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Executive Summary
 

In this fast pacing world of technology, the trends are changing every day. The new gadgets have arisen that changes the face of technology. iPads, Laptops, Vehicles and many computer systems also can be included in the success of modernization.
 

One thing is common in all such aggravating technological applications. Battery. All of them run on the electrical source of energy. The source which is renewable, because we cannot rely on nonrenewable fuel resources for the coming many decades. They are going extinct and humans had already used them for their good and bad.
 

The major problem with many of the batteries are their capacity. The daily life batteries that are used are generally of low capacity and do not suffice the needs of any industrial purpose. For that we require the batteries with huge and rather larger capacities. Such capacities an be utilized by making the batteries efficient in their chemical composition and optimized capacity resource by using microcontroller setups.
 

This project work is one such initiative in which the RC Battery Testing equipment is collaborated and utilized for defining the battery’s capacity and finding out its measures for reliability.
 

Keywords: Battery, Industrial battery, RC Battery test, Microcontroller
 

Chapter 1
 

Introduction
 

Most of the rechargeable batteries drain away quickly after some number of recharge cycles. There is a need for the user to know whether his/her battery has sufficient capacity to perform to the required expectation. Rechargeable battery Tester analyzes the battery capacity and let know the user the condition of the battery.
We analyze the voltage and load current attached to the battery test unit and determine the capacity (Ah) of the battery. Based on this capacity, we evaluate the condition of the battery. Some of the required properties that are needed for this process are [1]
 
• Battery voltage(volts)
• Load current(Ampere)
• Maximum capacity of battery(Ah)
• Battery internal impedance(Ohms)
• Maximum discharge current(Ampere)
 

• System may include modules like:
• System power supply
• Battery discharge unit
• Logical processor and Analyzer
• Display unit
 

Current Procedures
 

• Multi meter
 
• For a quick check, we can use multi meters which gives the voltage reading of the battery. But it cannot display the capacity of the battery.
 
• Manual process
 
By calculating the capacity of the battery manually. First we need to charge the battery and then after noting down the readings we need to discharge the battery. By some calculations we arrive at the capacity of the battery
 

• Battery Capacity Testers
 
• These are ready made products available in the market which gives the capacity of the battery in mAh. These often come with charging modules for charging batteries. These products can test the battery while it is in service.
• Limitations of current designs or technology
 
• The limitations for this system
• Confined to the daily usage batteries having low capacity, not the industrial batteries.
• Regarding the current that the battery can safely discharge and the time constraints regarding overall execution of the system.
 

Similarities and differences between your concept and existing technologies
The existing modules gives the battery parameters like voltage, current but cannot comment on whether the battery is good to use or not
Similarities
 
• Voltage indication
• Load Current indication
 
• Differences
• Discharge curve analysis
 

Chapter 3

 

Project and Concept Overview
 
Customer Needs and Analysis
 

• The whole equipment should be on a bench
• The system can have external power supply and perhaps external load
• The system can have a charged battery
• The system may use an external battery as power source
• The system should start the process at the hit of a button
• The system should determine whether the testing RC battery is “good” or “bad”
• The system gives rating for testing battery from 0-10 which describes it’s charge holding capacity
• The desirable or expected time for completion of whole process is less than or equal to a minute.
 

Functional Requirements
 
• The system will have external power supply and perhaps external load
• The system may have a charged battery
• The system may use an external battery as power source
• The system will have a logical unit like “Arduino” to process data.
• A charging unit is required to charge the “test unit”
• A controlled discharging unit (load) is required to drain battery for some time.
 

Context Diagram
 
Below presented context diagram represents the delivery aspects and receptor aspects that can be extracted from the project. The indulged activities are presented along with the different parameters that speak for the project.
 

a. Electric Grid: it defines how the power impact over the RC battery tester. The power is responsible for the operation of the battery tester and hence it is directly connected to it.
 
b. User (Tester): It shows the relation of the person using the RC battery tester. There are substantial delivery aspect and receiving aspect like providing the test unit and determining the test results respectively.
 
c. Developers: The team that regularly updates the system of RC battery testing unit is also a two-way specified relation with the unit. They provide and deliver the updates and expect the diagnostic status.
 
d. Customer: our customer who is expecting a successful project from us, Dr. Bigelow, helped in setting up the system and hence also expects positive returns with overall test results.
 
e. Maintainers: Their impact comes after the developers. The developers extract the diagnostic status and the maintainers give it as the input for the unit tester. In return they try to acquire diagnostics information.
 
f. RC Battery test unit: this setup is directly connected and is responsible for providing energy.
 
