Patent Publication Number: US-2022239110-A1

Title: Battery health self-test protocol

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 63/141,531 filed Jan. 26, 2021, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present disclosure relates to battery technologies, and more specifically, to a battery health self-test protocol for transport refrigeration units (TRU). 
     Truck trailers used to transport perishable and frozen goods include a refrigerated trailer pulled behind a truck cab unit. The refrigerated trailer, which houses the perishable or frozen cargo, requires a refrigeration unit for maintaining a desired temperature environment within the interior volume of the container. The refrigeration unit must have sufficient refrigeration capacity to maintain the product stored within the trailer at the desired temperature over a wide range of ambient air temperatures and load conditions. Refrigerated trailers of this type are used to transport a wide variety of products, ranging for example from freshly picked produce to deep frozen seafood. Product may be loaded into the trailer unit directly from the field, such as freshly picked fruits and vegetables, or from a warehouse. 
     BRIEF DESCRIPTION 
     According to an embodiment, a method for performing a battery health self-test protocol is provided. The method can include detecting, using a controller, that a transport refrigeration unit (TRU) is connected to standby power; and charging the battery to a known charge level during a charge cycle. The method can also include discharging the battery during a discharge cycle by coupling the battery to a battery test resistor; and calculating battery health assessment information for the battery. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include recharging the battery to a full charge level. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include using the standby power that is provided from a power grid, and detecting the TRU is plugged into the power grid. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include recharging the battery using the standby power from a power grid. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include recharging the battery using only the standby power from the power grid while a generator of the TRU is not in operation. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include providing a prompt to connect the battery to the standby power if the standby power is not detected. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include using a known charge level that is less than a fully charged state of the battery. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include charging the battery using a generator of the TRU during the charging cycle. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include receiving the battery information including an age and capacity of the battery, wherein the battery information is used to calculate the battery health assessment information. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include outputting the battery health assessment information to a display. 
     According to another embodiment, a system for performing a battery health self-test protocol is provided. The system can include a battery coupled to a transport refrigeration unit (TRU), and a controller coupled to the battery. The controller is configured to detect the TRU is connected to standby power; and charge the battery to a known charge level during a charge cycle. The controller can be configured to discharge the battery during a discharge cycle by coupling the battery to a battery test resistor; and calculate battery health assessment information for the battery. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include a controller that is further configured to recharge the batter to a full charge level 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include using the standby power that is provided from a power grid, and detecting the TRU is plugged into the power grid. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include recharging the battery using the standby power from a power grid. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include recharging the battery using only the standby power from the power grid while a generator of the TRU is not in operation. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include a controller that is further configured to provide a prompt to connect the battery to the standby power if the standby power is not detected. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include using a known charge level that is less than a fully charged state of the battery. 
     18. In addition to one or more of the features described herein, or as an alternative, further embodiments include charging the battery using a generator of the TRU during a charging cycle. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include a controller that is configured to receive the battery information including an age and capacity of the battery, wherein the battery information is used to calculate the battery health assessment information. 
     In addition to one or more of the features described herein, or as an alternative, further embodiments include a display to output the battery health assessment information. 
     Technical effects of embodiments of the present disclosure include performing a self-test for a battery which enables the battery to be replaced on an as-needed basis instead of a prescribed schedule which may replace a battery having some remaining useful life or not replace a battery that is exhibiting premature failure. 
     The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, that the following description and drawings are intended to be illustrative and explanatory in nature and non-limiting. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike: 
         FIG. 1  depicts a schematic illustration of a transport refrigeration unit (TRU) capable of performing a battery health self-test protocol in accordance with one or more embodiments; 
         FIG. 2  depicts a flowchart of a method for performing a battery health self-test protocol in accordance with one or more embodiments; and 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG. 1 , there is shown schematically, an exemplary embodiment of a truck trailer refrigeration system  100  including an engine  110 , an electric generator  120  operatively associated with the engine  110 , a system controller  130 , a power input selector  140  and a transport refrigeration unit  10  (commonly referred to as a “TRU”). Also shown in  FIG. 1 , the engine  110  is coupled to the TRU start battery  150  (hereinafter referred to as the “battery  150 ”), and the battery charger  160  is coupled to the controller  130  and the battery  150 . The transport refrigeration unit  10  described herein may function to regulate and maintain a desired product storage temperature range within a refrigerated volume wherein a perishable or frozen product is stored during transport, such as a refrigerated box of a trailer. As shown, the transport refrigeration unit  10  may include a compressor  20 , a condenser heat exchanger unit  30  including a condenser heat exchange coil  32  and associated condenser fan  34  and fan motor  36  assembly, an evaporator heat exchanger unit  40  including an evaporator heat exchanger coil  42  and associated evaporator fan  44  and fan motor  46  assembly, and an evaporator expansion device  50 , such as an electronic expansion valve (EXV) or a thermostatic expansion valve (TXV), connected in a conventional refrigeration cycle by refrigerant lines  2 ,  4  and  6  in a refrigerant flow circuit. The condenser heat exchanger unit  30  may also include a subcooling coil  38  disposed in series refrigeration flow relationship with and downstream of the primary condenser heat exchange coil  32 . In addition, the refrigeration system can also include other components that are known to be associated with refrigeration systems such as, sensors, other expansion devices, other types of heat exchangers, valves, thermostats, receivers, filter driers, etc. 
