery analysis method  400  in accordance with the present invention. The method begins at block  402 , where test module  24  reads design voltage register value  80  from voltage register  34 . At block  404 , test module  24  identifies a minimum predetermined design voltage value  82  corresponding to the quantity of cells in battery  14 . At block  406 , test module  24  identifies a maximum predetermined design voltage value  82  corresponding to a quantity of cells in battery  14 . At decisional block  408 , a determination is made whether design voltage register value  80  falls within the minimum and maximum predetermined design voltage values  82 . If design voltage register value  80  falls within the minimum and maximum predetermined design voltage values  82 , the method ends. If the design voltage register value  80  does not fall within the predetermined minimum and maximum design voltage values  82 , the method proceeds to block  410 , where test module  24  identifies battery  14  as defective.  
       FIG. 5  is a flow diagram illustrating another embodiment of a battery analysis method  500  in accordance with the present invention. The method begins at block  502 , where a test module  24  reads design voltage register value  80  from design voltage register  34 . At block  504 , test module  24  determines a quantity of cells in battery  14  based on design voltage register value  80 . At block  506 , test module  24  determines terminal voltage value  96  associated with a voltage level at a terminal of battery  14 . At block  508 , test module  24  identifies minimum and maximum predetermined terminal voltage threshold values  99  based on a quantity of cells in battery  14 .  
      At decisional block  510 , a determination is made whether terminal voltage value  96  exceeds a predetermined maximum terminal voltage threshold value  99 . If terminal voltage value  96  exceeds a predetermined maximum terminal voltage threshold value  99 , the method proceeds to block  520 , where test module  24  identifies battery  14  as defective. If terminal voltage value  96  does not exceed a maximum predetermined terminal voltage threshold value  99 , the method proceeds to decisional block  512 , where a determination is made whether terminal voltage value  96  falls below a predetermined minimum terminal voltage threshold value  99 . If terminal voltage value  96  does not fall below a minimum predetermined terminal voltage threshold value  99 , the method ends. If terminal voltage value  96  falls below a minimum predetermined terminal voltage threshold value  99 , the method proceeds to block  514 , where test module  24  determines terminal current value  98  associated with a current level at a terminal of battery  14 . At block  516 , test module  24  identifies a predetermined terminal current value  99  associated with charging battery  14 . At decisional block  518 , a determination is made whether terminal current value  98  exceeds the predetermined terminal charging current value  99 . If the terminal current value  98  does not exceed the predetermined terminal charging current value  99 , the method ends. If the terminal current value  98  exceeds the predetermined terminal charging current value  99 , the method proceeds to block  520  where test module  24  identifies battery  14  as defective.  
       FIG. 6  is a flow diagram illustrating another embodiment of a battery analysis method  600  in accordance with the present invention. The method begins at block  602 , where test module  24  reads design capacity register value  100  from design capacity register  49 . At block  604 , test module  24  reads last-learned capacity register value  102  from last-learned capacity register  50 . At decisional block  606 , a determination is made whether last-learned capacity register value  102  exceeds design capacity register value  100 . If last-learned capacity register value  102  exceeds design capacity register value  100 , the method proceeds to block  614 , where test module  24  identifies battery  14  as defective. If last-learned capacity register value  102  does not exceed design capacity register value  100 , the method proceeds to decisional block  608 , where a determination is made whether last-learned capacity register value  102  falls below a predetermined minimum design capacity value  104 . If last-learned capacity register value  102  does not fall below a predetermined minimum design capacity value  104 , the method ends. If last-earned capacity register value  102  falls below a predetermined minimum capacity value  104 , the method proceeds to block  610 , where test module  24  reads cycle count register value  110  from cycle count register  40 . At decisional block  612 , a determination is made whether cycle count register value  110  falls below a predetermined minimum cycle count value  112 . If cycle count register value  110  does not fall below a predetermined minimum cycle count value  112 , the method ends. If cycle count register value  110  falls below a predetermined minimum cycle count value  112 , the method proceeds to block  614 , where a test module  24  identifies battery  14  as defective.  
      Accordingly, embodiments of the present invention enable automatic determination of battery condition before replacement of the battery and/or return of the battery to a vendor. It should be understood that in the described methods, certain functions may be omitted, accomplished in a sequence different from that depicted in  FIGS. 2-6 , or performed simultaneously or in combination. Also, it should be understood that the methods depicted in  FIGS. 2-6  may be altered to encompass any of the other features or aspects of the invention as described elsewhere in the specification. Further, embodiments of the present invention may be implemented in software and can be adapted to run on different platforms and operating systems. In particular, functions implemented by test module  24 , for example, may be provided as an ordered listing of executable instructions that can be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device, and execute the instructions. In the context of this document, a “computer-readable medium” can be any means that can contain, store, communicate, propagate or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-readable medium can be, for example, but is not limited to, an electronic, magnetic, optical, electro-magnetic, infrared, or semi-conductor system, apparatus, device, or propagation medium.