Patent Publication Number: US-10317474-B2

Title: Systems and methods for identifying faulty battery in an electronic device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims the benefit of U.S. Provisional Patent Application No. 62/093,806 for a METHOD OF IDENTIFYING A BAD BATTERY IN AN ELECTRONIC DEVICE filed Dec. 18, 2014. The foregoing patent application is hereby incorporated by reference in its entirety. 
    
    
     FIELD 
     Embodiments of present invention generally relate to the field of electronic device maintenance and, more specifically, to systems and methods for identifying faulty batteries that have intermittent field failures. 
     BACKGROUND 
     A battery installed in an electronic device (e.g., a handheld device such as a portable data terminal (PDT), a personal data assistant (PDA), etc.) is a component that can develop internal failures over time from environmental stresses due to a user handling/mishandling the device (e.g., users dropping the device). In one regard, the battery can develop internal failures due to the internal solder joints breaking from the mechanical stresses of being dropped. 
     Internal battery failures due to broken internal solder joints can, however, be very intermittent. For example, the PDT (or other electronic device) may operate normally most of the time, but a bump or drop can separate the broken solder joint causing a power loss and a resulting reboot of the PDT. The specific cause of this intermittent device failure may be difficult for the user to determine because the electronic device may operate normally most of the time. 
     Moreover, when the electronic device having intermittent failures (i.e., failures that come and go) is returned for service by a user, it is difficult for a maintenance or repair technician to specifically identify a faulty battery component because the battery may not exhibit the failure at the time of the repair. Moreover, testing the suspect battery in a different board or device could cause a slight variation in the “twist,” “tension,” or “spring” pressure that is being applied to the battery/board connector interface such that the broken internal battery joint functions normally during battery testing. This can lead to missed repairs and repeat returns of failed devices causing frustration for the device user/customer. 
     Therefore, a need exists for more effective maintenance systems and methods for electronic devices, including but not limited to maintenance systems and methods that facilitate accurate detection and subsequent replacement of faulty (i.e., defective, bad, flawed, etc.) batteries in an intermittent failure mode. 
     SUMMARY 
     Exemplary systems and methods for identifying/repairing a faulty battery in an electronic device are disclosed. In an exemplary embodiment, a log is extracted from the electronic device having a battery. The log has a record of local charge events and can be used to identify a faulty battery. Although charge events are typically referred to herein, the term battery charge event is used in a broad, generic sense and the events may include additional battery status/information not specific to battery charge/discharge status. 
     An electronic device that may be utilized in connection with the exemplary systems/methods includes a battery and local software or firmware installed onto the device which is capable of creating a local log of battery charge events. The log may extract/include additional information relating to the battery including but not limited to the battery serial number, battery status, and a battery voltage. 
     For each battery charge event recorded in the log, the battery charge event may be analyzed to determine if the battery is out of tolerance. If the battery is out of tolerance, replacement of the battery may be indicated to the technician, and the technician may then replace the faulty battery. 
     The exemplary embodiment described herein identifies intermittent bad batteries by capturing specific battery charge events and logging these events. At the time of repair, these event logs are analyzed for specific operating characteristics that identify a defective battery. The results of the analysis may then be reported to the repair technician. In this regard, even if the battery currently appears to be operating appropriately based upon physical testing, the technician is advised that the battery has previously experienced failures (based upon the log report) and could therefore be defective. 
     The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a flowchart of an exemplary embodiment of the method to identify a bad battery. 
         FIG. 2  is a view of an exemplary embodiment of a log file generated by software embodying the exemplary method to identify a bad battery. 
         FIG. 3  is a screenshot of an exemplary embodiment of software embodying the exemplary method to identify a bad battery. 
         FIG. 4  is a screenshot of an exemplary embodiment of a properties setting screen of software embodying the exemplary method to identify a bad battery. 
         FIG. 5A  is a first part of a flowchart illustrating a log extraction step of the exemplary method to identify a bad battery. 
         FIG. 5B  is a second part of the flowchart of  FIG. 5A . 
         FIG. 6  is a flowchart illustrating an exemplary process of analyzing the log of the battery charge events to identify a bad battery. 
         FIG. 7A  is a first part of a flow chart illustrating an exemplary software upgrade process of the exemplary method to identify bad batteries. 
         FIG. 7B  is a second part of the flowchart of  FIG. 7A . 
     
    
    
     DETAILED DESCRIPTION 
     Generally, exemplary systems and methods for identifying defective batteries in an electronic device are disclosed. The electronic device includes software capable of creating a log of battery charge events as they occur. The log may include a record of battery charge events with properties including a battery serial number, a battery status, and a battery voltage. 
     The log may be extracted from the electronic device by a technician (e.g., using a personal computer (PC)) to diagnose the electronic device. The log may then be analyzed based upon the logged charge events to determine whether the battery of out of tolerance. If the battery is out of tolerance, replacement of the battery is indicated to the technician. Further, the software on the electronic device may be upgraded. 