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Functional Decomposition
 
The figure explained below is of functional decomposition that represents the path a unit covers from providing energy to displaying the unit of the battery capacity at the screen. In between there are many extravagant inputs and processes that let the function reach the end result.
 
The battery gives power to the connector whose work is to measure the unit and send it to the control sequence which further deals with it. The control sequence can either discharge the specified process input from the measurement unit or it can process it further to the time control unit. After the processing of the result is done, the result is shown on the screen. The screen is specified to show the battery capacity with certain unit of power.
 

The whole function of a functional diagram is to represent the function pf the project in a block wise manner. In this the calculative approach is prohibited and only the sequential functioning of the project is done.
 

Chapter 4

 

Concept Generation
 
Sub-system Concept 1 Concept 1-2
 
Manual Process Calculation of battery capacity by discharging battery using a load whose discharge current is known Requires a load and measuring equipment
Using discharge curve analysis Analysis of discharge curves of test battery against an ideal discharge curve at given load Requires load for discharging battery and programmed logical unit for data collection
 

Chapter 5

 
Concept Selection
 

The discharge curve analysis has proven to be one of the finest method to implement in order to find the major goal for determining a specified capacity of a rechargeable battery. If we look at the question of how to specify and test a battery, this process has been serving as an epitome of calculative approach for it.
 
The major properties of batteries are
 
a. Long-life reliability
b. High capacity
c. Deep cycle
d. Heavy duty
e. Quick charge and sometimes quick discharge too
 
Apart from them there are many other industrial parameters that define what these legal standards are. When we talk about the advertising, the seller can add any word they can to sell the product in the market, but it’s the inner properties and reliability of the battery that matters the most.
 

Discharge curves
 

Energy cells or power batteries as they are called have been developed for a quite a diversified range of applications. The technologies that have been used to define their reliability and capacity are trending and changing with time. When we look back, there were many types of Lithium-Ion batteries which changed their course to solar batteries too.
 
The graph shown below is a relationship in between percentage of capacity discharge and cell voltage. It is not relevant to the project work, but just an example for the question as why the
concept was generated and selected. The selected concept is supposed to have the following effects over the desired work:
 

i. The battery tester will control the variating rate of undesirable chemical reactions that determines the leakage of current among the positive and negative electrode.
ii. The internal impedance will also be checked and t eh current carrying capability of it will be determined.
iii. The cell chemistry is also to be maintained. Like for example, in many batteries there is a proportion of chemicals (zinc carbon for 2-3 years or alkaline for 5-6 years etc.)
 

Chapter 6

 

System Architecture
 
The system architecture of a RC battery tester comprises all the housing elements of it. The family of different members that contribute their fair share of elemental function to reach the on defined goal. The goal for a user to determine the capacity of a defined rechargeable battery.
In the give diagram below, there are different housing elements that comprise the gist of system architecture.
 

1. Input system architecture
 
a. Power supply port: It is the basic elements that enables the power or current to move from one area to the other. They are basically connected by wires and define their system by the placement of cathode and anode or negative and positive end of the electrode or the power transmission unit.
 
b. RC Battery test unit: technicians a dealing with batteries are comfortable when it comes to use the battery and check them with voltmeter. Generally, voltmeter is used as the RC battery test unit. But the changing chemistry of the batteries are not understood by many these days so there is a conundrum of what to look into and how to look into the battery. RC Battery test units,

also perform life-cycle testing of battery to stimulate the loads on the battery along with the checking of exasperating battery durability. The identification of cell balance of a multi cell pack is also the major specification, a RC battery test unit specifies.
 

