Current status

At the moment:

- tester  can automatically switch across 28 battery blocks (or less) , it can easily be expanded or reduced for needed number of battery blocks.

- charging current is about 30 Amps

- discharging current is about 25 Amps

- can choose several program modes - charging only, discharging only,  ch-disch-ch cycle , deep discharging, balancing and more.

Some difference from presented and actual model are - ordinary 12 car charger and 12v battery was excluded and instated is stronger charger (+100Amps/10v); added charging resistor, modified software...

Planed upgrades are - stronger logic board, with better computational capabilities and color display, exclude on PC analyse of collected data, making all analysis directly on tester with possibility to export collected data to the USB stick instead SDHC card for future processing. Additionally, after upgrading, tester will be capable to printout graphs and testing results on external printer.

New feature would be implemented after testing - RECONDITIONING of bad battery blocks!!! which will be huge improvement.

moji postovi na forumima na temu prius batery tester

moji postovi na forumima na temu prius batery tester

https://priuschat.com/

http://mhhauto.com

Testing and balancing HV batteryes in progres

This is fully automatic tester, you can chose different programs to execute, 

1.  Manual operation (charge, discharge, charge-discharge-charge, deep discharge, select only one block to operate or start from - end to... repeat ch-ds-ch cycle up to 5 times)
2.  Automatic operation
3.  Deep discharge
4.  Calibration
5.  Balancing
6.  And more

Before testing began, device read settings file from SD card and setup device, After that you can change some of values and start testing.

During testing, device keep all relevant data on SD card (battery voltage, charger voltage, charging-discharging current, no of battery, no of block, time, PWM sig for ch-dis...) couple times in second and create two files, one with all data and second with sum data (no bat, no block, and time - which is crucial for evaluate condition of each block). 

After whole battery is finished I put SD cart in my PC and analyse recorded data and sort battery blocks by quality. After couple finished batteries I have x*28 block and I chose 28 block with similar quality for one battery pack. Next step is balancing, each block are connected in parallel (all positive to one wire and all negative to second wire), the battery block stay that day or two and after that is ready to put orange connections and install in vehicle. Balancing can be done without jumper wires (as I do) using tester, but I use wires to save testers time and test another  battery pack during balancing first...

Tester is based on Arduino Mega board, which is opto isolated between  relays and their drivers, each block use its own relay (28 of them). On top of the box is resistor for discharging which can draw more of 30 Amps so charging and discharging current is monitored with current sensor and processor calculate how much to open MOSFET transistors for charging and discharging.

To operate I use ordinary 12V/20A battery charger and ordinary battery to deliver power during charging cycle. 

Under the battery is holder which is also designed to be used as air cooling in tandem with blower motor. 

That is it for now.

https://pejinasvastara.blogspot.com/2017/05/testing-and-balancing-hv-batteryes-in.html

coments

TOYOTA PRIUS BATTERY TESTER BY PEJA - PROTOTYPE

https://pejinasvastara.blogspot.com/2017/05/blog-post_17.html

Prius HV battery tester

https://pejinasvastara.blogspot.com/2017/05/blog-post_661.html

TOYOTA PRIUS BATTERY TESTER BY PEJA

https://pejinasvastara.blogspot.com/2017/05/blog-post_349.html

TOYOTA PRIUS BATTERY TESTER BY PEJA

UNDER TESTING

https://pejinasvastara.blogspot.com/2017/05/blog-post_708.html

TOYOTA PRIUS BATTERY TESTER BY PEJA - PROTOTYPING

BURNED ULN2803

TOYOTA PRIUS BATTERY TESTER - UNDER CONSTRUCTION

Toyota Prius battery tester - final testing

Finalni test je u toku, nakon bezbroj izmena hardvera i softvera kao i podesavanja. 