       FIG. 1  depicts a flow chart  100  of an exemplary embodiment of a method to identify defective batteries used in an electronic device. The exemplary method as shown includes three steps. First, a log of battery charge events is extracted from the electronic device  101 . Second, the battery event log is analyzed  102  to determine if the battery should be indicated to a technician for replacement and/or replaced. Third, and optionally, the software on the electronic device may be upgraded  103 . 
     Although the exemplary system and method embodiments may be described and utilized in connection with electronic devices such as personal data terminals (PDT), personal digital assistants (PDA), and/or personal computers (PCs), and more specifically a HONEYWELL 99EX PDT from Honeywell International, Inc., the methods/systems described herein may be implemented with any electronic device that includes a battery in order to diagnose battery defects. Generally, an exemplary electronic device (e.g., a PDT) may include, but is not limited to, operating components such as a central processing unit, a system bus, a main memory (e.g., RAM, ROM, etc.), a mass storage device (e.g., a hard disk), an operating system (e.g., MICROSOFT WINDOWS) stored on the mass storage device and executed by the central processing unit, and a computer touch screen (or other input/display devices) for receiving input from a user and displaying information. 
       FIG. 2  is an illustration of an exemplary battery log that the electronic device may be configured to keep relating to battery charge events. Firmware residing on the electronic device (i.e., stored in internal or external device memory) captures the battery status at charge events. 
     The firmware is designed to specifically monitor/log battery status events which may include: “LOW MAIN,” (i.e., the voltage of the battery is low when compared to operating tolerances, which leads to the device shutting down); “CHARGE START,” (i.e., battery charging has started, such as when external voltage has been applied to the electronic device); “CHARGE END,” (i.e., battery charging has ended, such as when external voltage has been removed from the electronic device, or when the battery is fully charged); “DISCHARGE START,” (i.e., discharge of the battery has started, such as when the battery is being used to power the device); “DISCHARGE END,” (i.e., discharge of the battery has ended, such as when the device is operating on external power); “SUSPEND CHARGE,” (i.e., charging of the battery has been suspended, such as when the battery is defective, the battery is over temperature, the battery charge time has been exceeded, etc.); “AC REMOVAL” (i.e., the external power supply has been removed from the electronic device), “AC PRESENT” (i.e., the external power supply has been applied to the electronic device), “BATT CHANGE” (i.e., the battery has been removed, and a new battery has been installed in electronic device.); “DOOR REMOVAL” (i.e., the battery compartment of the electronic device has been opened); “TIME LOG” (i.e., a battery status/state event has been recorded into the event log); and “BAD AC” (i.e., the external power supply is present, but is not at a level that is sufficient to charge the battery properly.). 
     More particularly, the system/method of detecting a bad battery is specifically concerned with two conditions, namely, a “LOW MAIN” status event or a “SUSPEND CHARGE” event. All captured events are saved in an event log file, titled as “BATTERY LOG” in the example at  FIG. 2 , but other names may be utilized for the log. 
     The log (e.g., the “BATTERY LOG” of  FIG. 2 ) may be formatted as an ASCII text file to conserve storage space. The log size may also be limited to a maximum size of 5000 characters, or some other limited number. Once the log has reached the maximum allowed size, the oldest portion of the log may be overwritten with new entries. 
     The log may be further structured such that each line in the text file is a separate charge/status event. As shown in  FIG. 2 , each entry may include various battery statistics, in addition to the status event in order to provide additional diagnostic data to the technician, such as: DATE; TIME; Battery Serial Number; “RUTH” (i.e., whether the battery is an authentic battery, such as an authentic HONEYWELL device battery); Battery Voltage (millivolts (mV)), Battery Temp (0.1 deg. C.), Remain Capacity (milliamp hours (mAh)), “Nom Avail Capacity” (mAh) (i.e., the remaining battery capacity, but not compensated for temperature and battery load); “Full Capacity” (mAh) (i.e., the full battery capacity, but not compensated for temperature and battery load); “State of Charge” (i.e., the battery capacity remaining expressed as a percentage of the full capacity); Max Temp (0.1 deg. C.), Min Temp (0.1 deg. C.), and “Cycle count” (i.e., the number of battery charge and discharge cycles). 
     The firmware may record the log in a delimited format, such as with tabs or commas, in order to permit simplified parsing of the log. Other delimiters or coding may be used. 
     The exemplary battery log illustrated in  FIG. 2  is illustrated in a comma delimited, ASCII format. The advantage of using an ASCII text file for storage of the log is that it is human readable (i.e., readable by a device technician), but the log may be encoded in other condensed formats, such as when storage space is critical. 
