Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02507543 2012-07-19
HANDHELD TESTER FOR STARTING/CHARGING SYSTEMS
TECHNICAL FIELD
[0002] The present invention relates generally to the field of electronic
testing devices,
and more specifically to a handheld device used to test the starting/charging
system of an internal
combustion engine in a vehicle, including testing storage batteries.
BACKGROUND
[0003] Internal combustion engines typically include a starting/charging
system that
typically includes a starter motor, a starter solenoid and/or relay, an
alternator having a regulator
(or other charger), a battery, and associated wiring and connections. It is
desirable to perform
diagnostic tests on various elements of starting/charging systems to determine
whether they are
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CA 0 25 0 75 4 3 2 0 0 5 - 0 5 -17
functioning acceptably. It is typical during many such tests, e.g., starter
tests, cranking tests,
various regulator tests, etc., to adjust the operation of the vehicle while
sitting in the driver's seat
e.g., starting the engine, turning lights and other loads on and off, revving
the engine to a specific
number of revolutions per minute, etc. Thus, it is desirable, if not
necessary, to have one person
sitting in the driver's seat during many starter/charger tests to perform the
tests. For other tests,
e.g., battery tests, the user need not necessarily be in the driver's seat.
0 0 04] Testers used to test the starting/charging system of an internal
combustion engine
are known. For example, the KAL EQUIP 2882 Digital Analyzer and KAL EQUIP 2888
Amp
Probe could be used together to perform a cranking system test, a charging
system test, an
alternator condition test, and an alternator output test. The KAL EQUIP 2882
Digital Analyzer
is a handheld tester. Other known testers capable of testing a
starting/charging system include
the BEAR B.E.S.T. tester and the SUN VAT 40 tester, both of which allowed a
user to test the
starter, alternator, etc. Other testers capable of testing a starting/charging
system exist. The
aforementioned BEAR B.E.S.T. and the SUN VAT 40 testers are not handheld
testers; they are
typically stored and used on a cart that can be rolled around by a user.
[ 0 0 0 5] Additionally, some other handheld testers capable of testing a
starting/charging
system are known. These devices typically have limited user input capability
(e.g., a few
buttons) and limited display capability (e.g., a two-line, 16 character
display) commensurate with
their relatively low cost with respect to larger units. The known handheld
starting/charging
system testers have several drawbacks. For example, the user interface on such
devices is
cumbersome. Additionally, some handheld starting/charging system testers have
been sold with
either a shorter (e.g., three feet) cable or a longer (e.g., fifteen feet)
cable. With the shorter cable,
two people would typically perform the tests of the starting/charging system,
with one person
under the hood with the tester and one person sitting in the driver's seat to
adjust the operation of
the vehicle. The longer cable would permit a single user to sit in the
driver's seat to perform the
tests and adjust the operation of the vehicle, but the user would need to wind
up the fifteen feet
of cable for storage. Lugging around the wound coils of the long cable becomes
especially
inconvenient when the user wants to use the tester for a quick battery check,
because the wound
coils of cable can be larger than the test unit itself. Additionally, the user
interface in such units
is typically very cumbersome.
SUMMARY
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CA 02507543 2010-07-14
[0(3063
An improved hand-held portable tester is provided. According to one aspect
of
the present invention, the handheld portable tester comprises a connector to
which various cables
can be removably connected to the tester. According to another aspect of the
present invention,
the portable handheld tester comprises an improved user interface that permits
a user to review
test data from previously performed tests and further permits a user to either
skip a previously
perfonhed test (thereby retaining the previously collected data for that test)
Or re-do the test
(thereby collecting new data for that test). According to yet another aspect
of the present
invention, the portable handheld tester performs a more complete set of tests
of the
starting/charging system. For example, the handheld portable tester preferably
performs a starter
test, three charging tests, and a diode ripple test. According to still
another aspect of the present
invention, the portable handheld tester performs an improved starter test.
More specifically to an
implementation of the starter test, the portable handheld tester performs a
starter test in which the
associated ignition has not been disabled, where a hardware trigger is used to
detect a cranking
state and then samples of cranking voltage are taken until either a
predetermined number of
samples have been collected or the tester determines that the engine has
started.
(0007]
One embodiment of the hand-held portable tester also comprises a system and
method for testing a charging system of a vehicle. The system and method
obtain measurements
during a plurality of conditions, for example different vehicle loads with the
engine speed at a
substantially constant RPM. The system and method provide a separate output
for each of the
different conditions.
[00081
Another embodiment of the hand-held portable tester comprises a system and
method of testing a plurality of types of batteries. The tester performs a
plurality of battery tests
for multiple types of batteries on a battery, without knowing the type of the
battery being tested,
and calculates and outputs results for multiple types of batteries. In
addition, one embodiment
comprises a system and method is also provided for encrypting (e.g., encoding
and/or
enciphering) test information and raw test data obtained by the hand-held
portable tester.
According to another exemplary embodiment, an exemplary method and system for
decrypting
(e.g., decoding and/or deciphering) test information and raw test data that
has been encrypted by
a hand-held portable tester is also provided that re-calculates the test
result and measured CCA
that may be substantially the same as the calculated test result and measured
CCA previously
calculated by the hand-held portable tester.
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CA 02507543 2010-07-14
Thus, the present invention provides, in one aspect, a hand-held, portable
tester for testing a starter/charger system of an internal combustion engine,
comprising a processor in circuit communication with an electronic test
circuit and a
display, said test circuit being capable of performing at least one test on
the
starting/charging system and said processor is programmed to execute code
implementing a user menu providing a user with at least the following
selectable
test options:
(a) a battery test option, which if selected causes the tester to:
i. perform a plurality of battery tests on a starter/charger system battery
connected to the tester, the plurality of tests including at least one test
for a first
type of battery and at least one test for a second type of battery; and
ii. display a plurality of different battery test results for the battery,
including
displaying at least one test result for the first type of battery and at least
one test
result for the second type of battery;
(b) a starter test option, which if selected causes the tester to prompt the
user to start the internal combustion engine and further causes the tester to
measure and display an output relating to a voltage across the battery while
the
internal combustion engine is started; and
(c) a charger test option, which if selected causes the tester to perform a
plurality of tests on a charging circuit of the starter/charger system by:
i. prompting the user to put the vehicle in a Fast-Idle, No-Load state and
then
measuring and displaying an output relating to a voltage across the battery in
the
Fast-Idle, No Load state;
ii. prompting the user to put the vehicle in a Fast-Idle, High-Load state and
then measuring and displaying an output relating to a voltage across the
battery in
the Fast-Idle, High Load state; and
iii. prompting the user to put the vehicle in a Fast-Idle state and then
performing and displaying an output relating to a ripple test across the
battery in the
Fast-Idle state.
3a
CA 02507543 2005-05-17
=
BRIEF DESCRIPTION OF THE DRAWINGS
[0009]
In the accompanying drawings, which are incorporated in and constitute a
part of
this specification, embodiments of the invention are illustrated, which,
together with a general
description of the invention given above, and the detailed description given
below, serve to
example the principles of this invention, wherein:
[00101
Figure lA is an isometric view of an embodiment of the startinglicharging
system
tester according to the present invention;
(00111
Figure 1B is a high-level block diagram showing an embodiment of the
starting/charging system tester according to the present invention;
[00121
Figure 2 is a medium-level block diagram showing a detection circuit and a
test
circuit of an embodiment of the starting/charging system tester according to
the present
invention;
[0013]
Figure 3A is a schematic block diagram showing more detail about one
implementation of a detection circuit according to the present invention;
[0014]
Figures 3B-3F are schematic diagrams showing equivalent circuits of a
portion of
the detection circuit of Figure 3A showing the detection circuit of figure 3A
in various use
configurations;
[0015]
Figure 4A is a schematic block diagram showing more detail about one
implementation of a voltmeter test circuit of the starting/charging system
tester according to the
present invention;
[0016]
Figure 4B is a schematic block diagram showing more detail about one
implementation of a diode ripple test circuit of the starting/charging system
tester according to
the present invention;
[00171
Figure 4C is a schematic diagram illustrating a test current generator
circuit of the
battery tester component of the present invention;
[0018]
Figure 4D is a schematic diagram illustrating the an AC voltage
amplifier/converter circuit of the battery tester component of the present
invention;
[0019]
Figure 5A shows a plan view of one implementation of a clamp cable for the
starting/charging system tester according to the present invention;
[0020]
Figure 5B shows a schematic diagram of connections within the clamp cable of
Figure 5A;
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CA 02507543 2005-05-17
[0021]
Figure 5C shows a rear view of the inside of the housing of the clamp cable of
Figure 5A;
[0022]
Figure 6A shows a plan view of one implementation of an extender cable for the
starting/charging system tester according to the present invention;
[0023]
Figure 6B shows a schematic diagram of connections within the extender cable
of
Figure 6A;
[0024]
Figure 7A shows a plan view of one implementation of a probe cable for the
starting/charging system tester according to the present invention;
[0025]
Figure 7B shows a schematic diagram of connections within the probe cable of
Figure 7A;
[0020
Figure 7C shows a rear view of the inside of the housing of the probe cable of
Figure 7A;
[0027]
Figure 8 is a block diagram of a sensor cable, e.g., a current probe, for the
starting/charging system tester according to the present invention;
[0028]
Figure 9 is a high-level flow chart showing some of the operation of the
embodiment of the starting/charging system tester of the present invention;
[0029]
Figure 10 is a medium-level flow chart/state diagram showing the operation of
the
test routine of the embodiment of the starting/charging system tester of the
present invention;
[0030]
Figures 11A-11D are a low-level flow chart/state diagram showing the operation
of the test routine of the embodiment of the starting/charging system tester
of the present
invention;
100311
Figure 12 is a low-level flow chart showing the operation of the starter test
routine
of an embodiment of the starting/charging system tester of the present
invention; and
[0032]
Figure 13 shows a plurality of representations of screen displays
exemplifying an
embodiment of a user interface according to the present invention.
[0033]
Figure 14 illustrates an exemplary methodology for a
battery/starting/charging
system tester for use with a hand-held portable tester.
[0034]
Figures 15A and 15B illustrate exemplary displays for a hand-held portable
testing device for testing multiple types of batteries.
[0035]
Figure 15C illustrates an exemplary methodology for testing multiple types of
batteries for use with a hand-held portable tester.
CA 02507543 2005-05-17
[0036]
Figure 16 illustrates an exemplary methodology for providing encrypted test
information and raw test data used to calculate test results by the hand-held
portable tester.
[0037]
Figure 17 illustrates an exemplary methodology for receiving the encrypted
data
provided to the user in Figure 16 and providing decrypted test information and
raw test data and
providing calculated test results that are likely to be substantially similar
to the test results
previously calculated by the hand-held portable tester.
[0038]
Figure 18 illustrates an exemplary methodology for a
battery/starting/charging
system tester for use with a hand-held portable tester.
[00391
Figure 19 illustrates an exemplary methodology for a charging system test for
use
with a hand-held portable tester.
(0040]
Figure 20 illustrates an exemplary methodology for a starting system test for
use
with a hand-held portable tester.
DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0041]
Referring to Figures lA and 1B, there is shown a handheld, portable tester 10
according to the present invention for testing a starting/charging system 11.
The tester 10
comprises a handheld, portable enclosure 12 housing an electronic circuit 14
that, among other
things, tests the starting/charging system 11. One or more user inputs 16,
shown in Figure 1A as
four momentary, switches implemented as pushbuttons 18-21, allow a user to
interface with the
tester 10. A display 24, shown in Figure IA as a liquid crystal display (LCD)
26 having four
lines of twenty characters each, allows the tester 10 to display information
to the user.
[0042]
The tester 10 is placed in circuit communication with the starting/charging
system
11 via a cable 28. "Circuit communication" as used herein indicates a
communicative
relationship between devices. Direct electrical, electromagnetic, and optical
connections and
indirect electrical, electromagnetic, and optical connections are examples of
circuit
communication. Two devices are in circuit communication if a signal from one
is received by
the other, regardless of whether the signal is modified by some other device.
For example, two
devices separated by one or more of the following¨amplifiers, filters,
transformers,
optoisolators, digital or analog buffers, analog integrators, other electronic
circuitry, fiber optic
transceivers, or even satellites¨are in circuit communication if a signal from
one is
communicated to the other, even though the signal is modified by the
intermediate device(s). As
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CA 0 25 0 7 5 4 3 2 0 0 5 - 0 5 -17
another example, an electromagnetic sensor is in circuit communication with a
signal if it
receives electromagnetic radiation from the signal. As a final example, two
devices not directly
connected to each other, but both capable of interfacing with a third device,
e.g., a CPU, are in
circuit communication. Also, as used herein, voltages and values representing
digitized voltages
are considered to be equivalent for the purposes of this application and thus
the term "voltage" as
used herein refers to either a signal, or a value in a processor representing
a signal, or a value in a
processor determined from a value representing a signal. Additionally, the
relationships between
measured values and threshold values are not considered to be necessarily
precise in the
particular technology to which this disclosure relates. As an illustration,
whether a measured
voltage is "greater than" or "greater than or equal to" a particular threshold
voltage is generally
considered to be distinction without a difference in this area with respect to
implementation of
the tests herein. Accordingly, the relationship "greater than" as used herein
shall encompass
both "greater than" in the traditional sense and "greater than or equal to."
Similarly, the
relationship "less than" as used herein shall encompass both "less than" in
the traditional sense
and "less than or equal to." Thus, with A being a lower value than B, the
phrase "between A and
B" as used herein shall mean a range of values (i) greater than A (in the
traditional sense) and
less than B (in the traditional sense), (ii) greater than or equal to A and
less than B (in the
traditional sense), (iii) greater than A (in the traditional sense) and less
than or equal to B, and
(iv) greater than or equal to A and less than or equal to B. To avoid any
potential confusion, the
traditional use of these terms "greater than and "less than," to the extent
that they are used at all
*thereafter herein, shall be referred to by "greater than and only greater
than" and "less than and
=
only less than," respectively.
[ 0043]
With respect to several advantages of the present invention, the tester 10
includes
a connector Jl to which test cable 28 is removably connected. Having the test
cable 28 be
removably connected to the tester 10 among other things (i) permits different
test cables (cables
of Figures 5A, 7A, and 8) to be used with a single tester thereby allowing a
wider range of
functions to be performed with the tester 10, (ii) permits an optional
extender cable (cable of
Figures 6A and 6B) to be used, thereby allowing the tester 10 to be used by
one person sitting in
a driver's seat for some tests, but allowing a shorter cable (Figure 5A) to be
used for others, and
(iii) allows the tester 10 to be stored separately from the cable.
