Early Spectro™ test results

The Spectro™ system promises to solve some of the shortcomings of AC conductance. Spectro™ was tested on randomly sampled automotive batteries of various states-of-health conditions. Automotive batteries serve the purpose well because of easy availability. To demonstrate the accuracy, we tested six typical automotive batteries (A, B, C, D, E, and F) with various state-of-health conditions. The batteries are flooded lead acid of the same model.

Prior to testing, the batteries were fully charged and the actual Cold Cranking Ampere (CCA) reading was established using standards developed under SAE J537. The batteries were then re-tested using AC conductance and Spectro™ ** methods. Figure 1.illustrates the comparison between AC conductance and Spectro™.
___________________
*Batteries are non-linear systems. The equations, which govern the battery's response becomes linear below 25mV/cell at 25°C. This voltage is called the battery thermal voltage.
** The test was conducted by using model-specific matrices.


Figure 1: Comparison readings of CCA and Spectro™. The blue markers compare readings with AC conductance. Spectro™ follows the CCA measurements very closely.

Batteries arrive for testing in all conditions, including low state-of-charge (SoC). With AC conductance, the charge level may affect the CCA readings to such a degree that the test results become meaningless. Figure 2 compares the estimated CCA readings at different charge levels using AC conductance and Spectro™ test methods.

Figure 2: CCA rapid-tests at various SoC. Spectro™ provides robust readings from 40-100% SoC. The readings with AC conductance are strongly affected by the charge level.

Ideally, the lines should flow perfectly horizontal. Spectro™ departs only moderately within the 40-100% SoC range. In comparison, the CCA approximations using AC conductance show a strong departure from the horizontal line, caused by the charge level.

In Figure 3, we evaluate the CCA readings of batteries F, D and C at various charge levels (0-100% charge). The high performing battery F provides solid readings from 10-100% SoC; battery D is steady from 40-100% SoC. The poorly performing battery C provides less stable readings.



Figure 3: Spectro ™ generated CCA approximations of three test batteries at various SoC levels.
Battery F provides solid readings from 10-100% SoC; battery D is steady from 40-100% SoC.


Conclusion
The Spectro™-based technology has the potential of becoming a new test standard for automotive, traction and stationary batteries. Complex hardware and software will, however, result in a higher unit price compared to AC conductance. Spectro™ may initially be reserved for applications in which other methods do not serve adequately and alternative methods are being sought.

Spectro™ is being examined to measure the state-of-charge and state-of-health of stationary batteries without applying a full discharge. Accurate measurements may be obtained by non-invasive means in just a few seconds. Further, Spectro™ will be studied for on-line monitoring to deliver continuous state-of-charge and state-of-health readings while the battery is in service. Work will be in progress utilizing Spectro to inspect the integrity of fuel cell stacks. Spectro™ may one day detect flaws in metals and other solid substances.

Cadex plans to release the first commercial Spectro™ units in a hand-held tester for automotive batteries towards the end of 2003. Testers for stationary batteries are scheduled for 2004. Research is continuing to allow testing a broad range of battery sizes and chemistries. Attempts are being made to reduce the test time from two minutes to about 20 seconds. Patents for Spectro™ have been applied for.

NEWS RELEASE - QuickTest™ gets better
January 2002

Cadex is introducing QuickLearn (Q-Learn), a program that simplifies preparing a new battery for quick testing. In the past, the matrix to run the Cadex QuickTest™ program could only be obtained by scanning a battery on the 5-hour Learn program. The new Q-Learn now generates the matrix in 5 minutes.

What does the matrix do? The matrix is a battery-specific data set needed to run the Cadex QuickTest™ program. Featured on the Cadex 7200 and 7400 battery analyzers, QuickTest™ reads the state-of-health of a battery in 3 minutes.

The matrices are commonly included with the purchase of the Battery Adapters and no further preparation is needed. However, on a new battery or when using a universal battery adapter, the matrix needs to be created.

To create a matrix, the user sets the correct C-Code on the analyzer (chemistry, voltage and mAh rating) and runs a 'known good battery' on the Q-Learn program. At completion of the program, the matrix is stored in the battery adapter together with the C-Code and the analyzer displays FINISHED.

You may ask what is a 'known good battery'? Any new battery that provides a normal runtime or reads 90% capacity and better on a battery analyzer is considered good.

Can I improve on the QuickTest matrix? The matrix created by Q-Learn will provide precise battery diagnostics on all batteries, and accurate numeric reading on batteries dwelling in the 80 to 100% performance level. If you need accurate numeric readings on weak batteries, scan batteries with capacities between 50% and 75% (or in between) on the Learn program. The Learn program lasts 5 hours per scan.

The matrix and C-Code are stored in the Battery Adapter and configure the analyzer to the correct settings when installed. The codes can be copied to other adapters, erased and re-entered. Each adapter stores 10 C-Codes with matrices to service 10 distinct batteries. Q-Learn is available with firmware Version 3.
For field upgrade, contact Cadex Electronics Inc.

NEWS RELEASE - The Cadex Boost program energizes batteries back to life
January 2002

A common Li-ion battery failure is caused by excessive low discharge. The internal safety circuit deactivates and the battery appears dead. Cadex has added the Boost program to the Cadex 7000 Series analyzers that applies a gentle current to re-energize the battery. Once the voltage reaches charging range, a full service program engages to condition the battery.

To prove the effectiveness of the Boost program, Cadex has tested a large number of supposedly dead Li-ion polymer batteries from various manufacturers. When first measured, these batteries had no voltage and appeared dead. Charging the packs in their respective chargers was unsuccessful. After boosting, most batteries accepted normal charge. The analyzer applied a full service program and attained capacities of 80 percent and higher in most batteries. All restored packs performed flawlessly when returned to service.