     Now referring to  FIG. 2 , a flowchart of a method  200  for performing the battery health self-test in accordance with one or more embodiments is shown. It should be understood the method  200  can be implemented in any suitable system, such as the system  100  shown in  FIG. 1  (although other suitable systems may be used to implement the method  200  in certain instances). The method  200  begins and proceeds to block  202  to initiate the battery health self-test (referred to herein as “self-test”). In one or more embodiments, the self-test can be automatically performed according to a schedule. In different embodiments, the self-test can be performed when a manual selection is provided and input to the controller  130 . 
     At decision block  204 , the controller  130  determines whether the TRU is connected to standby power such as the power from the power grid (which may be connected using a plug  170  or other suitable connection, as shown in  FIG. 1 ). In one or more embodiments, the controller  130  can use a voltage sensor/current sensor to determine if the TRU is coupled to the standby power. The standby power can be an external power source such as a power grid (AC power). As mentioned above, the TRU may be designed to be plugged into an outlet to receive the standby power which allows the charging of the battery  150  or provide a supply of power for other operations. In the event the TRU is not connected to the standby power (“No” branch), a message can be provided on a display of an interface to plug in the TRU at  206 . The method  200  then returns to block  204  to determine if the TRU has been connected to the standby power. 
     If the TRU is connected to the standby power (“Yes” branch), the method  200  proceeds to block  208  and displays a message to retrieve the battery information. In some embodiments, the battery information can be retrieved automatically from one or more sources the controller  130  may have access to such as a battery/power system, a diagnostic system (e.g., onboard diagnostic system (ODB)), or another type of TRU-related system. In other embodiments, the battery information can be manually input by an operator (block  210 ) and provided to the controller  130  and used for battery calculations. The battery information can include but is not limited to the battery age and capacity. It should be understood that additional information can be retrieved and input into the controller  130  to perform the self-test and is not intended to be limited by that shown in  FIG. 2 . 
     The method  200  continues to block  212  and starts the self-test and proceeds to block  214  which operates the TRU to charge the battery  150  (either fully or partially). In one or more embodiments, an engine  110  that converts fuel to mechanical energy to drive a generator  120  of the TRU is used to generate power to charge the battery to a known level to perform the self-test. In some embodiments, the charge level of the battery  150  is charged to a known level that is less than a fully charged level. In other embodiments, the battery can be fully charged. The source of power for the generator  120  can include a fuel-type source such as diesel. In one or more embodiments, the engine  110  of the TRU that drives the generator  120  is not in operation during the self-test. 
     At block  216 , the controller  130  checks the voltage and charge time of the battery  150 . If the expected voltage level and charge time are not met, the TRU continues to charge the battery to the expected level. If the voltage level and charge time are met (“Yes” branch), the method  200  proceeds to block  218  which runs a battery rest interval to settle the battery. The rest interval allows the charge level of the battery to settle at a voltage level and minimize the fluctuations in voltage resulting from charging so that an accurate test can be performed. At block  220 , the controller  130  determines whether the battery has settled during the rest interval. In a non-limiting example, the battery can be determined to be settled if the voltage level is within a margin. If not (“No” branch) the method  200  returns to block  218  to run/continue the battery rest interval. 
     If the battery  150  has settled (“Yes” branch), the method  200  continues to block  222  and runs the battery drain interval (which may be referred to as the discharge cycle). During the battery drain interval a known load (i.e., a battery test resistor) is connected to the battery  150  to discharge the battery  150 . At decision block  224 , the battery drain interval is checked to see if it is completed. In one or more embodiments, the battery drain interval is completed responsive to reaching a predetermined or known discharge level. In other embodiments, the battery drain interval can be completed responsive to the expiration of a period of time. If the battery drain interval is not completed (“No” branch), the method  200  returns to block  222  to run/continue to battery drain interval (i.e., the discharge cycle). 
     Upon completion of the discharge cycle, the known load is electrically disconnected from the battery  150  to stop the discharging of the battery  150  and various battery measurements can be taken. The method  200  proceeds to block  226  to start the recharge cycle for the battery  150  and calculate the battery health assessment information. At block  228 , the battery health assessment information can be output to a display. 
     In one or more embodiments, the battery recharge cycle only uses the wall power/grid power to recharge the battery  150 . In these instances, the engine  110  and generator are not required to recharge the battery  150  immediately after performing the self-test. At decision block  230 , the controller  130  determines whether the battery  150  has been fully recharged using the standby power. If not (“No” branch), the method  200  proceeds to block  232  to continue to recharge the battery  150 . If the battery  150  is fully recharged (“Yes” branch), the method  200  proceeds to block  234 , and the method  200  ends. The method  200  can be repeated at a scheduled time or upon manual initiation by an operator. It should be understood that a different sequence of steps or additional steps can be used. 
     The techniques described herein enable testing of the battery while the system is not in operation. Conventional systems are required to remain in operation to perform a battery health test. The battery can be tested and recharged to full capacity without operator intervention using the techniques described herein. The techniques described herein allow the batteries to be replaced on an as-needed basis as opposed to a prescribed maintenance schedule where usable life remains in the battery. 
     A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. 
     The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof 
     While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.