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CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 -1 7
(0044] Referring more specifically to Figure 1B, the tester 10 of the
present invention
preferably includes an electronic test circuit 14 that tests the
starting/charging system 11, which
test circuit 14 preferably includes a discrete test circuit 40 in circuit
communication with an
associated processor circuit 42. In the alternative, the test circuit 14 can
consist of discrete test
circuit 40 without an associated processor circuit. In either event,
preferably, the tester 10 of the
present invention also includes a detection circuit 44 in circuit
communicatiOn with the test
circuit 49 and/or the processor circuit 42. The test circuit 40 preferably
accepts at least one test
signal 46 from the starting/charging system 11 via the cable 28 and connector
J1. The detection
circuit 44 preferably accepts at least one detection signal 48 from the tester
cable 28 or other
device (e.g., sensor cable of Figure 8) placed in circuit communication with
the tester 10 via
connector J1. Tester 10 also preferably includes a power circuit 60 allowing
the tester 10 to be
powered by either the starting/charging system 11 via power connection 61 or
by an internal
battery 62.
(0045] The processor circuit 42, also referred to herein as just
processor 42, may be one
of virtually any number of processor systems and/or stand-alone processors,
such as
microprocessors, microcontrollers, and digital signal processors, and has
associated therewith,
either internally therein or externally in circuit communication therewith,
associated RAM,
ROM, EPROM, clocks, decoders, memory controllers, and/or interrupt
controllers, etc. (all not
shown) known tp those in the art to be needed to implement a processor
circuit. One suitable
processor is the SAB-0501G-L24N microcontroller, which is manufactured by
Siemens and
available from various sources. Another suitable processor is the P80C32
microcontroller, which
is manufactured by Philips. The processor 42 is also preferably in circuit
Communication with
various bus interface circuits (BICs) via its local bus 64, e.g., a printer
interface 66, which is
preferably an infrared interface, such as the known Hewlett Packard (HP)
infrared printer
protocol used by many standalone printers, such as model number 82240B from
HP, and which
communicates via infrared LED 67. The user input 16, e.g., switches 18-21,
preferably
interfaces to the tester 10 via processor 42. Likewise, the display 24
preferably is interfaced to
the tester 10 via processor 42, with the processor 42 generating the
information to be displayed
on the display 24. In addition thereto, or in the alternative, the tester 10
may have a second
display 68 (e.g., one or more discrete lamps or light emitting diodes or
relays for actuation of
remote communication devices) in circuit communication with the test circuit
40.
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CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
= (0046] Referring now to Figure 2, a more detailed block diagram
showing an
implementation of the test circuit 40 and detection circuit 44 is shown. In
the particular
implementation of Figure 2, the test circuit 40 and detection circuit 44 are
implemented using a
digital-to-analog converter (DAC) 80 that is in circuit communication with
processor 42 via bus
81 and in circuit communication with a number of comparators 82 via reference
voltage outputs
83, which comparators 82 in turn are in circuit communication with the
processor 42 via test
signals 85. Although the test circuit 40 and detection circuit 44 need not be
so implemented,
having at least a portion of the test circuit 40 be implemented using a DAC 80
and a comparator
82 in circuit communication with the processor 42 provides certain benefits,
as explained below.
[0 0 4 7]
The detection circuit 44 preferably includes a detection front end 84
and a
comparator 82a. The detection front end 84 preferably accepts as an input the
detection signal
48 and generates an output 86 to the comparator 82a. Referring to Figure 3A, a
circuit
implementation of the detection circuit 44 is shown schematically. The
preferred
implementation of the detection front end 84 is shown as circuitry 90 to the
left of node 92. The
circuitry shown includes a connection 31-6, J1-7, J1-8 to the battery of the
starting/charging
system 11, a PTC F2 (positive temperature coefficient device that acts as a
sort of automatically
resetting fuse), a diode D7, a voltage divider created by resistors R14 and
R15, and a connection
to detection signal 48 at J1-4 via resistor R29. The component values are
preferably
substantially as shown. Processor 42, via bus 81, causes DAC 80 to generate a
particular voltage
on reference voltage line 83a, which is input to comparator 82a. The detection
front end 90
generates a particular detection voltage at node 92, depending on what signals
are presented at
power signal 61 and detection signal 48. The comparator 82a will output a
logical ONE or a
logical ZERO to processor 42 depending on the relative values of the reference
voltage 83a and
the detection voltage at node 92. Thus, to detect which cable 28 or device is
attached to
connector J1, the processor 42 need only send a command to DAC 80 via bus 81,
wait a period
of time for the various voltages to stabilize, and read a binary input from
input 85a.
(0048]
Various connection scenarios for detection front end circuitry 90 are
shown in
Figures 3B-3F, which correspond to various test cables 28 and other signals
connected to
connector J1. In each, the voltage at node 92 is determined using
straightforward, known resistor
equations, e.g., resistor voltage divider equations, equivalent resistances
for resistors in series,
and equivalent resistance for resistors in parallel, etc. In Figure 3B, the
power signal 61 is
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CA 0250 754 3 2 0 05- 05-17
connected to the battery, which presents a battery voltage VBArr, and the
detection signal 48
(shown in Figure 3A) is left as an open circuit; therefore, the test voltage
at node 92 is
approximately 0.1=VBATT, because the battery voltage VBArr is divided by
resistors R14 (90.9 KO)
and R15 (10.0 Ks). In Figure 3C, the power signal 61 is connected to the
battery, which
presents a battery voltage VgArb and the detection signal 48 is grounded to
the battery ground;
therefore, the test voltage at node 92 is approximately 0.05=VBATr, because in
tliis scenario the
battery voltage is divided by R14 (90.9 Kil) and the combination of R15 (10.0
K() and R29
(10.0 Kri) in parallel (5.0 KO combined resistance). In Figure 3D, the power
signal 61 (shown
in Figure 3A) is left as an open circuit, and the detection signal 48 is
connected to an. applied
voltage VA; therefore, the test voltage at node 92 is YNA, because the applied
voltage VA is
divided equally by resistors R29 (10.0 KC) and R15 (10.0 KO ). In Figure 3E,
the power signal
61 is connected to the battery, which presents a battery voltage VBArr, and
the detection signal 48
is grounded to the battery ground via an additional resistor R29'; therefore,
the test voltage at
node 92 is the following function of VgAm
Re q
V92 = =V
BATT
Re q
where
1
Re q =
1 1
R15 R29+ R29'
because in this scenario the battery voltage is divided by R14 and the
combination of R15 in
parallel with R29 and R29' in series, which is about 0.07=VBArr if R29' is
10.0 K.Q. Finally, in
Figure 3F, the power signal 61 (shown in Figure 3A) is open circuit and the
detection signal 48
(shown in Figure 3A) is open circuit; therefore, the voltage at node 92 is
pulled to ground by
resistor R15. In all these scenarios, power ground 94 is preferably connected
to signal ground 96
either at the negative battery terminal or within test cable 28. The processor
42, DAC 80., and
comparator 82a preferably use the known successive approximation method to
measure the
voltage generated by the detection circuit front end 84.
[0 0 4 91 Thus, in the general context of Figures 1A, 1B, 2, and 3A-3F, a
specific test cable
28 connected to connector 31 will cause the voltage 86 (i.e., the voltage at
node 92) to be a
specific voltage, which is measured using the successive approximation method.
The processor
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 -1 7
42 then preferably determines from that voltage 86 which cable 28 is connected
to the tester at
connector J1 and executes appropriate code corresponding to the particular
cable 28 connected to
the connector Jl. Various specific connectors 28 are described below in
connection with Figures
5A-5C, 6A-6B, 7A-7C, and 8.
[0 0 5 Ol Referring back to Figure 2, the test circuit 40 preferably
includes a voltmeter
circuit 100 and a diode ripple circuit 102. The voltmeter circuit 100 is
preferably implemented
using a DAC 80 and comparator 82b, to facilitate testing the starting portion
of the
starting/charging system 11. In a preferred embodiment, the voltmeter circuit
100 comprises an
autozero circuit 104 in circuit communication with a signal conditioning
circuit 106. The
autozero circuit 104 preferably accepts as an input the test signal 46. The
signal conditioning
circuit 106 generates a test voltage 107 that is compared to a reference
voltage 83b by
comparator 82b, which generates test output 85b. Similarly, the diode ripple
circuit 102 is
preferably implemented using a DAC 80 and comparator 82c. In a preferred
embodiment, the
diode ripple circuit 102 comprises a bandpass filter 108 in circuit
communication with a signal
conditioning circuit 110, which in turn is in circuit communication with a
peak detect circuit 112.
The diode ripple circuit 102 accepts as an input the test signal 46. The peak
detect circuit 112
generates a test voltage 114 that is compared to a reference voltage 83c by
comparator 82c,
which generates test output 85c.
[0051] Referring now to Figure 4A, a schematic block diagram of a
preferred
embodiment of the voltmeter circuit 100 is shown. The signal conditioning
circuit 106
preferably comprises a protective Zener diode Z4 and amplifier circuit 115.
Amplifier circuit
115 preferably comprises an operational amplifier U8-A and associated
components resistor
R16, resistor R20, capacitor C21, capacitor C45, and diode D12, connected in
circuit
communication as shown. Amplifier circuit 115 generates test signal 107 as an
input to
. comparator 82b. The processor 42, DAC 80, amplifier circuit 115, and
comparator 82b
preferably use the known successive approximation method to measure the
voltage input to the
amplifier 115, which is either the signal 46 or a ground signal generated by
the autozero circuit
104 responsive to the processor 42 activating transistor Ql. After using the
successive
approximation method, the processor 42 has determined a value corresponding to
and preferably
representing the voltage at 46. The autozero circuit 104 preferably comprises
a transistor Q1 in
circuit communication with processor 42 via an autozero control signal 116.
Ordinarily, the
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CA 0250 754 3 2 0 05- 05-17
signal 46 from cable 28 passes through resistor R26 to amplifier 115. However,
responsive to
the processor 42 asserting a logical HIGH voltage (appmximately 5 'VDC) onto
the autozero
control signal 116, transistor Q1 conducts, causing the signal 46 to be pulled
to signal ground 96
through resistor R26. As known to those in the art, the voltage measured at
signal 107 while the
autozero control signal 116 is asserted is used as an offset for voltage
measurements taken with
voltmeter 100 and is used to offset the value corresponding to and preferably
representing the
voltage at 46.
[O 0 5 2] Having the voltmeter 100 be implemented in this manner, i.e.,
with a processor, a
DAC, and a comparator, provides several benefits. One benefit is reduced cost
associated with
not having to have a discrete analog-to-digital converter in the circuit.
Another benefit is
demonstrated during the test of the starting portion of the starting/charging
system 11. In that
test, the test circuit 40 waits for the battery voltage to drop to a
predetermined threshold value,
which indicates that a user has turned the key to start the starter motor. The
voltage drops very
rapidly because the starter motor presents almost a short circuit to the
battery before it begins to
rotate. The particular implementation of Figure 4A facilitates the process of
detecting the
voltage drop by permitting the processor 42 to set the threshold voltage in
the DAC 80 once and
then continuously read the input port associated with input 85b from
comparator 82b. As the
battery voltage drops to the threshold voltage set in DAC 80, the output
comparator almost
instantaneously changes, indicating to processor 42 that the voltage drop has
occurred.
[ 0 0 5 3] Referring now to Figure 4B, a schematic block diagram of the
diode ripple circuit
102 is shown. As discussed above, in a preferred embodiment, the diode ripple
circuit 102
comprises a bandpass filter 108 in circuit communication with a signal
conditioning circuit 110,
which in turn is in circuit communication with a peak detect circuit 112. The
bandpass filter 108
preferably compriies operational amplifier U14-A and associated components--
resistor R46,
resistor R47, resistor R48, capacitor C40, capacitor C41, and Zener diode Z1--
connected as
shown. Zener diode Z1 provides a pseudo-ground for the AC signal component of
signal 46.
The bandpass filter 108 has a gain of approximately 4.5 and has bandpass
frequency cutoff
values at approximately 450 Hz and 850 Hz. Signal 109 from bandpass filter 108
is then
conditioned using signal conditioner 110. Signal conditioner 110 preferably
comprises an
amplifier U14-B and a transistor Q10 and associated components--resistor R11,
resistor R47,
resistor R49, resistor R50, and Zener diode Z1--connected as shown. Signal
conditioner circuit
12
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
110 generates a DC signal 111 corresponding to the amplitude of the AC signal
component of
signal 46. The resulting signal 111 is then input to peak detector 112,
preferably comprising
diode D9, resistor R51, and capacitor C42, connected as shown, to generate
signal 114. The
signal 114 from the peak detect circuit 112 is measured by the processor 42,
DAC 80, and
comparator 82c using the successive approximation method. This value is
compared to a
threshold value, preferably by processor 42, to determine if excessive diode
ripple is present. An
appropriate display is generated by the processor 42. In the alternative, the
signal 85c can be
input to a discrete display to indicate the presence or absence of excessive
diode ripple.
[0 0 5 4] Referring once again to Figure 2, test circuit 40 further has a
battery tester
component 117. The battery tester component 117 includes a test current
generator circuit 118
and an AC voltage amplifier/converter circuit 119. The battery tester
component 117 is
preferably implemented using DAC 80 and a comparator 82d, to facilitate the
testing of a
battery. The test current generator circuit 118 preferably applies a load
current to the battery
under test. The AC voltage amplifier/converter circuit 119 measures the
voltage generated by
the load current applied to the battery. The measuring preferably includes
amplifying the voltage
and converting it to a ground referenced DC voltage.
[0 0 5 5] In this regard, reference is now made to Figure 4C where the
preferred
embodiment of test current generator circuit 118 is illustrated. The circuit
118 includes resistors
R21, R22, R27, R28, R36, R37, R40, and R42, capacitors C24, C28, C29, and C33,
operational
amplifiers U10-A and U10-B, and transistors Q6, Q8, and Q9, all interconnected
as shown. In
operation, processor 42 and DAC 80 together produce a variable voltage pulse
signal that is
output on node 122. A filter is formed by resistors R28, R27, R36, capacitors
C24 and C28 and
amplifier U10-B, which converts the signal on node 122 to a sine wave signal.
The sine wave
signal is applied to a current circuit formed by amplifier U10-A, R22, C29,
Q6, Q8, and R40
arranged in a current sink configuration. More specifically, the sine wave
signal is applied to the
"+" terminal of amplifier Q10-A. The sine wave output of amplifier of Q10-A
drives the base
terminal of Q6 which, in turn, drives the base terminal of Q8 to generate or
sink a sine wave test
current. This causes the sine wave test current to be applied to the battery
under test through
terminal 61 (+ POWER). It should also be noted that an enable/disable output
121 from
processor 42 is provided as in input through resistor R36 to amplifier U10-B.