Boosting Lithium-based batteries is safe. However, if the cell voltage has fallen to 1.5 volts and has dwelled in that state for several days, a recharge should be avoided. A very deep discharge may form copper shunts in the cells, which can develop an electrical short. The Cadex battery analyzers identify such faults and terminate the service.

Nickel-based batteries can also benefit from the Boost program. Older batteries or those with advanced cycle count exhibit high self-discharge, a condition that cannot be corrected. If activated with Boost and left unattended, the battery may revert back to its former state.

NEWS RELEASE - Cadex FlexArm™ simplifies battery connection
January 2002

Connecting batteries for testing has been a challenge for technicians and engineers alike. Many so-called 'engineering specials' with springs and levers have appeared, only to disappear because of impracticality. Cadex solved the problem with the FlexArm™ adapter.

Snapped into the Cadex 7200 and 7400 battery analyzers, the Cadex FlexArm™ accommodates virtually any battery type. By lowering the two arms, narrow and awkwardly placed contacts can be reached. Magnetic guides on an insulated steel floor keep the battery in any position, horizontally or vertically. The gold plated Pogo contacts are field replaceable. Self-locking hardware allows adjustments of desired tension in the wrist, elbow and shoulder joints. A spring-loaded temperature sensor monitors the battery temperature. Banana jacks allow cable connection on batteries fitted with a plug rather than flat contacts.

The Cadex FlexArm™ requires setting of battery chemistry, voltage and mAh rating. The Edit key on the Cadex battery analyzer prompts the user to enter the specifications. The battery setting (C-Code) is stored in the FlexArm™. There is room for 10 battery types, each of which can be given a unique name.

The Cadex FlexArm™ allows quick testing of batteries. The matrix associated with the Cadex QuickTest™ can be obtained by running a working battery on the analyzer's Learn program. Best results are achieved by learning several batteries with different state-of-health conditions. The matrix is stored in the FlexArm™, together with the C-Code, which can be copied to other adapters.

Once programmed, the user simply selects the appropriate C-Code (1-10) and connects the battery. A common Cadex QuickTest™ matrix may be used for batteries that have similar chemistry, voltage and capacity rating. If the readings are inaccurate, a separate matrix will be required.
The Cadex FlexArm™ is best suited for technicians who deal with constantly changing batteries. Large groups of identical batteries (fleet environment) are best served with custom adapters.

NEWS RELEASE- QuickTest™ measures battery state-of-health
December 2001

Cadex Electronics has introduced a technique to measure the state-of-health of a battery in three minutes. Based on inference technology, the Cadex Quicktest™ uses battery unique matrices that are obtained through a "trend learning" process using artificial intelligence. The ability to self-learn enables the system to adapt to new battery chemistries without changing hardware.

Quicktest™ is available on the Cadex 7200 (two-station) and 7400 (four-station) battery analyzer/ reconditioners. The system accommodates Li-ion, NiMH, NiCd and lead acid batteries; the required charge level is 20 to 90 percent. If outside this range, the analyzer automatically applies a brief charge or discharge.
The matrix obtained through Learn is stored in the battery adapters that also contain the battery parameters (C-Codes) to configure the analyzer. Popular battery adapters include the matrix at time of purchase. For other batteries, the matrix can be obtained by running a battery on the analyzer's Learn program. Best results are achieved by learning several batteries with varying state-of-health conditions. Once attained, the matrix can be copied to other battery adapters. Testing a battery with a properly learned matrix achieves an accuracy of +/-5 percent on most batteries.

The Cadex 7000 Series battery analyzers are user-programmable and perform such functions as priming, reconditioning, fast charging, life testing and boosting. Boost energizes batteries that have fallen asleep due to low discharge. Cadex analyzers are designed to service batteries for cell phones, two-way radios, laptops, scanners, medical equipment, video cameras, power tools and defense instruments.

NEWS RELEASE - Entrepreneur of the Year - 2001
September 2001

Isidor Buchmann, President of Cadex Electronics, is a finalist for the 2001 B.C. Entrepreneur of the Year Award. The award is the "pre-eminent reward and recognition program for entrepreneurial talent…it showcases the innovation and drive which fuels our nation's business spirit." (Author: www.eoy.ca)

One of three finalists in the Technology and Communications category, Isidor was previously nominated for the award in 1998. The Vancouver Sun, The National Post, BC Business Magazine and Corporate Living magazine have all featured interviews with Mr. Buchmann in connection with his nomination. The Awards Banquet for the Pacific region of Canada will be held Thursday, October 4, 2001 at the Vancouver Trade and Convention Center.

NEWS RELEASE - "Batteries in a Portable World"
May 2001

Cadex Electronics has released the second edition of Batteries in a Portable World - A Handbook on Rechargeable Batteries for Non-Engineers. The 300-page book addresses the strengths and limitations of the modern battery and explains which chemistry is most appropriate for each application. The reader will learn about recommended maintenance methods, prolonging battery life and available methods to restore weak batteries.

Batteries in a Portable World is easy to read and makes minimal use of technical jargon. It is especially helpful to the busy professional who needs a crash course in understanding the battery. The book retails for $29.50US and is available through bookstores or www.buchmann.ca.

The author Isidor Buchmann has studied the behavior of rechargeable batteries in practical, everyday applications. With many articles to his credit, Mr. Buchmann has delivered technical papers on battery maintenance technology at seminars and conferences throughout the world. He is the founder and CEO of Cadex Electronics Inc. and is sharing his battery knowledge on the Battery Information Website www.buchmann.ca.