       FIGS. 3 and 4  illustrate screenshots of an exemplary software utility for extracting and analyzing logs, as well as updating firmware on an electronic device. Although the software utility is shown with a graphical user interface (“GUI”), the method may be performed in a command line or other interface as well. The GUI provides an enhanced user interface that is easy to read and run for a technician diagnosing a battery for defects. 
     With reference to  FIGS. 3 and 4 , the GUI includes a window  200 , including standard operating system controls  202  (e.g., MICROSOFT WINDOWS controls). The exemplary window  200  is divided into three main panes: a tool bar  204 , an activity pane  206 , and a diagnostic pane  208 . The tool bar  204  includes three buttons: start  210 , stop  212 , and print  214 . The start button  210  starts the extraction and analysis of the log and upgrades the firmware, if desired, on the electronic device. The stop button  212  stops and/or aborts the activities commenced or underway. The print button  214  prints the results of the diagnostic pane  208  of the software utility. Optionally, the results of the activity pane  206  may also be included on a print out. 
     Although a MICROSOFT WINDOWS operating environment is shown, the software utility may be programmed in any desirable language and run on any operating system as desired. It is contemplated that the software utility run on a technician&#39;s device, such as a PC, and the electronic device under repair be connected to the technician&#39;s device through a wired connection, such as a serial port interface, USB interface, or other connection. Proprietary communications connections may also be used. Although a wired connection is contemplated, the communications may also be wireless and even performed remotely, at least to identify a faulty battery, saving the user/customer time, expense, and loss of use of the electronic device relating to time in transit for devices not needing a battery replacement. 
     The activity pane  206  lists the actions being taken and the status of those actions as they are performed by the software utility, which is useful for the technician to see that the software utility is performing correctly (e.g., not “hanging up,” exiting prematurely, etc.). 
     The diagnostic pane  208  provides a formatted output of the analysis of the log and identifies if the battery should be replaced by the technician. A completed report is best seen in  FIG. 3 . The results are reported in a chart including a row for the battery log analysis and a column for the recommended repair action, “RepairActions” (i.e., providing an indication in the column as to whether the battery should be replaced, such as a red bar indicating the battery is bad). In addition to the formatted output of the analysis, the diagnostic pane  208  also includes the device serial number of the electronic device and the date and time the report was created. As shown, the diagnostic tool may also include additional tests, such as testing for whether a touch panel screen of the electronic is defective. 
       FIG. 4  provides an illustration of a properties window  216  (accessible under the “Tools/Settings” menu), which includes settings for memory storage location, name, and directory path for the log. Further, if an upgrade to the electronic device firmware is needed (e.g., to upgrade device parameters), file names and paths to the firmware upgrade may be provided so that the upgrade of the firmware may be performed by the software utility. As described further below, entries in the fields of the properties pane are used to identify whether an upgrade is needed and where to find those upgrade files. 
       FIGS. 5A and 5B , collectively, provide a flowchart illustrating an exemplary log extraction process (step  500 ) from an electronic device. A step  501 , the software utility ascertains whether the required properties values are set in the preferences window (as best shown at  FIG. 4 ). If not, the software prevents the user from activating the start button by graying it out at step  502 . If, however, the required properties are set, the start button is marked black and remains active in step  503 . At step  504 , the software utility waits for user input. 
     If the user selects “Help/About” (step  505 ), the software utility displays the software utility name and version, and thereafter returns to step  504  after a short delay at step  519 . At step  506 , if the user (e.g., a repair technician) selects “Close,” the software utility exits the program. 
     At step  507 , if the user selects “Tools/Settings” the software utility displays the properties windows at step  508  (which is best seen in  FIG. 4 ), and waits for user input at step  509 . The user may then: change, delete, or edit the fields of the properties window at step  510  and select “Apply” at step  511  which saves the changed fields of the properties window at step  512 , but leaves the properties window open for further review and/or editing; select “OK” at step  513 , which saves the changed fields of the properties window at step  514  and returns to step  501 ; or select “Cancel” at step  515  which closes the properties window without saving the fields and returns to step  501 . 
     If the user presses the start button, illustrated at step  516 , the software utility verifies that the required values of the properties window have been set at step  517 . If not, the software utility displays an error message at step  518  and returns to step  504  after a short delay at step  519 . If the required values are set, the software utility at step  520  prepares the electronic device by copying the settings file locally, transferring changes to the system (such as to the registry) to the electronic device, and terminating running processes on the electronic device. 
     As shown at  FIG. 5B , once the running processes have been terminated, the electronic device is rebooted at step  521 . The software utility waits for the electronic device to finish booting at step  522 . At step  523 , the serial number and manufacturing data are queried from the electronic device. At step  524 , the software utility may create directories for the log storage directory and subdirectories according to the settings in the required properties window on the technician&#39;s computer. At step  525 , the log file is copied from the electronic device. 