The enable/disable
output 121 disables the test current generator circuit 118 at start-up until
DAC 80 has been
13
CA 02507543 2005-05-17
,
initialized. Also, a surge suppressor F2 and diode D7 are provided to protect
the circuitry from
excessive voltages and currents. Preferably, F2 is a power thermal cutoff
(PTC) for excessive
over current protection, such as, for example a short, such as a failure of
Q8. Preferably, D7
provides reverse hookup protection. As described above, the test current
generates a voltage
across the terminals of the battery, which is measured by AC voltage
amplifier/converter circuit
119. This AC voltage at 120 is indicative of the battery's internal impedance
(and would, in the
alternative, be indicative of the battery's internal resistance if the voltage
is synchronized to the
test current, e.g., with a synchronous detector).
I 0 0 5 6] Referring now to Figure 4D, AC voltage amplifier/converter
circuit 119 will now
be discussed in more detail. The circuit is formed of two amplifier stages and
a filter stage. The
first amplifier stage is formed by diodes D3 and D5, resistors R30, R31, R32,
R33, R34,
amplifier U9-A, and zener diode Z5. The second amplifier stage is formed by
resistors R9, R24,
R25, and R17, capacitor C27, amplifier U9-B, and transistor Q4. The filter
stage is formed by
resistors R8, R18, R19, capacitors C15, C17, and C19, and amplifier U7-A.
[0057] In operation, the AC voltage to be measured appears on node 46
(+SENSE) and is
coupled to amplifier U9-A through C32, which removes any DC components. An
offset voltage
of approximately 1.7 volts is generated by resistors R33 and R34 and diodes D3
and D5.
Resistor R32 and zener diode Z5 protect amplifier U9-A against excessive input
voltages. The
gain of amplifier U9-A is set by resistors R30 and R31 and is approximately
100. Hence, the
amplified battery test voltage is output from amplifier U9-A to the second
amplifier stage.
[0058] More specifically, the amplified battery test voltage is input
through capacitor
C27 to amplifier U9-B. Capacitor C27 blocks any DC signal components from
passing through
to amplifier U9-B. Resistors R9 and R25 and zener diode Z3 bias amplifier U9-
B. Coupled
between the output and (-) input of amplifier U9-B is the emitter-base
junction of transistor Q4.
The collector of Q4 is coupled to the ground bus through resistor R17. In
essence, the second
amplifier stage rectifies the decoupled AC signal using amplifier U9-B and
transistor Q4 to
invert only those portions of the decoupled AC signal below approximately 4.1
volts and
referencing the resulting inverted AC signal, which appears across R17, to the
potential of the
ground bus. The resulting AC signal is provided downstream to the filter
stage.
[0059] Input to the filter stage is provided through a resistor-capacitor
networked formed
by resistors R18, R19, and R8, and capacitors C17 and C19. Amplifier U7-A and
feedback
14
CA 02507543 2012-07-19
capacitor C15 convert the AC input signal at the (+) input of the amplifier U7-
A to a DC voltage
that is output to node 120. Node 120 provides the DC voltage as an input to
the (-) terminal of
comparator 82d. The (+) terminal of comparator 82d receives the output of DAC
80 on node
83d. The output of comparator 82d is a node 85d that is in circuit
communication with an data
input on processor 42. Through DAC 80 and comparator 82d, processor can use a
successive
approximation technique to determine the amplitude of the DC voltage on node
120 and,
therefore, ultimately the internal impedance of the battery under test. This
internal impedance
value, along with user input information such as the battery's cold-cranking
ampere (hereinafter
CCA) rating, and the battery's open circuit voltage, can determine if the
battery passes or fails
the test. If the battery fails the test, replacement is suggested. Additional
battery tester circuitry
can be found in US Patent Nos. 5,572,136 and 5,585,728. Thus, the circuitry of
Figure 4D may be modified so that the AC voltage on node 120 is synchronous
with
the test current, in which case the AC voltage on node 120 would represent the
battery resistance.
[0 0 6 0]
Referring now to Figures 5A-5C, a two-clamp embodiment 128 of a test cable 28
is shown. The cable 128 of this embodiment preferably comprises a four-
conductor cable 130 in
circuit communication with a connector 132 at one end, connected as shown in
Figures 5B and
5C, and in circuit communication with a pair of hippo clips 134, 136 at the
other end. The cable
128 is preferably about three (3) feet long, but can be virtually any length.
The connector 132
mates with connector J1 of tester 10. The four conductors in cable 130 are
preferably connected
to the hippo clips 134, 136 so as to form a Kelvin type connection, with one
conductor
electrically connected to each half of each hippo clip, which is known in the
art. In this cable
128, the power ground 94 and signal ground 96 are preferably connected to form
a star ground at
the negative battery terminal. Resistor R128 connects between the +sense and -
sense lines. In
test cable 128, pin four (4) is open; therefore, the equivalent circuit of the
detection circuit 44 for
this cable 128 is found in Figure 3B. More specifically, with the hippo clips
134, 136 connected
to a battery of a starting/charging system 11, and connector 132 connected to
mating connector
Jl on tester 10, the equivalent circuit of the detection circuit 44 for this
cable 128 is found in
CA 02507543 2012-07-19
Figure 38. The processor 42 determines the existence of this cable 128 by (i)
measuring the
battery voltage VBAn. using voltmeter 100, (ii) dividing the battery voltage
VbAU by ten, and (iii)
determining that the voltage at node 92 is above or below a threshold value.
In this example the
15a
CA 02507543 2005-05-17
threshold value is determined to be approximately two-thirds of the way
between two expected
values or, more specifically, (VBATT/20 + VBATT/10.5)/1.5. If above this
value, then cable 128 is
connected.
[0 0 6 1] Referring now to Figures 6A-6B, an embodiment of an extender
cable 228 is
shown. The cable 228 of this embodiment preferably comprises a four-conductor
cable 230 in
circuit communication with a first connector 232 at one end and a second
connector 234 at the
other end, connected as shown in Figure 6B. The cable 128 is preferably about
twelve (12) feet
long, but can be virtually any length. Cable conductors 230a and 230b are
preferably in a
twisted pair configuration. Cable conductor 230d is preferably shielded with
grounded shield
231. Connector 232 mates with connector J1 of tester 10. Connector 234 mates
with connector
132 of cable 128 of Figs. 5A-5C (or, e.g., with connector 332 of cable 328
(Figs. 7A-7C) or with
connector 432 of cable 428 (Fig. 8)). In cable 228, the power ground 94 and
signal ground 96
are not connected to form a star ground; rather, the extender cable 228 relies
on another test
cable (e.g., cable 128 or cable 328 or cable 428) to form a star ground. In
cable 228, pin four (4)
of connector 232 (detection signal 48 in Figure 3A) is grounded to signal
ground 96 (pin eleven
(11)) via connection 236; therefore, the equivalent circuit of the detection
circuit 44 for this cable
128 is found in Figure 3C. More specifically, with a cable 128 connected to
connector 234, and
with the hippo clips 134, 136 of cable 128 connected to a battery of a
starting/charging system
11, and connector 232 connected to mating connector J1 on tester 10, the
equivalent circuit of the
detection circuit 44 for this cable combination 128/228 is found in Figure 3C.
The processor 42
determines the existence of this cable 128 by (i) measuring the battery
voltage VsArr using
voltmeter 100, (ii) dividing the battery voltage VgArr by twenty and, (iii)
determining that the
voltage at node 92 is above or below a threshold value. In this example the
threshold value is
determined to be approximately two-thirds of the way between two expected
values or, more
specifically, (VBATT/20 + VBATT/10.5)/1.5. If below this value, then cable 128
is connected.
00 6 21 In response to detecting an extended cable combination 128/228,
the processor 42
may perform one or more steps to compensate the electronics in the test
circuit for effects, if any,
of adding the significant length of wiring inside cable 228 into the circuit.
For example, voltage
measurements taken with voltmeter 100 might need to be altered by a few
percent using either a
fixed calibration value used for all extender cables 228 or a calibration
value specific to the
specific cable 228 being used. Such a calibration value might take the form of
an offset to be
16
CA 02507543 2005-05-17
added to or subtracted from measurements or a scalar to be multiplied to or
divided into
measurements. Such alterations could be made to raw measured data or to the
data at virtually
any point in the test calculations, responsive to determining that the
extender cable 228 was
being used.
[0 0 63] Referring now to Figures 7A-7C, a probe embodiment 328 of a test
cable 28 is
shown. The cable 328 of this embodiment preferably comprises a two-conduC,tor
cable 330 in
circuit communication with a connector 332 at one end, connected as shown in
Figures 7B and
7C, and in circuit communication with a pair of probes 334, 336 at the other
end. The cable 328
is preferably about three (3) feet long, but can be virtually any length. The
connector 332 mates
with connector J1 of tester 10. In this cable 328, the power ground 94 and
signal ground 96 are
connected by connection 338 inside housing 340 of connector 332 to form a star
ground inside
housing 340. In cable 328, the battery power signal 61 is open and the
detection signal 48 (pin
four (4) of connector J1) is open; therefore, the equivalent circuit of the
detection circuit 44 for
this cable 328 is found in Figure 3F. More specifically, with connector 332
connected to mating
connector J1 on tester 10, the equivalent circuit of the detection circuit 44
for this cable 328 is
found in Figure 3F, i.e., the voltage at node 92 is at zero volts or at about
zero volts. The
processor 42 determines the existence of this cable 328 by (i) measuring the
battery voltage
VBATT, (ii) dividing the battery voltage VBATr by a predetermined value such
as, for example, ten
or twenty, and (iii) determining that the voltage at node 92 is above or below
a threshold value.
IO 0 64] The power circuit 60 allows the tester 10 to power up using the
internal battery 62
when using the cable 328 with probes. More specifically, pressing and holding
a particular key,
e.g., key 21, causes the internal battery 62 to temporarily power the tester
10. During an initial
start-up routine, the processor determines the battery voltage using voltmeter
100 and determines
that there is no battery hooked up via power line 61. In response thereto, the
processor 42 via
control signal 63 causes a switch, e.g., a MOSFET (not shown) in power circuit
60 to close in
such a manner that the tester 10 is powered by the internal battery 62 after
the key 21 is released.
[0 0 6 53 Referring now to Figure 8, a block diagram of a proposed sensor
cable 428 is
shown. Sensor cable 428 is preferably an active, powered device and preferably
comprises a
four-conductor cable 430, a connector 432, a power supply circuit 434, an
identification signal
generator 436, a control unit 438, a sensor 440, a pre-amp 442, and a
calibration amplifier 446,
all in circuit communication as shown in Figure 8. Connector 432 mates with
connector J1 of
17
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 -1 7
tester 10. Sensor cable 428 may or may not be powered by a battery being
tested and may
therefore be powered by the internal battery 62 inside tester 10. Accordingly,
sensor cable 428
preferably comprises battery power connections 430a, 430b to the internal
battery 62. Power
supply circuit 434 preferably comprises a power regulator (not shown) to
generate from the
voltage of battery 62 the various voltages needed by the circuitry in sensor
cable 428. In
addition, power supply circuit 434 also preferably performs other functions qf
known power
supplies, such as various protection functions. The sensor cable 428 also
preferably comprises
an identification signal generator 436 that generates an identification signal
430c that interfaces
with detection circuit 44 of tester 10 to provide a unique voltage at node 92
for this particular
cable 428. Identification signal generator 436 may, for example, comprise a
Zener diode or an
active voltage regulator (neither shown) acting as a regulator on the internal
battery voltage to
provide a particular voltage at 430c, thereby causing the detection circuit to
behave as in Figure
3D, with the voltage at node 92 being about half the voltage generated by
identification signal
generator 436. In the alternative, another circuit of Figures 3B-3F may be
used to uniquely
identify the sensor cable 428. Sensor cable 428 is preferably controlled by
control unit 438,
which may be virtually any control unit, e.g., discrete state machines, a
preprogrammed
processor, etc. Control unit 438 preferably controls and orchestrates the
functions performed by
sensor cable 428. Sensor cable 428 also preferably comprises a sensor 440,
e.g., a Hall effect
sensor, in circuit communication with a pre-amp 442, which in turn is in
circuit communication
with a calibratioh amplifier 446. Calibration amplifier 446 outputs the signal
430d, which is
measured by voltmeter 100. Pre-amp 442 and calibration amplifier 446 may be in
circuit
communication with control unit 438 to provide variable gain control or
automatic gain control
to the sensor cable 428. The particular identification signal 430c generated
by ID generator 436
can be made to change by control unit 438 depending on a particular gain
setting. For example,
if the sensor 440 is a Hall effect sensor and the sensor cable 428 implements
a current probe, the
particular identification signal 430c generated by ID generator 436 can be set
to one voltage '
value for an ampere range of e.g. 0-10 Amperes and set to a different voltage
value for an
ampere range of e.g. 0-1000 Amperes, thereby specifically identifying each
mode for the probe
and maximizing the dynamic range of the signal 46 for each application. In
this type of system,
the processor 42 would need to identify the type of cable attached before each
measurement or
periodically or in response to user input.
18
CA 02507543 2005-05-17
(0 0 6 6] Referring now to Figure 9 in the context of the previous figures,
a very high-level
flow chart 500 for the operation of tester 10 is shown. The tasks in the
various flow charts are
I
preferably controlled by processor 42, which has preferably been preprogrammed
with code to
implement the various functions described herein. The flow charts of Figures 9-
12 are based on
a tester 10 having a hippo clip cable 128 connected to an extender cable 228,
which in turn is
connected to tester 10 at connector J1. Starting at task 502, the user first
powers up the tester 10
at task 504 by connecting the tester 10 to a battery of a starting/charging
system 11. If the tester
is to be powered by internal battery 62, the user presses and holds the button
21 until the
processor 42 latches the battery 62, as described above. In response to the
system powering up,
the processor 42 initializes the tester 10, e.g., by performing various self-
tests and/or calibrations,
such as autozeroing, described above.
(0 0 6 7] Next, at task 506, the tester 10 detects the type of cable 28
attached to connector
J1, e.g., as being one of the cables 128, 228, 328, or 428, discussed above.
In general, this is
done by having the processor measure the voltage at node 92 using a successive
approximation
technique with DAC 80 and comparator 82a, comparing the measured value of the
voltage at
node 92 to a plurality of voltage values, and selecting a cable type based on
the measured voltage
relative to the predetermined voltage values. One or more of the plurality of
voltage values may
depend on, or be a function of, battery voltage; therefore, the processor may
measure the battery
voltage and perform various computations thereon as part of determining the
plurality of voltage
values such as, or example, those described in connection with Figures 5A-7B,
above. Then, the
user tests the starting/charging system 11, at task 508, and the testing ends
at task 510.
00 6 8] Referring now to Figure 10, a medium-level flow chart is presented
showing a
preferred program flow for the testing of the starting/charging system and
also showing some of
the beneficial aspects of the user interface according to the present
invention. The test routine
508 preferably performs a starter test, a plurality of charger tests, and a
diode ripple test. The
tester 10 preferably accepts input from the user (e.g., by detecting various
keys being pressed) to
allow the user to look over results of tests that have already been performed
and to either skip or
redo tests that have already been performed. In general, preferably the user
presses one key to
begin a test or complete a test or to indicate to the processor 42 that the
vehicle has been placed
into a particular state. The user presses a second key to look at the results
of previously
completed tests and the user presses a third key to skip tests that have
already been performed.
