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Introduction
The battery produces electricity to operate the starting motor and ignition system while starting the engine. Discharging - Battery changes chemical energy into electrical energy - Current flow out of the battery Charging - Electrical energy is converted into chemical energy
Automotive Batteries
An automotive battery is a type of rechargeable battery that supplies electric energy to an automobile. Automotive batteries (usually of lead-acid type) provide a nominal 12-volt potential difference by connecting six galvanic cells in series. Each cell provides 2.1 volts for a total of 12.6 volt at full charge. Lead-acid batteries are made up of plates of lead and separate plates of lead dioxide, which are submerged into an electrolyte solution of about 35% sulfuric acid and 65% water.
To operate starter motor, ignition system, relays during cranking of the engine
2.
Supply all of the electrical power for the car whenever the
engine is not running
3.
Store electrical energy for extended periods Act as a voltage stabilizer that smoothen the current
To allow dynamic memory and alarm system to remain active when the vehicle is left for a period of time
When engine is stopped, the battery operates all electrical devices . When engine is starting, the battery operates the starter motor discharged current flows from the battery
After the engine starts, the alternator operates all electrical devices & recharges the battery at the same time - charging current flows into the battery
Right after the engine is started, if the electrical load is too great for the alternator, the battery contributes electrical power - discharged current flows from the battery
While the car is running, almost all power is supplied by the alternator. An imbalance in the relationship between the battery and the alternator may cause the battery to become discharge.
Heavy duty
Electrolyte - Sulfuric acid & distilled water(H2O) Electrolyte that are used in batteries today have a specific gravity (S.G) of either 1.26 or 1.28 (at 20C) when the battery is fully charged . The difference is due to the particular ratio of distilled water to sulphuric acid the electrolyte having a S.G of 1.26 contains 65% distilled water and 35% sulphuric acid while the electrolyte having a S.G of 1.28 contains 63% distilled water and 37% sulphuric acid
Batteries that are made in Japan are given a battery identification code according to a Japan Industrial Standard (JIS) The code indicates the battery capacity, dimensions and the position of the positive terminal (right or left side)
38820 R/L
46824R/L 50824 R/L 55824 R/L 32 C 24 R/L 50D20R/L 55 D 23 R/L 65 D 23 R/L 48 D 26 R/L 55 D 26 R/L
28
36 36 36 32 40 48 52 . 40 48
95D31R/L
95E41 R/L 105E41 R/L 115E41 R/L 130E41 R/L 115F51 150 F 51 145 F 51 170 F 51
64
80 83 88 92 96 108 112 120
F
G H
213
213 220
182
222 278
CELL THEORY
A lead-acid cell works by a simple principle: when two different metals are immersed in an acid solution, a chemical reaction creates an electrical pressure. Lead dioxide (Pb02) has a positive electrical charge. The other metal is sponge lead (Pb). It has a negative electrical charge. The electrolyte, acid solution is a mixture of sulfuric acid (H2SO4) and water (H20).
If a conductor and a load are connected between the two metals, current will flow. This discharging will continue until the metals become alike and the acid is used up. The action can be reversed by sending current into the cell in the opposite direction. This charging will continue until the cell materials are restored to their original condition.
The electromotive force (EMF) generated by one cell is approximately 2.1 V, regardless of the quantity or size of the plates Since automobile batteries have six cells that are connected in series, their nominal output EMF is about 12 V
ELECTROCHEMICAL REACTION
A lead-acid storage battery can be partially discharged and recharged many times. There are four stages in this discharging/charging cycle. 1. CHARGED: A fully charged battery contains a negative plate of sponge lead (Pb), a positive plate of lead dioxide (Pb02), and electrolyte of sulfuric acid (H2SO4) and water (H20).
ELECTROCHEMICAL REACTION
2.