2. Process housing system architecture
 
a. Charging unit: this unit takes the charge from the input system architecture. Whatever process the RC battery test unit comprises, the Processing unit carries it forward for the accumulated goal.
b. Logical unit: it can be a microcontroller that specifies its work and makes the functioning rather easier. A load resistance to fully charge battery can determine the exact battery specification by monitoring its voltage until it comes down completely. But by applying a logical unit this work can be done in a rather more non-tedious manner. The capacity in milliamp hours can certainly be determined.
c. Controlled discharging unit: the load resistors are used for discharging the batteries when certainly the FET is turned on. The testing of NiCd and NiMh batteries have been successful in the past by load resistors. The power dissipation has ben observed to be under the capacity of 1 watt.
 

3. Output Indication Unit
 
a. A display digital monitor or screen: not much large. Just a small like the one attached in voltmeters. It would specify the readings collected from the previously done phases and give the exact reliability of the rechargeable battery, that is the charge remaining before it needs to be recharged again.
 

Chapter 7

 

Detailed Design Analysis
 
The RC battery tester is supposed to test different types of test simultaneously and display the results on a specified screen of LCD or LED. The voltage of the battery is monitored while the tester works through the process of discharging the battery. The lowest threshold indicates the finishing of work and hence the load is disconnected from the battery.

 

A microcontroller of ATMega 168 specification can be used for this purpose. It consists of 6 analogs to digital converters on the chip. The major purpose the solve is to read the battery voltage along with finding the load current. Each battery generally needs 2 analogs to digital converters per cell, the maximum number of cells that can be considered here cannot go beyond the unit of 3.
 
An Arduino board is also set up and used for the purpose of getting the load resistors in line.
The discharging circuit’s function is quite easy to understand. Each battery will have a respective load resistor attached to it. The purpose of it is to discharge the battery when the FET is turned on. The microcontroller is something that helps in managing the switching part. The battery’s voltage is monitored by the analog to digital converter. The current flows through the resistor and a different analog to digital converter is attached the FET which identifies the current specified earlier. Some of the following calculations can be done by depicting them into formula.
 

Current = Battery Voltage – FET Voltage
Discharging current = (Battery Voltage – FET Voltage)/ Resistance
Milliamp hour value = (Battery Voltage – FET Voltage)/ Resistance * time
 

Chapter 8

 

Other Considerations
 

It is not just the technical factors that specifies the successful design and working of the RC Battery charger. There are many other factors involved that specify the earlier and majorly come under the category of non-technical factors. Some of the relevant ones that affect and impact the RC Battery tester in many ways are
 
1. Cost factor: In market there are many Battery Testers that are available for rather low cost. The material that they use in them can be light and non-reliable but the public looking to buy cheap ones are more in number. But we should not do that. Maintenance of quality is the top most priority. Plus, apart from that the security and user interface of the mechanism should be friendly.
 

2. Market competition: Different battery testing equipment manufacturing agencies have collaborated themselves over a due course of time and know their market very well. This was an initiative to give them a little bit of competition and extract the same information from various resources to enable them into this work.
 
3. Portability: This is also one major concerned effective issue. The battery charger and capacity enhancer and corrector should be portable to carry. It should not be heavy enough to be kept on one corner. The Nano world has defined many elements that certainly help things to reduce their sizes without reducing their effect and quality along with capacity.
 
Apart from the defined status of students taking their task in an evident manner, there are certain issues that came up during the research. Some issues and their solutions are
 
a. The unavailability of most research papers over the provided topic. The major internet links were also not authentic. For this solution, some of the research study was done from the library and effective books. In fact, the insight by the project guide from many angles has also been very generous for the study.
 
b. The complexity of an Arduino controller was also an issue of major concern. With the help of studies done with micro-controller, the operation and effective settlement of the unit in the compiled equipment was determined.
 

Chapter 9

 

Design Confidence Assessment

The team is rather feeling positive regarding their efforts over the excellent work done with the esteemed guidance of the professors. The team is rather also confident about the project to serve excellently in the aid of RC battery testing works. All the works are done with utter diligence and authentication. Each word in this material has been hand typed and no such plagiarism or copy paste is followed under any circumstance. We are quite confident about the design as it had shown sufficient detailed analysis while the period of testing. The beta phase, we can say it.
 

 
Product code: physiscs-QA463
 
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