.19
CA 02507543 2005-05-17
Code implementing the user interface preferably conveys to the user via the
display 24 whether a
test may be skipped or not. More specifically to the embodiment shown ill the
figures, the user
presses the star button 18 to cause the processor to begin a test or complete
a test or to indicate to
the processor 42 that the vehicle has been placed into a particular test
state, thereby prompting
the processor to take one or more measurements. After one or more tests are
performed, the user
may press the up button 19 to review the results of tests that have been
performed. Thereafter,
the user may skip or redo tests that have already been done. The user may skip
a test that has
already been done by pressing the down button 20.
(0 0 6 9) More particular to Figure 10, starting at 520, the routine 508
first performs the
starter test, at 522. As will be explained below in the text describing
Figures 11 and 12, for the
various tests the user is prompted via the display 24 to place the vehicle
into a particular state
and to press a key when the vehicle is in that state, then the tester 10 takes
one or more
measurements, then the data is processed, and then test results are displayed
to the user via
display 24. ,
[0 0 7 0] In a preferred embodiment, there are five test states: a starter
test state 522, a first
charger test state 524, a second charger test state 526, a third charger test
state 528, and a diode
ripple test state 530. The tester successively transitions from one state to
the next as each test is
completed. There is also a finished state 531 which is entered after all of
the tests are completed,
i.e., after the clic:tide-ripple test is completed. For each test, preferably
the user is prompted via the
display 24 to place the vehicle into a particular state, the user presses the
star key 18 to indicate
that the vehicle is in that state, then the tester 10 takes one or more
measurements, then the data
is processed, then test results are displayed to the user via display 24, then
the user presses the
start key 20 to move to the next test. As each test is completed, the
processor 42 sets a
corresponding flag in memory indicating that that test has been completed.
These flags allow the
code to determine whether the user may skip a test that has already been
performed. As shown,
the user presses the star key 18 to move to the next test. As shown in Figure
10, if the user
presses the down key 20 while in any of the various states, the code tests
whether that test has
been completed, at 532a-532e. If so, the code branches to the next state via
branches 534a-534e.
If not, the code remains in that state as indicated by branches 536a-536e. If
the user presses the
up key 19, while in any of states 524-530, the code branches to the previous
test state, as
indicated by branches 538a-538e. Thus, the user may use the up key 19 to look
at previously
CA 02507543 2005-05-17
performed tests, and selectively use either (a) the down key 20 to skip (keep
the previously
recorded data rather than collecting new data) any particular test that has
li)ern performed or (b)
the star key 18 to redo any particular test that has already been performed.
For example, assume
that a vehicle has passed the Starter Test 522, failed Charger Test No. 1 524,
passed Charger Test
No. 2 526, and passed Charger Test No. 3 528. In this situation, the user may
want to redo
Charger. Test No. 1 without having to redo the other two tests. In that case,
the user may hit the
up key 19 twice to move from state 528 to the Charger Test No. 1, which is
state 524. In that
state, the user may perform Charger Test No. 1 again. After performing Charger
Test No. 1
again, the user may move to the next test, the Diode Ripple Test 530, by
actuating the down key
twice (if in state 526) or thrice (if still in state 524), thereby skipping
the Charger Test No. 2 and
Charger Test No. 3 and retaining the previously collected data for those
tests.
[0 0 7 1] After all the tests are complete, the tester 10 enters the All
Tests Complete state
531. While in this state, the user may actuate the up key 19 to view one or
more previously
completed tests or may actuate the star key 18 to return, at 540.
[0 0 7 2] Referring now to Figures 11A-11D and 12, additional aspects of
the routines
discussed in connection with Figure 10 are shown. Figures 11A-11D are set up
similarly to
Figure 10; however, the symbols representing the decisions at 532a-532e and
branches at 536a-
536e in Figure 10 have been compressed to conserve space in Figures 11A-11D.
Figures 11A-
11D focus on the user interface of the present invention and provide
additional information about
the various tests. Figure 12 provides additional information about the starter
test while de-
emphasizing the user interface. The small diamonds extending to the right from
the various
"down arrow" boxes in Figures 11A-11D represent those decisions 532a-532e and
branches back
to the same state 536a-536e, as will be further explained below.
[0 0 7 3] Starting at 600 in Figure 11A, the test routine 508 first prompts
the user at 602 to
turn the engine off and to press the star key 18 when that has been done. The
user pressing the
star key 18 causes the code to branch at 604 to the next state at 606. At
state 606, the user is
prompted to either start the engine of the vehicle under test or press the
star key 18 to abort the
starter test, causing the code to branch at 608 to the next state at 610.
00 7 4] While in state 610, the tester 10 repeatedly tests for the star
key 18 being actuated
and tests for a drop in the battery voltage indicative of the starter motor
starting to crank, as
further explained in the text accompanying Figure 12. If an actuation of the
star key 18 is
21
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
detected, the code branches at 611 and the starter test is aborted, at 612. If
a voltage drop
indicative of the start of cranking is detected, the tester 10 collects
cranking voltage data with
voltmeter 100, as further explained in the text accompanying Figure 12. If the
average cranking
voltage is greater than 9.6 VDC, then the cranking voltage is deemed to be
"OK" no matter what
the temperature is, the code branches at 618, sets a flag indicating that the
cranking voltage
during starting was "OK" at 620, sets a flag indicating that the starter test
has ben completed at
622, and the corresponding message is displayed at 624. On the other hand, if
the average
cranking' voltage is less than 8.5 VDC, then the battery voltage during
starting ("cranking
voltage") is deemed to be "Low" no matter what the temperature is, i.e., there
might be problems
with the starter, the code branches at 630, sets a flag indicating that the
cranking voltage during
starting was "Low" at 632, sets a Starter Test Complete Flag indicating that
the starter test has
been completed at 622, and the corresponding message is displayed at 624.
Finally, if the
average cranking voltage is between 8.5 VDC and 9.6 VDC, then the processor 42
needs
temperature information to make a determination as to the condition of the
starter, and the code
branches at 633. Accordingly, the processor 42 at step 634 prompts the user
with respect to the
temperature of the battery with a message via display 24 such as, "Temperature
above xx ?"
where xx is a threshold temperature corresponding to the average measured
cranking voltage. A
sample table of cranking voltages and corresponding threshold temperatures is
found at 954 in
Figure 12. On the one hand, if the user indicates that the battery temperature
is above the
threshold temperature, then the code branches at 636, sets a flag indicating
that the cranking
voltage during starting was "Low" at 632, sets the Starter Test Complete Flag
indicating that the
starter test has been completed at 622, and a corresponding "Low" message is
displayed at 624.
On the other hand, if the user indicates that the battery temperature is not
above the threshold
temperature, then the code branches at 638, sets a flag indicating that the
cranking voltage during
starting was "OK" at 620, sets the Starter Test Complete Flag indicating that
the starter test has
been completed at 622, and a corresponding "OK" message is displayed at 624.
While. in state
624, if the user presses the star key 18, the code branches at 660 to state
662.
[0075]
The No Load/Curb Idle charger test begins at state 662, in which the user is
prompted to adjust the vehicle so that the starting/charging system is in a No
Load/Curb Idle
(NLCI) condition, e.g., very few if any user-selectable loads are turned on
and no pressure is
being applied to the accelerator pedal. The battery voltage of the vehicle
while in the NLCI
22
CA 02507543 2005-05-17
condition provides information about the condition of the regulator's ability
to regulate at its
lower limit; the battery voltage with the vehicle in the NLCI condition should
be within a
I it
particular range. Once the user has adjusted the vehicle to be in this
condition, the user presses
the star key 18, causing the code to branch at 664 to task 668 in which the
tester 10 measures the
battery voltage using voltmeter 100. The battery voltage may be measured once
or measured a
number of times and then averaged or summed. It is preferably measured a
Ourality of times
and averaged. In either event, a determination is made as to whether the
battery voltage (or
average or sum) is within an acceptable range while in the NLCI condition. The
end points of
this range are preferably determined as functions of battery base voltage
(battery voltage before
the vehicle was started), Vb. These endpoints are preferably calculated by
adding fixed values to
the base voltage Vb, e.g., Vi.w = Vb + 0.5 VDC and Vhigh = 15 VDC. In the
alternative, these
endpoints can be determined by performing another mathematical operation with
respect to the
base voltage Vb, e.g., taking fixed percentages of the base voltage Vb. The
range selected for the
embodiment shown in the figures is between Vb + 0.5 VDC and Vb = 15 VDC. If
the battery
voltage (or average or sum) is between those endpoints with the vehicle in the
NLCI condition,
then the regulator is probably in an acceptable condition with respect to its
lower limit of
regulation. If the battery voltage (or average or sum) is less than Vb + 0.5
VDC with the vehicle
in the NLCI condition, then the battery voltage (or average or sum) is lower
than acceptable
and/or expected. If the battery voltage (or average or sum) is greater than Vb
= 15 VDC with the
vehicle in the NLCI condition, then the battery voltage (or average or stun)
is higher than
acceptable and/or expected. The code continues at 670 to task 672, where a
NLCI Test
Complete Flag is set indicating that the NLCI test has been performed. Then at
674, the code
continues to state 676, in which the results of the NLCI test are displayed.
Preferably, the
following information is displayed to allow the user to make a determination
as to whether the
regulator is in an acceptable condition: base battery voltage and the battery
voltage with the
vehicle in the NLCI condition. Also, if the battery voltage with the vehicle
in the NLCI
condition was below the acceptable/expected range, a "Low" indication is
presented to the user
near the test battery voltage. Similarly, if the battery voltage with the
vehicle in the NLCI
condition was above the acceptable/expected range, a "Hi" indication is
presented to the user
near the test battery voltage. With this information, the user can make a
determination as to
23
CA 02507543 2005-05-17
whether the regulator is in an acceptable condition with respect to its lower
regulation limit.
While in state 676, if the user presses the star key 18, the code branches at
67$ to state 690.
I
[0 0 7 6]
The No Load/Fast Idle charger test begins at state 690, in which the user is
prompted to adjust the vehicle so that the starting/charging system is in a No
Load/Fast Idle
(NLFI) condition, e.g., very few if any user-selectable loads are turned on
and pressure is being
applied to the accelerator pedal to cause the vehicle motor to operate at
about 2000 revolutions
per minute (RPM). The battery voltage of the vehicle while in the NLFI
condition provides
information about the condition of the regulator's ability to regulate at its
upper limit; the battery
voltage with the vehicle in the NLFI condition should be within a particular
range. Once the user
has adjusted the vehicle to be in this condition, the user presses the star
key 18, causing the code
to branch, at 692, to task 694 in which the tester 10 measures the battery
voltage using voltmeter
100. The battery voltage may be measured once or measured a number of times
and then
averaged or summed. Preferably it is measured a number of times and then
averaged. In either
event, a determination is made as to whether the battery voltage (or average
or sum) is within an
acceptable range while in the NLFI condition. The end points of this range are
preferably
determined as functions of battery base voltage (battery voltage before the
vehicle was started),
Vb. These endpoints are preferably calculated by adding fixed values to the
base voltage Vb,
e.g., V10,, = Vb + 0.5 VDC and Vhigh = 15 VDC. In the alternative, these
endpoints can be
determined by performing another mathematical operation with respect to the
base voltage VI)/
e.g., taking fixed percentages of the base voltage Vb. The range selected for
the embodiment
shown in the figures is between Vb + 0.5 VDC and Vb = 15 VDC. If the battery
voltage (or
average or sum) is between those endpoints with the vehicle in the NLFI
condition, then the
regulator is probably in an acceptable condition with respect to its upper
limit of regulation. If
the battery voltage (or average or sum) is less than Vi, + 0.5 VDC with the
vehicle in the NLFI
condition, then the battery voltage (or average or sum) is lower than
acceptable and/or expected.
If the battery voltage (or average or sum) is greater than VI, = 15 VDC with
the vehicle in the
NLFI condition, then the battery voltage (or average or sum) is higher than
acceptable and/or
expected. The code continues at 696 to task 698, where a NLFI Test Complete
Flag is set
indicating that the NLFI test has been performed. Then at 700, the code
continues to state 702,
in which the results of the NLFI test are displayed. Preferably, the following
information is
displayed to allow the user to make a determination as to whether the,
regulator is in an
24
CA 02507543 2005-05-17
acceptable condition: base battery voltage (battery voltage before the vehicle
was started) and
the battery voltage with the vehicle in the NLFI condition. Also, if the
battery voltage with the
vehicle in the NLFI condition was below the acceptable/expected range, a "Low"
indication is
presented to the user near the test battery voltage. Similarly, if the battery
voltage with the
vehicle in the NLFI condition was above the acceptable/expected range, a "Hi"
indication is
presented to the user near the test battery voltage. With this information,
the user can make a
determination as to whether the regulator is in an acceptable condition with
respect to its upper
regulation limit. While in state 702, if the user presses the star key 18, the
code branches at 704
to state 720.
[0 0 7 7]
The Full Load/Fast Idle charger test begins at state 720, in which the user
is
prompted to adjust the vehicle so that the starting/charging system is in a
Full Load/Fast Idle
(FLFI) condition, e.g., most if not all user-selectable loads (lights,
blower(s), radio, defroster,
wipers, seat heaters, etc.) are turned on and pressure is being applied to the
accelerator pedal to
cause the vehicle motor to operate at about 2000 RPM. The battery voltage of
the vehicle while
in the FLFI condition provides information about the condition of the
alternator with respect to
its power capacity; the battery voltage with the vehicle in the FLFI condition
should be within a
particular range. Once the user has adjusted the vehicle to be in this
condition, the user presses
the star key 18, causing the code to branch, at 722, to task 724 in which the
tester 10 measures
the battery voltage using voltmeter 100. The battery voltage may be measured
once or measured
a number of times and then averaged or summed. Preferably it is measured a
number of times
and then averaged. In either event, a determination is made as to whether the
battery voltage (or
average or sum) is within an acceptable range while in the FLFI condition. The
end points of
this range are preferably determined as functions of battery base voltage
(battery voltage before
the vehicle was started), Vb. These endpoints are preferably calculated by
adding fixed values to
the base voltage Vb, e.g., V10õ = Vb + 0.5 VDC and \Thigh = 15 VDC. In the
alternative, these
endpoints can be determined by performing another mathematical operation with
respect to the
base voltage Vb, e.g., taking fixed percentages of the base voltage Vb. The
range selected for the
embodiment shown in the figures is between Vb + 0.5 VDC and Vb = 15 VDC. If
the battery
voltage (or average or sum) is between those endpoints with the vehicle in the
FLFI condition,
then the alternator is probably in an acceptable condition with respect to its
power capacity. If
the battery voltage (or average or sum) is less than Vb 0.5 VDC with the
vehicle in the FLFI
.25
CA 02507543 2005-05-17
condition, then the battery voltage (or average or sum) is lower than
acceptable and/or expected.