Zice i plocice su razbacane na sve strane. nakon ispitivanja funkcionalnosti sledi face lifting.

prvobitni post

Prius battery tester by Peja

Pre vise od godinu dana sam pustio u rad tester baterija, napravljen za testiranje baterija za Toyotu Prius. Uspesno je odradio preko 20-ak baterija od kojih svaka ima po 28 clanaka. Testiranje se odvijalo u fazama, prvo se prikaci jedan clanak, ukljuci tester koji sa SD kartice ucita seting fajl i zatim na osnovu zadatih parametara krece proces testiranja. Program je tako osmisljen da daje mogucnost operateru da promeni neke od zadatih parametara u setings fajlu, kao sto je broj ponavljanja ciklusa punjenja i praznjenja, broj baterije koja se testira kao i broj svakog pojedinacnog clanka. Nakon definisanja svih parametara krece proces, prvo se baterija dopunjava jer u startu svaka baterija je drugacije napunjena pa se tezi tome da se svaki clanak napuni podjednako da bi se testirala. Kada napon clanka dostigne setovanu vrednost punjenje se zaustavlja, pravi se pauza od 1 minuta kako bi se baterija stabilizovala a zatim krece praznjenje. Praznjenje se vrsi preko jednog mrezastog otpornika koji je u satnju da povuce i preko 30 ampera a kako je merno kolo sposobno da ocita max 30 ampera tako je iz tog razloga softverski struja praznjenja ogranicena na 25 ampera. U trenutku kada struja prekoraci 25 A smanjuje se vreme otvorenosti glavnog tranzistora tako da linearno opada i struja praznjenja. Kako opada napon clanka smanjuje se i struja praznjenja tako da nakon nekog vremena struja opadne ispod 25A i tada tranzistor ostaje otvoren 100%. Kada napon clanka opadne do setovane vrednosti praznjenje se zaustavlja i ponovo sledi stabilizanija od 1 minuta.

Nakon toga se predhodna dva procesa (punjenje i praznjenje) ponavljaju jos dva puta (najcesce je to dovoljno za test) i kada se sve zavrsi aparat ce poceti da daje zvucni signalda je zavrsio clanak. Tada je potrebno prebaciti kablove na sledeci clanak i ponoviti predhodni ciklus jos 27 puta za svaki clanak. Za svo vreme testiranja kontroler upisuje sve vrednosti napona, struje i vreme na SD katricu sa koje nakon zavrsene procedure testiranja baterije iscitavamo podatke na kompjuteru i analizom podataka utvrdjujemo kvalitet svakog clanka ponaosob

prvobitni post

Prius battery tester by Peja

U fazi razvoja i probnog rada je tester baterija za vozilo Toyota Prius.
Do sada je uspesno servisirano desetak baterija upotrebom Voltcraft-ovog BS6 battery testera, s obzirom da je testiranje na ovaj nacin predugo trajalo (oko 20 dana za jedan battery pack) pristupilo se razvoju testera koji bi testiranje sveo na  manje vremena.
trenutna verzija 2,22 je u probnom radu, za jedan clanak je potrebno oko 3-4 sata, zavisno od stanja samog clanka. Prilikom testiranja moguce je zadati parametre napona i struje na osnovu kojih ce se vrsiti testiranje, odrediti koliko puta ce se ciklus ponoviti a sve izmerene vrednosti (napon baterije, punjaca, struju punjenja, praznjenja, vreme punjenja...) upisati u log fajl na memorijskoj kartici kako bi se kasnije izvrsilo analiziranje podataka i utvrdilo stanje svakog clanka ponaosob.
Aparat puni bateriju strujom do 20 ampera, u zavisnosti od razlike zadatog i postignutog napona baterije, odredjuje koliko ce struje pustiti u bateriju. Nakon zavrsenog punjenja pravi se pauza radi stabilizacije baterije a zatim krece praznjenje batreije strujom preko 25 ampera i prazni je do zadatog napona nakon zavrsenog praznjenja se opet pravi pauza radi stabilizacije i tako se ciklus ponavlja zadati broj puta .

ovo je starii ne objavljeni post od pre vise od godinu dana.

prvobitni post