     At steps  526 ,  527 ,  528 ,  529 , and  530 , the software utility may also rebuild the battery log file and install the battery check program in the proper subdirectory. At step  531 , the log extraction is complete. 
       FIG. 6  provides a flowchart of the software utility analyzing the battery log file to determine if the battery should be recommended for replacement because it is experiencing intermittent failures (step  600 ). The software utility obtains the battery serial number at step  601 . At step  602 , the software utility opens the log file. The software utility then reads a line from the log file at step  603  parsing the log file (i.e., reading each line from the log file to determine if the battery is out of tolerance). Notably, the software utility parses the line to determine the battery status, the battery serial number, and the battery voltage at the time of the battery charge event was recorded (step  604 ). 
     At step  605 , the software utility determines if the battery status is a “LOW MAIN,” for example, that the voltage of the battery was determined to be low when compared to operating tolerances leading to a device shut down. If true, the software utility determines if the battery serial number in the log matches the battery serial number queried directly from the electronic device at step  606 . If false, and if the battery serial number is unknown (at step  614 ), the battery is indicated as bad at step  611 , and the parsing stops at step  613 . If true (i.e., the serial number matches at step  606 ), the software utility determines if the battery voltage is greater than or equal to a battery voltage threshold, such as 3300 millivolts (mV) (step  609 ). If true, the battery is indicated as bad at step  611  and the parsing stops at step  613 . If false (i.e., the battery voltage is less than a battery voltage threshold), the software utility checks to see if it has reached the end of the log file at step  612 . If false, the software utility returns to step  603  and reads the next line from the log file. If true, the software utility stops parsing at step  613 . 
     At step  607 , if the battery status was not “LOW MAIN” at step  605 , the software utility determines if the battery status is “SUSPEND CHARGE.” If false, the software utility checks to see if it has reached the end of the log file at step  612 . If step  607  was true, the software utility increments a “SUSPEND CHARGE” counter at step  608 . At step  610 , the software utility determines if the “SUSPEND CHARGE” counter has counted more than a specified number of events, such as ten “SUSPEND CHARGE” battery status events. If true, the battery is indicated as bad at step  611  and the parsing stops at step  613 . If false, the software utility checks to see if it has reached the end of the log file at step  612 , repeating the process until the end of the battery log file. 
     In sum, as set forth above and illustrated in  FIG. 6 , if the battery exceeds the battery voltage threshold on a “LOW MAIN” event, the battery serial number is unknown on a “LOW MAIN” event, or the number of “SUSPEND CHARGE” events exceeds ten, the battery can be flagged as bad and the technician can replace the battery. 
       FIGS. 7A and 7B , collectively, provide a flowchart illustrating the process of updating the firmware on an electronic device as shown at step  700 . At step  701 , the outdated files are deleted from the electronic device. At step  702 , the new files are copied to the electronic device from a folder previously designated in the required properties window. The copy operation progress and status will be displayed in the Activity pane  206 . 
     At step  703 , if the electronic device further includes removable memory storage (e.g., an SD Card), those files will be deleted as well. At step  704 , if the electronic device includes a custom firmware package designated in the optional properties window, the software utility will copy the custom firmware from the folder designated at step  705  and unpack it at step  706 . 
     At step  707 , if the electronic device includes a battery profile designated in the optional properties window, the software utility will copy the battery profile from the folder designated to the electronic device at step  708 . The copy operation progress and status will be displayed in the Activity pane  206 . 
     At step  709 , if an optional service pack update is designated in the optional properties window, the software utility will copy the service pack update from the folder designated at step  710 . The copy operation progress and status will be displayed in the Activity pane. 
     As illustrated in  FIG. 7B , at step  711  if a registry file is designated in the optional properties window, the software utility will copy the registry file from the folder designated at step  712 . The copy operation progress and status will be displayed in the Activity pane. At step  713 , if an Autorun file is designated in the optional properties window, the software utility will copy the Autorun file from the folder designated at step  714 . The copy operation progress and status will be displayed in the Activity pane. 
     At step  715 , if a UGP file is designated in the optional properties window (or some other firmware upgrade file type), the software utility will copy the UGP file from the folder designated at step  716 . The copy operation progress and status will be displayed in the Activity pane. At step  717 , the UGP file will be run. At step  718  the upgrade status will be displayed in the Activity pane as complete. At step  719 , the upgrade is complete. 
     In summary, it can be appreciated from the foregoing description and illustrations that the exemplary systems and methods for identifying bad batteries in an electronic device facilitate electronic device repairs. By analyzing intermittent failures and determining whether the frequency of failures exceeds certain tolerance specifications, a technician can accurately conclude whether to replace the battery, thereby minimizing missed repairs and repeat return of failing devices. 
     To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:
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     In the specification and/or figures, typical embodiments and environments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.