If the battery voltage (or average or sum) is greater than VI, = 15 VDC with
the vehicle in the
FLFI condition, then the battery voltage (or average or sum) is higher than
acceptable and/or
expected. The code continues at 726 to task 728, where a FLFI Test Complete
Flag is set
indicating that the FLFI test has been performed. Then at 730, the code
continues to state 732, in
which the results of the FLFI test are displayed. Preferably, the following'
information is
displayed to allow the user to make a determination as to whether the
alternator is in an
acceptable condition: base battery voltage (battery voltage before the vehicle
was started) and
the battery voltage with the vehicle in the FLFI condition. Also, if the
battery voltage with the
vehicle in the FLFI condition was below the acceptable/expected range, a "Low"
indication is
presented to the user near the test battery voltage. Similarly, if the battery
voltage with the
vehicle in the FLFI condition was above the acceptable/expected range, a "Hi"
indication is
presented to the user near the test battery voltage. With this information,
the user can make a
determination as to whether the alternator is in an acceptable condition with
respect to its power
capacity. While in state 732, if the user presses the star key 18, the code
branches at 734 to state
750.
[0 0 7 8]
The alternator diode ripple test begins at state 750, in which the user is
prompted
to adjust the vehicle so that the starting/charging system is in a Medium
Load/Low Idle (MLLI)
condition, e.g., the lights are on, but all other user-selectable loads
(blower(s), radio, defroster,
wipers, seat heaters, etc.) are turned off and pressure is being applied to
the accelerator pedal to
cause the vehicle motor to operate at about 1000 RPM. For the diode ripple
test, the diode ripple
circuit 102 is used and the processor measures the diode ripple voltage at 114
at the output of the
peak detect circuit 112. The diode ripple voltage with the vehicle while in
the MLLI condition
provides information about the condition of the diodes in the alternator with
a known load (most
vehicle lights draw about 65 Watts of power per lamp). The diode ripple
voltage 114 with the
vehicle in the MLLI condition should be less than a predetermined threshold,
e.g., for the circuit
of Figure 4B less than 1.2 VDC for a 12-volt system and less than 2.4 VDC for
a 24-volt system.
Once the user has adjusted the vehicle to be in this condition, the user
presses the star key 18,
causing the code to branch, at 752, to task 754 in which the tester 10
measures the ripple voltage
using ripple circuit 102. The ripple voltage 114 may be measured once or
measured a number of
times and then averaged or summed. Preferably it is measured a number of times
and then
,26
CA 02507543 2005-05-17
averaged. In either event, a determination is made as to whether the ripple
voltage 114 (or
average or sum) is less than the acceptable threshold while in the MLLI
condition. The threshold
ripple voltage selected for the embodiment shown in Figure 4B is 1.2 VD( for a
12-volt system
and 2.4 VDC for a 24-volt system.. If the ripple voltage 114 is lower than
that threshold with the
vehicle in the MLLI condition, then the alternator diodes are probably in an
acceptable condition.
The code continues at 756 to task 758, where a Diode Ripple Test Complete Flag
is set
indicating that the diode ripple test has been performed. Then at 760, the
code continues to state
762, in -Which the results of the diode ripple test are displayed. Preferably,
either a ripple voltage
"OK" or ripple voltage "Hi" message is displayed, depending on the measured
ripple voltage
relative to the threshold ripple voltage. With this information, the user can
make a determination
as to whether the alternator diodes are in an acceptable condition. While in
state 762, if the user
presses the star key 18, the code branches at 764 to state 770.
[0 0 7 9] State 770 an extra state in that it is not a separate test of the
starting/charging
system 11. As shown in Figure 10 and discussed in the accompanying text, the
user may use the
up key 19 (up button) and the down key 20 (down button) to review the results
of past tests, to
redo previously performed tests and/or skip (keep the data for) previously
performed tests. One
implementation of this feature of the user interface is shown in more detail
in Figures 11A-11D.
State 770 provides the user with a state between the results of the last test
and exiting the test
portion of the code so that the user can use the up key 19 and down key 20 to
review previous
test results and 'skip and/or redo some of the tests. Pressing the star key 18
while in state 770
causes the code to end, i.e., return, at 772.
[ 0 0 8 0] While in state 602, in which the user is prompted to turn the
engine off, pressing
the up key 19 does nothing. While in state 602, if the Starter Test has
already been performed,
i.e., if the Starter Test Complete Flag is set, e.g., at task 672, the display
conveys to the user that
the down key 20 is active, e.g., by displaying an image corresponding to that
key, such as an
image of a downwardly pointing arrow. Figure 13 shows a number of screens for
display 26
showing this feature of the user interface. Screen 1000 of Figure 13 shows a
display of a Starter
Test prompt, before the Starter Test has been performed, i.e., with the
Starter Test Complete Flag
cleared. Screen 1002 of Figure 13 shows a display of the same Starter Test
prompt, with the
Starter Test Complete Flag set, i.e., after the Starter Test has been
performed at least once since
the tester 10 was last powered up. Note the presence of down arrow 1004 in
screen 1002 that is
27
CA 02507543 2012-07-19
not in screen 1000, indicating that the down arrow key is active and may be
used to skip the
Starter Test.
[0 0 8 1] Thus, while in state 602, pressing the down key 20 causes thei
code to branch to a
decision at 780 as to whether the Starter Test has already been performed,
i.e., whether the
Starter Test Complete Flag is set. If the down key 20 is pressed while the
Starter Test Complete
Flag is not set, the code remains in state 602 and waits for the user to press
the star key 18,
which will cause the Starter Test to be redone, starting with branch 604. If
the down key 20 is
pressed while the Starter Test Complete Flag is set, the code branches at 782
to state 624,
discussed above, in which the results of the Starter Test are displayed. Thus,
from state 602, if
the Starter Test has already been performed, the user may redo that test by
pressing the star key
18, or may skip the test (thereby retaining the data and results from the
previous execution of that
test) by pressing the down key 20.
[0082] While in state 606, in which the user is prompted to start the
engine, pressing the
up key 19 causes the code to branch at 784 back to state 602, discussed above.
While in state
606, if the Starter Test has already been performed, i.e., if the Starter Test
Complete Flag is set,
e.g., at task 622, the display conveys to the user that the down key 20 is
active, e.g., by
displaying an image corresponding to that key, such as an image of a
downwardly pointing arrow
(e.g., down arrow 1004 in the screen shots in Figure 13). While in state 606,
pressing the down
key 20 causes the code to branch to a decision at 786 as to whether the
Starter Test has already
been performed, i.e., whether the Starter Test Complete Flag is set. If the
down key 20 is
pressed while the Starter Test Complete Flag is not set, the code remains in
state 606 and waits
for the comparator 82b (Figures 2 and 4A) to detect a crank and waits for the
user to press the
star key 18, which will exit the Starter Test 612 via branch 611. If the down
key 20 is pressed
while the Starter Test Complete Flag is set, the code branches at 788 to state
624, discussed
above, in which the results of the Starter Test are displayed. Thus, from
state 606, the user may
back up to the previous step by pressing the up key 19 and, if the Starter
Test has already been
performed, the user may redo that test by pressing the star key 18, or may
skip the test (thereby
28
CA 02507543 2012-07-19
retaining the data and results from the previous execution of that test) by
pressing the down key
20.
(0083]
While in state 624, in which the results of the Starter Test are presented to
the
user, pressing the up key 19 causes the code to branch at 790 to a decision at
792 as to whether
28a
CA 02507543 2005-05-17
-
the user was prompted to enter a battery temperature during the Starter Test,
i.e., whether the
battery voltage measured during cranking is between 8.5 VDC and 9.6 VDC and
therefore
battery temperature is relevant to the cranking voltage determination. If so,
the code branches at
794 to state 634, discussed above, in which the user is prompted to enter data
with respect to
battery temperature. If not, the code branches at 796 to state 606, discussed
above, in which the
user is prompted to start the engine. While in state 624, if the NLCI Test has
already been
performed, i.e., if the NLCI Test Complete Flag is set, e.g., at task 672, the
display conveys to
the user that the down key 20 is active, e.g., by displaying an image
corresponding to that key,
such as an image of a downwardly pointing arrow. Screen 1006 of Figure 13
shows a display of
the results of a hypothetical Starter Test before the NLCI Test has been
performed, i.e., with the
NLCI Test Complete Flag cleared. Screen 1008 of Figure 13 shows a display of
the same Starter
Test results, with the NLCI Test Complete Flag set, i.e., after the NLCI Test
has been performed
at least once since the tester 10 was last powered up. Note the presence of
down arrow 1004 in
screen 1008 that is not in screen 1006, indicating that the down arrow key is
active and may be
used to skip to the results of the NLCI Test.
[0 0 8 4] Thus, while in state 624, pressing the down key 20 causes the
code to branch to a
decision at 800 as to whether the NLCI Test has already been performed, i.e.,
whether the NLCI
Test Complete Flag is set. If the down key 20 is pressed while the NLCI Test
Complete Flag is
not set, the code remains in state 624 and waits for the user to press the
star key 18, which will
cause the code to branch to the beginning of the NLCI Test, via branch 660. If
the down key 20
is pressed while the NLCI Test Complete Flag is set, the code branches at 802
to state 676,
discussed above, in which the results of the NLCI Test are displayed. Thus,
from state 624, the
user may back up to the previous step(s) by pressing the up key 19 and, if the
NLCI Test has
already been performed, the user may redo that test by pressing the star key
18, or may skip the
test (thereby retaining the data and results from the previous execution of
that test) by pressing
the down key 20.
[0 0 8 5] While in state 662, which is the start of the NLCI Test, pressing
the up key 19
causes the code to branch at 804 to state 624, discussed above, in which the
results of the Starter
Test are presented. While in state 662, if the NLCI Test has already been
performed, i.e., if the
NLCI Test Complete Flag is set, e.g., at task 672, the display conveys to the
user that the down
key 20 is active, e.g., by displaying an image corresponding to that key, such
as an image of a
29
CA 02507543 2005-05-17
downwardly pointing arrow (e.g., down arrow 1004 in the screen shots in Figure
13). While in
state 662, pressing the down key 20 causes the code to branch to a decision at
806 as to whether
the NLCI Test has already been performed, i.e., whether the NLCI Test Complete
Flag is set. If
the down key 20 is pressed while the NLCI Test Complete Flag is not set, the
code remains in
state 662 and waits for the user to press the star key 18, which will cause
the code to take a
measurement of battery voltage, via branch 664. If the down key 20 is pressed
whilethe NLCI
Test Complete Flag is set, the code branches at 808 to state 676, discussed
above, in which the
results of the NLCI Test are displayed. Thus, from state 662, the user may
back up to the
previous test step (the end of the Starter Test) by pressing the up key 19
and, if the NLCI Test
has already been performed, the user may redo that test by pressing the star
key 18, or may skip
the test (thereby retaining the data and results from the previous execution
of that test) by
pressing the down key 20.
(0086] While in state 676, in which the results of the NLCI Test are
presented to the user,
pressing the up key 19 causes the code to branch at 810 to state 662,
discussed, above, in which
the user is prompted to adjust the vehicle into the NLCI condition. While in
state 676, if the
NLFI Test has already been performed, i.e., if the NLFI Test Complete Flag is
set, e.g., at task
698, the display conveys to the user that the down key 20 is active, e.g., by
displaying an image
corresponding to that key, such as an image of a downwardly pointing arrow.
Screen 1010 of
Figure 13 showsi a display of the results of a hypothetical NLCI Test before
the NLFI Test has
been performed, i.e., with the NLFI Test Complete Flag cleared. Screen 1012 of
Figure 13
shows a display of the same NLCI Test results, with the NLFI Test Complete
Flag set, i.e., after
the NLFI Test has been performed it least once since the tester 10 was last
powered up. Note the
presence of down arrow 1004 in screen 1012 that is not in screen 1010,
indicating that the down
arrow key is active and may be used to skip to the results of the NLFI Test.
[0 0 8 7] Thus, while in state 676, pressing the down key 20 causes the
code to branch to a
decision at 812 is to whether the NLFI Test has already been performed, i.e.,
whether the NLFI
Test Complete Flag is set. If the down key 20 is pressed while the NLFI Test
Complete Flag is
not set, the code remains in state 676 and waits for the user to press the
star key 18, which will
cause the code to branch to the beginning of the NLFI Test, via branch 678. If
the down key 20
is pressed while the NLFI Test Complete Flag is set, the code branches at 814
to state 702,
discussed above, in which the results of the NLFI Test are displayed. Thus,
from state 676, the
CA 02507543 2005-05-17
user may back up to the previous step (state 662) by pressing the up key 19
and, if the NLFI Test
has already been performed, the user may redo that test by pressing the star
key 18, or may skip
the test (thereby retaining the data and results from the previous execution
of that test) by
pressing the down key 20.
[0 0 8 8] While in state 690, which is the start of the NLFI Test, pressing
the up key 19
causes the code to branch at 816 to state 676, discussed above, in which the
results of the NLCI
Test are presented. While in state 690, if the NLFI Test has already been
performed, i.e., if the
NLFI Test Complete Flag is set, e.g., at task 698, the display conveys to the
user that the down
key 20 is active, e.g., by displaying an image corresponding to that key, such
as an image of a
downwardly pointing arrow (e.g., down arrow 1004 in the screen shots in Figure
13). While in
state 690, pressing the down key 20 causes the code to branch to a decision at
820 as to whether
the NLFI Test has already been performed, i.e., whether the NLFI Test Complete
Flag is set. If,
the down key 20 is pressed while the NLFI Test Complete Flag is not set, the
code remains in
state 690 and waits for the user to press the star key 18, which will cause he
code to take a
measurement of battery voltage, via branch 692. If the down key 20 is pressed
while the NLFI
Test Complete Flag is set, the code branches at 822 to state 702, discussed
above, in which the
results of the NLFI Test are displayed. Thus, from state 690, the user may
back up to the
previous test step (the end of the NLCI Test) by pressing the up key 19 and,
if the NLFI Test has
already been performed, the user may redo that test by pressing the star key
18, or may skip the
test (thereby retaining the data and results from the previous execution of
that test) by pressing
the down key 20.
(0 0 8 9] While in state 702, in which the results of the NLFI Test are
presented to the user,
pressing the up key 19 causes the code to branch at 824 to state 690,
discussed above, in which
the user is prompted to adjust the vehicle into the NLFI condition. While in
state 702, if the FLFI
Test has already been performed, i.e., if the FLFI Test Complete Flag is set,
e.g., at task 728, the
display conveys to the user that the down key 20 is active, e.g., by
displaying an image
corresponding to that key, such as an image of a downwardly pointing arrow.
Screen 1014 of
Figure 13 shows a display of the results of a hypothetical NLFI Test before
the FLFI Test has
been performed, i.e., with the FLFI Test Complete Flag cleared. Screen 1016 of
Figure 13
shows a display of the same NLFI Test results, with the FLFI Test Complete
Flag set, i.e., after
the FLFI Test has been performed at least once since the tester 10 was last
powered up. Note the
31
CA 02507543 2005-05-17
presence of down arrow 1004 in screen 1016 that is not in screen 1014,
indicating that the down
arrow key is active and may be used to skip to the results of the FLFI Test.
[0 0 9 0] Thus, while in state 702, pressing the down key 20 causes the
code to branch to a
decision at 830 as to whether the FLFI Test has already been performed, i.e.,
whether the FLFI
Test Complete Flag is set. If the down key 20 is pressed while the FLFI Test
Complete Flag is
not set, the code remains in state 702 and waits for the user to press the
star keyi 18, which will
cause the code to branch to the beginning of the FLFI Test, via branch 704. If
the down key 20
is pressed while the FLFI Test Complete Flag is set, the code branches at 832
to state 732,
discussed above, in which the results of the FLFI Test are displayed. Thus,
from state 702, the
user may back up to the previous step (state 690) by pressing the up key 19
and, if the FLFI Test
has already been performed, the user may redo that test by pressing the star
key 18, or may skip
the test (thereby retaining the data and results from the previous execution
of that test) by
pressing the down key 20.
[0 0 9 1] While in state 720, which is the start of the FLFI Test, pressing
the up key 19
causes the code to branch at 834 to state 702, discussed above, in which the
results of the NLFI
Test are presented. While in state 720, if the FLFI Test has already been
performed, i.e., if the
FLFI Test Complete Flag is set, e.g., at task 728, the display conveys to the
user that the down
key 20 is active, e.g., by displaying an image corresponding to that key, such
as an image of a
downwardly pointing arrow (e.g., down arrow 1004 in the screen shots in Figure
13). While in
state 720, pressing the down key 20 causes the code to branch to a decision at
840 as to whether
the FLFI Test has already keen performed, i.e., whether the FLFI Test Complete
Flag is set. If
the down key 20 is pressed while the FLFI Test Complete Flag is not set, the
code remains in
state 720 and waits for the user to press the star key 18, which will cause
the code to take a
measurement of battery voltage, via branch 722. If the down key 20 is pressed
while the FLFI
Test Complete Flag is set, the code branches at 842 to state 732, discussed
above, in which the
results of the FLFI Test are displayed. Thus, from state 720, the user may
back up to the
previous test step (the end of the NLFI Test) by pressing the up key 19 and,
if the FLFI Test has
already been performed, the user may redo that test by pressing the star key
18, or may skip the
test (thereby retaining the data and results from the previous execution of
that test) by pressing
the down key 20.
32
=
CA 02507543 2005-05-17
[ 0 0 9 2] While in state 732, in which the results of the FLFI Test are
presented to the user,
pressing the up key 19 causes the code to branch at 844 to state 720,
discussed above, in which
the user is prompted to adjust the vehicle into the FLFI condition. While in
state 732, if the
Diode Ripple Test has already been performed, i.e., if the Diode Ripple Test
Complete Flag is
set, e.g., at task 758, the display conveys to the user that the down key 20
is active, e.g., by
displaying an image corresponding to that key, such as an image of a
doWnwardly pointing
arrow. Screen 1018 of Figure 13 shows a display of the results of a
hypothetical FLFI Test
before he Diode Ripple Test has been performed, i.e., with the Diode Ripple
Test Complete Flag
cleared. Screen 1020 of Figure 13 shows a display of the same FLFI Test
results, with the Diode
Ripple Test Complete Flag set, i.e., after the Diode Ripple Test has been
performed at least once
since the tester 10 was last powered up. Note the presence of down arrow 1004
in screen 1020
that is not in screen 1018, indicating that the down arrow key is active and
may be used to skip to
the results of the Diode Ripple Test.
[ 0 0 9 3] Thus, while in state 732, pressing the down key 20 causes the
code to branah to a
decision at 850 as to whether the Diode Ripple Test has already been
performed, i.e., whether the
Diode Ripple Test Complete Flag is set. If the down key 20 is pressed while
the Diode Ripple
Test Complete Flag is not set, the code remains in state 732 and waits for the
user to press the
star key 18, which will cause the code to branch to the beginning of the Diode
Ripple Test, via
branch 734. If the down key 20 is pressed while the Diode Ripple Test Complete
Flag is set, the
code branches at 852 to state 762, discussed above, in which the results of
the Diode Ripple Test
are displayed. Thus, from state 732, the user may back up to the previous step
(state 720) by
pressing the up key 19 and, if the Diode Ripple Test has already been
performed, the user may
redo that test by pressing the star key 18, or may skip the test (thereby
retaining the data and
results from the previous execution of that test) by pressing the down key 20.
(0 0 9 4] While in state 750, which is the start of the Diode Ripple Test,
pressing the up key
19 causes the code to branch at 854 to state 732, discussed above, in which
the results of the
FLFI Test are presented. While in state 750, if the Diode Ripple Test has
already been
performed, i.e., if the Diode Ripple Test Complete Flag is set, e.g., at task
758, the display
conveys to the user that the down key 20 is active, e.g., by displaying an
image corresponding to
that key, such as an image of a downwardly pointing arrow (e.g., down arrow
1004 in the screen
shots in Figure 13). While in state 750, pressing the down key 20 causes the
code to branch to a
33
CA 02507543 2012-07-19
decision at 860 as to whether the Diode Ripple Test has already been
performed, i.e., whether the
Diode Ripple Test Complete Flag is set. If the down key 20 is pressed while
the Diode Ripple
Test Complete Flag is not set, the code remains in state 750 and waits for the
user to press the
star key 18, which will cause the code to take a measurement of battery
voltage, via branch 752.
If the down key 20 is pressed while the Diode Ripple Test Complete Flag iis
set, the code
branches at 862 to state 762, discussed above, in which the results of the
Diode Ripple Test are
displayea. Thus, from state 750, the user may back up to the previous test
step (the end of the
FLFI Test) by pressing the up key 19 and, if the Diode Ripple Test has already
been performed,
the user may redo that test by pressing the star key 18, or may skip the test
(thereby retaining the
data and results from the previous execution of that test) by pressing the
down key 20.
[0 0 9 5] While in state 762, in which the results of the Diode Ripple Test
are presented to
the user, pressing the up key 19 causes the code to branch at 864 to state
750, discussed above, in
which the user is prompted to adjust the vehicle into the Diode Ripple
condition. While in state
762, the display conveys to the user that the down key 20 is active, e.g., by
displaying an image
corresponding to that key, such as an image of a downwardly pointing arrow.
Screen 1022 of
Figure 13 shows a display of the results of a hypothetical Diode Ripple Test.
Note the presence
of down arrow 1004 in screen 1022, indicating that the down arrow key is
active and may be
used to skip to the last state 770. Thus, while in state 762, pressing the
down key 20 causes the
code to branch via branch 866 to state 770. Thus, from state 762, the user may
back up to the
previous step (state 750) by pressing the up key 19 and advance to the next
step (state 770) by
either pressing the star key 18 or by pressing the down key 20.
[0096] While in state 770, which is All Tests Complete state, pressing
the up key 19
causes the code to branch at 868 back to state 762, discussed above, in which
the results of the
Diode Ripple Test are presented. This screen is shown as screen 1024 in Figure
13.
[0 0 9 7 ] Therefore, while in state 770, after all of the tests have been
performed, it takes
twelve (12) presses of the up key 19 to move from state 770 back up to the
beginning at state 602
(state 770 back to state 762 back to state 750 back to state 732 back to state
720 back to state 702
back to state 690 back to state 676 back to state 662 back to state 624 back
to either state 634 or
34
CA 02507543 2012-07-19
state 606 back to state 602) and takes seven (7) presses of the down key 20 to
move back down
from state 602 to state 770 (state 602 down to state 624 down to state 676
down to state 702
down to state 732 down to state 762 down to state 770). This user interface of
the present
invention greatly facilitates the user reviewing results of and redoing, if
necessary, previously
performed tests with the tester 10. In the alternative, the tester 10 can be
coded so that while in
state 770, after all of the tests have been performed, it takes twelve (12)
presses of the up key 19
to move from state 770 back up to the beginning at state 602, and takes twelve
(12) presses of the
down key 20 to move from state 602 back down to state 770.
[0098] The Starter Test was previously discussed in the context of task
522 in Figure 10
and tasks 602-624 in Figures 11A-11B. Referring now to Figure 12, additional
information
about the Starter Test is provided, focusing more on the preferred testing
method and less on the
user interface than the previous discussions. The Starter Test begins at task
900 in Figure 12.
The Starter Test routine first prompts the user at 902 to turn the engine off
and to press the star
key 18 when that has been done. The user pressing the star key 18 causes the
code to branch at
904 to the next task 906, in which the base battery voltage Vb is measured
using the voltmeter
circuit 100. Additionally, a crank threshold voltage Vref is calculated by
subtracting a fixed value
from the base voltage Vb, e.g., Vref = Vb - 0.5 VDC. In the alternative, the
crank threshold
voltage Vi.ef can be determined by performing another mathematical operation
with respect to the
base voltage Vb, e.g., taking a fixed percentage of the base voltage Vb. In
any event, a value
corresponding to the threshold voltage Vref is transferred from the processor
42 to the DAC 80
via bus 81 to cause the DAC 80 to output the threshold voltage Vref at output
83b as one input to
comparator 82b. In this state, after the voltage at output 83b stabilizes, the
comparator 82b
constantly monitors the battery voltage, waiting for the battery voltage to
drop to less than (or
less than or equal to) the threshold level Vref.
[0099] Next, at step 908, the user is prompted to either start the engine
of the vehicle
under test or press the star key 18 to abort the starter test. Next, via
branch 910, the code enters a
loop in which the processor 42 periodically polls the input corresponding to
comparator 82b to
determine if the battery voltage has dropped to less than (or less than or
equal to) the threshold
level Vref and periodically polls the inputs corresponding to switches 18-21
to determine if any
CA 02507543 2012-07-19
key has been pressed. Thus, at decision 912, if the output 85b of comparator
82b remains in a
HIGH state, the processor tests at 914 whether any key has been pressed. If
not, the processor 42
again tests the comparator to determine whether the comparator has detected a
battery voltage
drop, and so on. If at test 914 a key press has been detected, the message
"Crank Not Detected"
is displayed at 916 and the routine ends at 918.
35a
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 -17
[0 0 1 0 0] On the other hand, at decision 912, if the processor 42
determines that the output
85b of comparator 82b has transitioned from a HIGH state to a LOW state, then
the battery
voltage has dropped to less than the threshold level \Tref and the processor
branches via 920 to
code at 922 that waits a predetermined period of time, preferably between
about 10 milliseconds
and about 60 milliseconds, more preferably about 40 milliseconds, and most
preferably 40
milliseconds, before beginning to sample the battery voltage, i.e., the
cranking voltage. Waiting
this period of time permits the starter motor to stabilize so that the
measured voltage is a stable
cranking voltage and not a transient voltage as the starter motor begins to
function. Additionally,
the code at 922 also sets a variable N to 1 and preferably displays a message
to the user via
display 24, e.g., "Testing." The variable N is used to tack the number of
samples of cranking
voltage that have been taken.
[0 0 1 0 1] Next at 924 the cranking volts V, are measured using voltmeter
100 and the
measured cranking voltage is stored by processor 42 as V,(N). Then the most
recently measured
cranking voltage sample V(N) is compared to the value corresponding to the
threshold voltage
Vf that was previously used at step 912 to determine the start of the cranking
cycle, at 926. On
the one hand, if at 926 the battery voltage is still less than Vref, then it
is safe to assume that the
starter motor is still cranking and the measurement V(N) represents a cranking
voltage.
Accordingly, the processor next at 928 determines if eight (8) samples have
been taken. If so,
the code branches at 930 to task 932. If not, then N is incremented at 934 and
another cranking
voltage sample is taken and stored at 924 and the loop iterates.
[0 0 1 0 2] On the other hand, if at 926 the battery voltage has risen to
the extent that it is
greater than Vi,f, then it is safe to assume that the car has started and it
is meaningless to
continue to measure and store battery voltage, because the battery voltage
samples no longer
represent a cranking voltage. Accordingly, the processor next at 936 tests to
determine if only
one sample has been collected. If so, then the code branches to task 932. If
not, then the
processor 42 has taken more than one measurement of battery voltage and one
voltage may be
discarded by decrementing N at 938 under the assumption that the Nth sample
was measured
after the car had started (and thus does not represent a cranking voltage),
and the code continues
to task 932.
[ 0 0 0 3 ] At 932, the N collected cranking voltages are averaged to
determine an average
cranking voltage V. At this stage, the rest of Figure 12 is essentially like
that shown in Figure
36
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
11A, except that a table of threshold values is set forth in Figure 12. If the
average cranking
voltage Vc"g is greater than 9.6 VDC, then the cranking voltage is deemed to
be "OK" no matter
what the temperature is, and the code branches at 946, displays a
corresponding message at 948,
and ends at 950. On the other hand, if the average cranking voltage Vcavg is
less than 8.5 VDC,
then the battery voltage during starting ("cranking voltage") is deemed to be
"Tow" no matter
what the temperature is, i.e., there might be problems with the starter, and
the code branches at
940, displays a corresponding message at 942, and ends at 944. Finally, if the
average cranking
voltage is between 8.5 VDC and 9.6 VDC, then the processor 42 needs
temperature information
to make a determination as to the starter. Accordingly, the processor 42 at
step 952 prompts the
user with respect to the temperature of the battery with a message via display
24 such as,
"Temperature above xx ?" where xx is a threshold temperature corresponding to
the average
measured cranking voltage from the table 954 in ,Figure 12. For example, if
the average cranking
voltage Vcavg is between 9.1 VDC and 9.3 VDC, the user is preferably prompted
to enter whether
the battery temperature is above 30 F. Similarly, if the average cranking
voltage Vcavg is
between 9.3 VDC and 9.4 VDC, the user is preferably prompted to enter whether
the battery
temperature is above 40 F. In the alternative, the processor 42 can
interpolate between the
various temperatures in the table in 954. For example, if the average cranking
voltage Vcavg is
9.2 VDC, the user can be prompted to enter whether the battery temperature is
above 35 F and if
the average cranking voltage V:" is 9.35 VDC, the user can be prompted to
enter whether the
battery temperature is above 45 F. On the one hand, if the user indicates that
the battery
temperature is greater than the threshold temperature, then the code branches
at 956, displays a
corresponding message at 942, and ends at 944. On the other hand, if the user
indicates that the
battery temperature is less than the threshold temperature, then the code
branches at 958,
displays a corresponding message at 948, and ends at 950.
(0 0 1 04 ] In another exemplary embodiment, hand-held portable tester 10'
comprises
Substantially the same system, hardware and software/logic described above in
connection with
tester 10, except that hand-held portable tester 10' comprises additional and
or modified
software/logic for testing storage batteries, vehicle charging systems and
vehicle starting systems
in accordance with the exemplary methodologies described in more detail below.
0 0 1 0 5] Figure 14 illustrates another exemplary methodology 1100 of a
testing device for
testing one or more of the following: a battery, a starting system, and/or a
charging system.
37
CA 02507543 2012-07-19
Preferably the user connects the tester 10' across the battery prior to
initiating the test. The
methodology begins at block 1102 and proceeds to block 1104 where the user is
prompted to
select the desired test to be performed. Preferably the separately selectable
tests include an "in-
car" battery test, a "bench" (out-of-vehicle) battery test, a starting test
and a charging test. The
desired test can be selected by using virtually any user interface, for
example, using the up/clown
arrow keys 19, 20 respectfully, to highlight the desired test and then
pressing the "*" ("star") key
18 to select the desired test.
(001 0 6]
As previously mentioned, exemplary testing techniques and methodologies have
been described in detail above for performing the tests referenced in the
methodology 1100 and
those techniques and methodologies are not fully reproduced below. At block
1106 an in-car
battery test has been selected. Upon selection of the in-car battery test at
block 1106, the testing
device obtains in-car test parameters. The in-car test parameters are used to
tweak, or adjust,
these results to account for the battery being connected to the vehicle.
Alternatively, the
parameters are default parameters and need only be modified for the bench
test. At block 1114
the user is prompted to identify the rated CCA of the battery being tested.
Identifying the rated
CCA of the battery can be accomplished by, for example, using the up/down
arrow keys 19, 20
to increment the displayed CCA value, and using the star key 18 to select the
correct value.
Preferably, the user is prompted at block 1116 to enter or select a
temperature or temperature
range, such as for example, above 32 F. or below 32 F. Again this can be
easily accomplished
by using virtually any user interface, for example, using the arrow keys 19,
20 to highlight the
selection and pressing the star key 18 to select the temperature range.
Alternatively, the test can
be performed without entering the temperature range, and only prompt the user
to select the
temperature range if the battery fails the test without compensating for the
temperature. The
tester 10' performs a battery test, preferably a small-signal battery test
such as an impedance-
based or resistance-based battery test, on the battery at block 1118. The
battery test is preferably
the same as the impedance-based battery test described above in connection
with Figures 2, 4C,
and 4D. Other battery tests may be used in addition or in the alternative,
such as load tests,
38
CA 02507543 2012-07-19
battery voltage bounce-back tests, etc. During the battery test, the tester
10' obtains raw test
data, e.g., one or more values representing battery impedance (or resistance)
and/or battery open
circuit voltage. Some, or all, of the raw test data is used to calculate the
test result(s). The tester
calculates the battery test result(s) and preferably also calculates a
measured CCA value at
38a
CA 02507543 2005-05-17
block 1120. At block 1122 the calculated battery test result(s) is displayed,
and if desired, the
calculated measured CCA is also displayed. Preferably, other data, such as,
for example, battery
open circuit voltage, is also displayed at block 1122.
[0 010 7 ] Block 1110 indicates the selection of a bench battery test, i.e.
the battery is out of
the vehicle and thus, is not connected to the vehicle. Upon such a selection,
the tester 10
retrieves bench test parameters. Just as with the in-car parameters, the bench
parameters are
used to adjust or tweak the test results so that the result does not take into
effect variables
associated with the battery being connected to the vehicle. Alternatively,
these parameters are
default parameters that are replaced if the user selects the in-car test
parameters. Upon retrieval
of the bench test parameters, the methodology proceeds in the same manner as
that described
above with respect to the in-car battery testing procedures. Thus, the user is
prompted to input
the rated CCA at block 1114. Optionally, the user is also preferably prompted
to select a
temperature range at block 1116, if necessary, and a battery test is performed
at block 1118 to
obtain raw test data. Just as above, the battery test result(s) and measured
CCA are calculated
at block 1120 and the output is displayed at block 1122.
[0 0 10 8] Preferably upon completion of the battery test, a determination
is made whether
the user would like to run another test at block 1124. The determination is
made by, for
example, a user selection. If the user chooses not to run another test, the
methodology ends at
block 1126. If the user chooses to run another test, the methodology loops to
block 1104 and the
user is prompied to select another test. Optionally, the code at 1124 may
automatically loop
back to the menu at 1102 or 1104 without first querying the user as to whether
the user wishes to
perform another test.
[0 010 9] Block 1128 indicates a starting test has been selected. In short,
the starting test
for tester 10' may be the same as the exemplary starter tests described above
in connection with
Figures 11 and 12 for tester 10, and will not be described again in detail
here. In the alternative,
the method of Figure 12 may be used except, at Step 932, if the average Vc is
between. 8.5 V and
9.6 V, the user is prompted to bench test the starter rather than enter a
temperature for the tester
10' to make a determination as to whether or not the cranking voltage is
acceptable or not. Upon
completion of the starting test, and the display of the starting test results
(e.g., cranking volts test
results), preferably just as above the user is prompted to determine whether
the user desires to
run another test at block 1124. Again, in the optionally, the code at 1124 may
automatically
39
CA 02507543 2005-05-17
loop back to the menu at 1102 or 1104 without first querying the user as to
whether the user
wishes to perform another test.
[0 0 1 1 0] Block 1130 illustrates the selection of the charging test. In
short, the charging test
for tester 10' may be the same as the exemplary charging tests described above
in connection
with Figures 10 and 11A-11D for tester 10, except the Curb-Idle test discussed
above is
eliminated and the diode ripple test is performed at 2000 RPM instead of 10q0
RPM (using
either High-Load or Lights-Only load). Thus, the charging test for tester 10'
may be a method
that is suinmarized as follows: (1) the voltage across the battery is measured
at Fast-Idle, No
Load and displayed, (2) the voltage across the battery is measured at Fast-
Idle, High-Load and
displayed, and (3) the diode ripple voltage is measured at Fast-Idle and
either High-Load or
Lights-Only load. Thus, the individual charging tests for tester 10' may all
be done at Fast-Idle
(e.g., 2000 RPM). The tester 10' preferably promptly displays each result as a
function of the
one condition under which a voltage was measured; none of the test results for
any of the
charging system tests for tester 10' depend on the test results of any of the
other of the tests. As
with the tests shown in Figures 11A-11D and described in connection with those
figures, the
code in the tester 10' preferably permits the user to go back and review the
results of any of the
individual charger tests and also potentially permits the user to re-do any of
the individual tests
or keep the existing test data and results for that step.
[0 0 1 1 1] More specifically with reference to Figure 14, at block 1132
the user is instructed
to turn off all loads, such as, for example, the lights, the fan motor and
heater, and increase the
RPM to a fast idle, such as for example, 2000 RPM. Preferably, the testing
device detects that
the engine is revved by the user pressing the "*" key and measures the voltage
that is being
developed across the battery by the charging system at block 1134. Optionally,
the testing
device automatically detects that the engine is revved. The testing device can
automatically
detect that the engine is revved by, for example, sensing an increase in
voltage being generated.
The voltage measurement(s) are displayed at block 1136. In addition;
preferably the tester 10'
indicates whether the no load/fast idle voltage measurement is satisfactory at
block 1136.
Preferably, the testing device proceeds to block 1138 after the displayed
results have been
viewed. This is accomplished by, for example, pressing the star key 18 to
continue.
Alternatively, a timer or other suitable method can be used to continue to
block 1138.
CA 02507543 2012-07-19
[00112] At bock 1138 the user is prompted to fully load the charging
system. The
charging system is fully loaded by, for example, turning on the lights,
heater, and fan motor. In
addition, the user is instructed to again increase the RPMs of the engine to a
fast idle, e.g., 2000
RPM. Upon detection of the fast idle, the testing device measures the voltage
across the battery
at block 1140__Preferably, the- testing-device-1-0'-also-measures -the-ripple
at block-1142 and
displays the measurements at block 1146. Preferably the tester 10' indicates
whether the full
load/fast idle measurement is satisfactory and whether the ripple measurement
is ok. In an
alternative embodiment, the ripple test is performed independently from the
full load/fast idle
battery voltage measurement. In such a case, it is preferable that for the
ripple test the load
include only the lights (or some other load that is relatively consistent
between many vehicles)
and again the diode ripple is tested with the engine at fast idle. Upon
displaying the results at
block 1146, a determination is made at block 1124 regarding whether an
additional test is
desired. If it is determined that no other tests are required the methodology
ends at block 1126.
Optionally, the code at 1124 may automatically loop back to the menu by
branching to task 1102
or 1104.
[00113] The embodiment of the hand-held portable tester 10 described in
detail above is
capable of testing multiple types of batteries. However, the embodiment of the
hand-held
portable tester 10 described above tests all the batteries using the same
equation(s) stored in the
software/logic. Different types of batteries, however, may have different
characteristics than
standard flooded lead-acid batteries and therefore, a tester may more
accurately determine the
condition of the battery by using battery type test logic that contains
equations that are tailored to
the specific type of battery. The embodiment of the hand-held portable tester
10' described
below allows a user to more accurately test a plurality of types of batteries,
such as, for example,
standard flooded lead-acid batteries and absorbed (or absorptive) glass mat
("AGM") batteries by
using battery type test logic tailored to the specific types of batteries. In
addition, preferably
different equations are provided for different types of battery constructions
within each general
type of battery, such as, for example, "AGM Spiral" or "AGM Flat Plate."
41
CA 02507543 2012-07-19
I0 0 1 1 4] The hand-held portable tester 10' preferably performs the
battery test substantially
as was described above, hi this embodiment, however, the hand-held portable
tester 10'
performs two or more different battery tests on the battery and stores the
results. The tester 10'
also preferably displays the plurality of test results of the different
battery tests for the one
battery being tested. The tests are performed using battery type test logic.
Each of the plurality
of tests performed on the battery use battery type test logic that includes
logic tailored for a
different type of battery. Tlius, for example, the hand-held portable tester
10' can be configured
to test a plurality of batteries, such as, for example, "Standard" and "AGM
Spiral" and "AGM
Flat Plate" batteries. In this example, the hand-held portable tester 10' is
connected to the battery
and conducts a battery test for a "Standard" battery, conducts a battery test
for an "AGM Spiral"
battery, and conducts a battery test for an "AGM Flat Plate" battery. In the
alternative, the tester
10' may perform a subset of these tests (e.g., tests for a Standard battery
and an AGM Spiral
battery) or a superset of these tests. The hand-held portable tester 10'
calculates and preferably
outputs (e.g., displays) test results for each progratnmed type of battery and
preferably calculates
and outputs the measured CCA for each programmed type of battery. Thus, in
this embodiment,
for each battery tested the tester determines and outputs three test results,
one for each possible
type of battery. On the one hand, if all the test results are the same (e.g.,
"Good" or "Pass") the
user need not know the battery type to know the state of the battery under
test. In this case, the
tester may, in the alternative, display a single battery test result to the
user. On the other hand, if
some of the test results are different, the user need only look at the battery
and identify its type to
determine which battery test result correlates to that battery.
[00115] Exemplary output displays for such a hand-held portable tester 10'
configured to
test a plurality of battery types are illustrated in Figures 15A and 15B.
Output display 1150 and
output display 1166 are preferably displayed on a screen, such as the liquid
crystal display
(LCD) 26 discussed above in connection with the hand-held portable tester 10.
The output,
however, can be in any form including visual and audio and electronic outputs.
Output display
1150 illustrates one embodiment wherein the measured CCA 1152 is the same for
three tested
types of batteries. In such a case, the measured CCA 1152 is preferably
displayed on the first
line, with the battery type 1154, 1158, and 1162 in a first column below the
measured CCA 1152
42
CA 02507543 2012-07-19
and condition of the battery listed in a second column below the measured CCA
1152. In this
example, the first battery type is "Standard" 1154, and has a test result or
condition of "Good"
1156. The second battery type is "AGM Spiral" 1158 has a test result or
condition of "Charge."
The third battery type is "AGM Flat" 1162 and the test result or condition is
"Replace" 1164.
Similarly, display 1166 provides two columns, wherein the first column 1168
contains the
42a
CA 02507543 2005-05-17
'battery type, and the second column 1170 contains the test result, or
condition of the battery and
the measured CCA.
[00116] Optionally, a means to shift or adjust the display is provided,
such as for example
a selector switch or hot key (not shown). In this embodiment, the hand-held
portable tester 10'
performs the same multiple tests for the different types of batteries. The
output to the display is
masked or adjusted, however, so that the only one test result is visible. This
may be
implemented, for example, by having a memory-mapped display, having the
selector switch or
hot key select which region in a display space is displayed, and having each
separate test result
be mapped to a different display space (all not shown). For example, if a
selector switch is set at
"AGM Spiral" the display is shifted so that the only result that is visible to
the user is the result
that was obtained using the "AGM Spiral" equations. One advantage of such a
tester is that if
the battery is tested with the selector switch in the wrong position, the user
merely needs to move
the switch to promptly cause the tester to display the correct battery test
result. Therefore, the
user does not need to initiate and run a new test on the battery to obtain the
correct result. For
example, if the switch is positioned to display "AGM Spiral" battery type
results and the test is
run on a standard battery, the user need only move the switch to the
"Standard" battery position
to view the correct result for a standard battery type.
[00117] Optionally, the means to adjust or mask the display provides for
a selected
number of battery type tests to be displayed and masks any remaining battery
type tests. This
embodiment is extremely useful for testers that are configured to test
multiple types of batteries
that are not common in the market place, thus the results of the un-common
battery types can be
hidden for most instances, and displayed only when needed.
[00118] Still yet, optionally, results of the multiple tests can be
displayed on different
screens. In this exemplary embodiment (not shown) each screen displays the
"battery type," the
"test result, the "battery voltage", and the "measured CCA." In addition, the
screen contains a
message to press "*" to "Exit," and press the down arrow "4" to scroll to the
next screen.
[00119] Figure 15C illustrates an exemplary methodology 1200 of a battery
test for use in
a hand-held portable tester 10. The hand-held portable tester 10 is connected
across a battery,
preferably with a Kelvin-Type connection 28. The methodology begins at block
1207 and a user
selects battery test at block 1208. At block 1210, the tester 10 prompts the
user to enter test
information, such as rated CCA of the battery, and ambient temperature. The
information may
43
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
be entered by selecting from a predetermined list by using a user interface,
such as the up/down
arrow keys 19, 20 and the star key 18 discussed above in the context of tester
10. The
methodology proceeds to block 1212 and the tester performs a first battery
test tailored to a first
type of battery, such as for example, a small signal standard flooded acid
battery test using
impedance-based battery type test logic that includes the standard flooded
acid battery
equation(s). Next, a second battery test tailored to a second type of battery
is cionducted at block
1214, such as, for example a small signal AGM Spiral test using the impedance-
based battery
type test logic that includes the AGM Spiral battery equation(s). The
methodology proceeds to
block 1216 and performs yet another battery test for a third type battery,
such as for example,
AGM Flat, again using impedance-based battery type test logic that includes
the AGM Flat
battery equation(s). While the methodology has been described using three
types of batteries, it
should be apparent from this disclosure that this methodology may be practiced
using as few as
two different battery types, and alternatively as many different battery types
as desired.
[00120] Preferably, at block 1217 the hand-held tester calculates the test
tesults/conditions
of the battery for each battery type test and calculates the measured CCA.
This step may be
carried out contemporaneously with the hand-held tester 10' performing the
plurality of battery
type tests described above, e.g., calculating a result for the step 1212 test
before or during the
step 1214 test and calculating a result for the step 1214 test before or
during the step 1216 test.
At block 1218 Ale results are preferably displayed for all of the battery type
tests. In the event of
a large number of battery type tests conducted, it may be necessary to split
up the results and
display a partial listing on the first screen and a partial listing on one or
more following screens.
Alternatively, the output on the display can be shifted or masked as described
above and tied to a
selector switch or hot key, as described above. The methodology ends at block
1219, e.g., by
branching back to a main menu or branching to a main menu after first
prompting the user to
select a particular battery test result for future display and/or encryption
and/or printing.
[00121] In another embodiment, the hand-held portable tester 10' provides
an encrypted
output. The encrypted output may be used to provide a remote user with the raw
data and/or test
condition data 'I:obtained by the hand-held portable tester 10 that was used
to perform the field
test. In addition, test information may be encrypted allowing the end user to
determine if the
field test was performed correctly. The term "encrypt" and variations thereof
as used herein is
used in its broadest sense and includes encoding and/or enciphering. The
output code is
.44
CA 02507543 2005-05-17
preferably a numeric code, an alphanumeric code, or an alphabetic code.
Preferably, the output
code is in a format that is not easily decrypted by the user of the hand-held
portable tester 10'.
More preferably, a very strong encryption can be used making it virtually
impossible for a
typical user to decrypt the code without having access to specific decryption
software.
[0 012 2 ] An exemplary methodology 1220 for providing an encrypted output
is illustrated
in Figure 16. The methodology may include performing one or more battery tests
or may use
information, e.g., test condition information and/or raw test data, saved from
an earlier battery
test. The methodology 1220 is an example of the former and begins at block
1222 with the user
selecting a battery test to be performed at block 1224. As described above,
preferably the user
selects the battery test by using the up and down arrow keys 19, 20
respectfully, to highlight the
desired battery test and uses the star key 18 to select the battery test. At
block 1226, the user is
instructed to input or select test information. The test information includes,
for example, the
rated CCA of the battery and the ambient temperature range. Again, the
information is
preferably selected by the user as described above. Other test information can
be input or
selected at block 1226, such as, battery type, battery temperature, battery
standard, rated battery
voltage, battery location, i.e. bench test, or in-car test, etc.
[0 012 3 ] Next the hand-held portable tester 10' performs a battery test
at block 1228.
During the battery test, the tester 10 obtains raw test data. The raw test
data includes information
that is used to calculate test results and measured CCA values. Preferably,
the raw test data
includes data, I such as, for example, measured battery open circuit voltage,
pulse width
modulations ("PWMs") expressed in "ticks" that are also used to calculate the
battery open
circuit voltage, cold cranking amps (CCA) PWM ticks used to calculate the
measured CCA,
tester calibration values, etc. The hand-held portable tester 10 uses the raw
test data to calculate
the condition of the battery or test result at block 1232. In addition,
preferably, the tester 10
calculates the measured CCA value at block 1232 as well. The calculated test
result, and
calculated measured CCA are displayed at block 1234. Preferably, some test
information and/or
raw data is also displayed at block 1234.
(00124] The hand-held portable tester 10' then encrypts, e.g., encodes or
enciphers, the test
information and/or the raw data obtained while performing the test at block
1236 (or previously
obtained from a prior battery test). Preferably, the generated code is an
alphanumeric code that
includes both the test information and the raw data. Alternatively, the hand-
held portable tester
=
CA 02507543 2012-07-19
codes the test information separately from the raw test data and thus,
generates two codes, one
for the test information and one for the raw test data. In any event the
encrypted, or coded, data
is output at block 1238. Preferably the output is displayed on the LCD 26,
however, any suitable
output, such as a printed output or an audio output or an electronic output
may be used. The
methodology ends at block 1240, e.g., by branching back to a main menu.
[00125]
After the code is generated, preferably through use of encryption techniques,
a
decryption methodology 1250, such as is illustrated in Figure 17, is
preferably used to decrypt
the information in the code and re-calculate the test results and measured CCA
corresponding to
the data decrypted from the code, which may be substantially the same as
displayed by the tester
10'. The decryption methodology 1250 begins at block 1252. The code,
preferably an encrypted
code, is entered into a device having a processor and memory, such as a
standard computer
system (not shown) at block 1254. In one embodiment, non-encrypted, or non-
coded
information is also entered into the computer, along with the encrypted code.
The code is
decrypted or decoded at block 1256 and the test information and raw test datai
measured by the
tester 10' are obtained. In an alternative embodiment, the code contains only
the raw test data,
and the test information is provided in a non-coded format. In any event, the
raw test data, and
preferably the test information, is used to recalculate a test result at block
1258. The test result
may be substantially the same as the test result that was calculated and
previously provided by
the hand-held portable tester 10'. In addition, preferably the decryption
methodology 1250
calculates the measured CCA from the test information and the raw test data at
block 1260.
Again, this newly calculated measured CCA may be substantially the same as the
calculated
measured CCA that was previously provided by the hand-held portable tester
10'. Finally, the
computer preferably outputs the newly calculated result at block 1262.
Preferably the test result
that is output is displayed on a monitor, however, the output can be any type
of output, such as a
print out. Preferably, the output at block 1262 contains the recalculated test
result, recalculated
measured CCA, and decrypted test information. Other information can be output
at block 1262
as well, such as, for example, some or all of the decrypted raw test data.
Some or all of this
information mai), be stored on the computer system or computer network for
later use, e.g., in a
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CA 02507543 2012-07-19
database or spreadsheet program.
[00126]
In yet another preferred embodiment a hand-held portable tester 10" comprises
substantially the same system, hardware and software/logic described above for
performing the
/
46a
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
testing functions. The hand-held portable tester 10" comprises additional and
or modified
software/logic for testing storage batteries, vehicle charging systems and
vehicle starting systems
in accordance with the exemplary methodologies described in more detail below.
[0 0 1 2 7 ] Figure 18 illustrates yet another methodology 1800 of a
testing device 10" for
testing one or more of the following: a battery, a starting system, and/or a
charging system.
Preferably the user connects the tester device 10" across the battery prior to
initiating the test.
The methodology begins at the start block 1802 and proceeds to block 1804
where the user is
prompted to select the desired test to be performed. Preferably the selectable
tests include an
"in-car" battery test, a "bench," or out-of-car battery test, a starting test
and a charging test. Just
as described above, the desired test can be selected by, for example, using
the up/down arrow
keys 19, 20 respectfully, to highlight the desired test and then pressing the
"*" ("star") key 18 to
select the desired test.
[00128] As previously mentioned, exemplary testing techniques and
methodologies have
been described in detail above for performing the tests referenced in the
methdology 1800 for
tester 10" and those techniques and methodologies are not fully reproduced
below. At block
1806 an "in-car" battery test has been selected. Upon selection of the in-car
battery test at block
1806, the testing device verifies that the key is in the off position. The
testing device verifies
that the key is off in any manner, such as, for example, monitoring the
voltage at the battery.
The testing device proceeds to block 1812 and checks the state of charge of
the battery.
Alternatively, it a bench battery test is selected at block 1804, the
methodology proceeds to
block 1810, indicating that a bench test was selected, and proceeds to block
1812.
[ 00129] At block 1812 the tester device checks the state of charge of the
battery. The state
of charge of the battery is determined by measuring the battery voltage. A
decision on which
way to proceed is made at block 1814 based on the battery state of charge. If
the state of charge
is equal to, or less than, a first threshold voltage, such as, for example
12.3 the methodology
provides a "Bad Cell, Replace" output at block 1817. Alter the user
acknowledges the output, by
for example, pressing the star key, the methodology returns to the main menu
at block 1804.
[00130] k at block 1814 the state of charge is greater than the first
threshold voltage of,
for example 12.3 volts, and less than a second threshold voltage, such as, for
example, 12.4 volts
the methodology proceeds to block 1816, where a determination is made of
whether the battery .
has been previously been charged. The determination permits the tester 10" to
operate in a
;47
CA 0 2 5 0 7 5 4 3 2 0 0 5 - 0 5 - 1 7
manner to prevents a user from being stuck in a so-called "charge and retest
loop" and may be
made by, for example, prompting the user respond to a question as to whether
the battery has
been recently charged. If the battery has been previously charged, the
methodology proceeds to
block 1817 and the "Bad Cell, Replace" output is displayed. If it is
determined at block 1816
that the battery has not been charged, the methodology proceeds to block 1818.
If at block 1814,
it is determined that the battery voltage is greater than or equal to the
second threshold voltage,
such as, for example, 12.4 volts, the methodology proceeds to block 1818.
(0 0 1 1 1] At block 1818, the user is prompted to identify the rated CCA
of the battery being
tested. Identifying the rated CCA of the battery can be accomplished by, for
example, using the
up/down arrow keys 19, 20 to increment the displayed CCA value, and using the
star key 18 to
select the correct value. Preferably, the user is prompted at block 1819 to
enter or select a
temperature or temperature range, such as for example, above 32 F. or below
32 F. Again this
can be easily accomplished by, for example, using the arrow keys 19, 20 to
highlight the desired
range and pressing the star key 18 to select the temperature range.
Alternative4f, the test can be
performed without entering the temperature range, and only prompt the user to
select the
temperature range if the battery fails the test without compensating for the
temperature. The
tester 10" performs a battery test, preferably an impedance based battery
test, on the battery at
block 1820. During the battery test, the tester 10" obtains raw test data.
Some, or all, of the raw
test data is used to calculate the test result(s). The tester 10" calculates
the battery test result(s)
and preferably Calculates a measured CCA value. At block 1822 the calculated
test result(s) is
displayed, and if desired, the calculated measured CCA is also displayed.
Preferably, other
"raw" data, such as, for example, open circuit voltage, is also displayed at
block 1822. Again,
the exemplary embodiment of the hand-held portable tester 10", like the tester
10' described
above in connection with Figures 15A-15C, is capable of testing a plurality of
types of batteries.
As discussed above, the user may be prompted to select for future use a
battery test result from
the plurality of different battery test results.
I0 0 1 3 2] Preferably upon completion of the battery test, a determination
is made whether
the user would 'like to run another test at block 1824. If the user chooses
not to run another test,
the methodology ends at block 1826. If the user chooses to run another test,
the methodology
loops to block 1804 and the user is prompted to select another test.
48
CA 02507543 2005-05-17
[ 0 0 1 3 3] Block 1828 illustrates the selection of the charging test,
which is illustrated in
Figure 19. At block 1902 the user is instructed to start the engine if the
engine has not already
been started. At block 1904 the user is instructed to turn off all loads, such
as, for example, the
lights, the fan motor and heater, and increase the RPM to a fast idle, such as
for example, 2000
RPM. The testing device detects that the engine is revved, as described above,
and measures the
voltage that is being developed by the charging system at block 1906. The
Measurements are
displayed at block 1908. The tester 10 indicates whether the no load/fast idle
measurement is
satisfactory at block 1908. The testing device proceeds to block 1910 after
the displayed results
have been viewed. This is accomplished by, for example, pressing the star key
18 to continue.
Alternatively, a timer or other suitable method can be used to continue to
block 1910.
[ 0 0 1 3 4] At bock 1910 the user is prompted to load the charging system.
The charging
system is loaded by, for example, turning on the lights, heater, and fan
motor. In addition, the
user is instructed to increase the RPMs of the engine to a fast idle. Upon
detection of the fast
idle, the testing device measures the voltage at block 1912. The measurement S
are displayed at
block 1912. The tester 10, preferably indicates whether the full load/fast
idle measurement is
satisfactory at block 1912 as well. The testing device proceeds to block 1916
after the displayed
results have been viewed. This is accomplished by, for example, pressing the
star key 18 to
continue. Alternatively, a timer or other suitable method can be used to
continue to block 1916.
At block 1916, the ripple test is performed. The charging system is partially
loaded by, for
example, tumink on the head lights at block 1916. In addition, the user is
instructed to increase
the RPMs of the engine to a fast idle. Upon detection of the fast idle, the
testing device measures
the ripple at block 1918. The results are displayed at block 1920. Upon
displaying the results at
block 1920 the methodology proceeds to block 1894 (Figure 18) and a
determination is made at
block 1824 regarding whether an additional test is desired. If it is
determined that no other tests
are required the methodology ends at block 1826.
[0 0 1 3 5] Figure 20 illustrates an exemplary starter test. The starter
test is selected at block
1804 (Figure 18) and an indication is made that the starter test has been
selected at block 1830.
The user is insttlucted to make sure that the ignition is off and that the
engine is off at block 2002.
At block 2004, the user is instructed to turn the ignition on, but not to
start the engine. At block
2006, a determination is made whether the vehicle has a diesel engine. The
determination is
made by, for example prompting the user to respond, or by monitoring the
voltage on the battery.
=
49
CA 02507543 2012-08-29
If it is determine that the engine is a diesel, the user is instructed to wait
until the engine is ready
to start at block 2008 before proceeding to block 2010. If at block 2006, it
is determined that the
engine is not a diesel, the methodology proceeds to block 2010.
[00136] At block 2010 the user is instructed to crank the engine. The
voltage is measured
during the cranking of the engine at block 2012 and the measured voltage is
displayed at block
2012. Upon completion of the starting test, and the display of the starting
test results, the user is
prompted to determine whether the user desires to run another test at block
1824.
[0 0 13 71 While the present invention has been illustrated by the
description of
embodiments thereof, and while the embodiments have been described in some
detail, it is not
the intention of the applicant to restrict or in any way limit the scope of
the appended claims to
such detail. Additional advantages and modifications will readily appear to
those skilled in the
art. For example, a tester according to the present invention may be
configured to perform
multiple battery tests on a battery, each test corresponding to a different
type of battery, and
provide one result if the raw data indicates that the battery is good (or
replae, or charge and
retest, etc.) irrespective of the type of battery being tested. Therefore, the
invention in its broader
aspects is not limited to the specific details, representative apparatus and
methods, and
illustrative examples shown and described. Accordingly, departures may be made
from such
details without departing from the scope of the claims.