DISCHARGING : As the battery is discharging, the electrolyte becomes diluted and the plates become sulfated The electrolyte divides into hydrogen (H+) and sulfate(S042-) The ion hydrogen (H+) combines with oxygen (02-) from the positive plate to form more water (H20). The sulfate combines with the lead (Pb) in both plates to form lead sulfate (PbS04)
Chemical reaction equation (Discharging) At Positive Plate: Pb02+ S042- + 4H+ + 2ePbS04 + 2H20 At Negative Plate: Pb + S042PbS04 + 2eNet reaction equation Pb02 + 2H2S04 + Pb 2PbS04 + 2H20
ELECTROCHEMICAL REACTION
3. DISCHARGED: In a fully discharged battery, both plates are covered with lead sulfate (PbSO4) and the electrolyte is diluted to mostly water (H2O).
ELECTROCHEMICAL REACTION
4. CHARGING: During charging, the chemical action is reversed. Sulfate (S042-) leaves the plates and combines with hydrogen (H+) to become sulfuric acid (H2SO4). Free oxygen (0) combines with lead (Pb) on the positive plate to form lead dioxide (Pb02). Gassing occurs as the battery nears full charge, and hydrogen bubbles out at the negative plates, oxygen at the positive.
Chemical reaction equation (Charging) At Positive Plate: PbS04 + 2H20 Pb02 + S042- + 4H+ + 2eAt Negative Plate: PbS04 + 2ePb + S042Net reaction equation 2PbS04 + 2H20 Pb02 + 2H2S04 + Pb
1.Reserve capacity rating Defined as the time in minutes for the fully charged battery voltage to fall to 10.5 V with a constant load of 25 A at 80F (26.7'C) - how long the battery can sustain a 25 A discharge. Batteries used on various Toyota vehicles have RC ratings ranging from 55 to 115 minutes.
Standard NS40ZAL
NS60 NS70 N70
275
325 420 445 355 360
55023 DIN
Internal Resistance
All batteries have internal resistance but it is very low. Eg; 0.005 ohm for a good condition battery and may be 0.05 ohm for a fair condition battery. The internal resistance of the battery causes the battery's output voltage to decrease As battery age, internal resistance increase V = E-Ir
Batteries Self-discharge
Over a period of time, a battery which is not used will gradually lose its charge due to several factors;
1.
2. 3.
Internal chemical reaction due to antimony deposits on negative plate. Leakage currents due to dirt and fume to form conducting path Sediment at the bottom of the battery
Self discharge at the rate of 0.2% to 1 % of the battery Ah per day, depending on the age of the battery and temperature.
To avoid high temperature discharge, Store in cool place Charge battery every month if not use Once fully discharge it may not fully recover even after recharge
Sulphation
Under normal discharging, fine crystals of lead sulphate are formed on the plates and by charging, these are convertible If battery is left discharge for long period, the crystal turns into coarse lead sulphate which are not easily convertible Sulphation causes the reduction in battery Ah and also slowdown the charging process causing the battery to become very hot
In minor sulphation cases, extended period of charging at low current will improve but in serious cases the battery is condemned due to internal short
Safety precautions :
Wear gloves and safety glasses. Remove rings, watches, other jewelry. Never use spark-producing tools near a battery. Never lay tools on the battery. When removing cables, always remove the ground cable first.
Battery Maintenance
Battery Maintenance includes: 1. Making visual inspection of the battery 2. Cleaning the battery top, terminal and cable clamp 3. Testing the battery 4. Charging the battery
Corrosion around the terminals and clamps can be cleaned by using a battery-terminal brush (with a solution of baking soda and water)
The two main causes of battery troubles are overcharging and undercharging
1. Overcharging Causes damage to the plate and shortens battery life. The high voltage can also damage other electrical and electronic components For a vent-cap battery - shown by frequent addition of water For a maintenance-free battery - shown by low electrolyte level Other signs of overcharging: 1. Voltage> 15 volt 2. Electrolyte dry too fast 3. Vigorous bubbles 4. Pungent smell 5. Surface always wet 6. Bulb always burnt 7. Battery bulge
All batteries have a limited life, but some conditions can shorten that life.
1.ELECTROLYTE LEVEL: A low electrolyte level exposes active material, and any sulfate hardens and resists chemical action. Loss of electrolyte may be caused by a cracked case, poor maintenance (not adding water when needed). Severe overcharging which causes high internal heat and excessive gassing. Too much electrolyte is just as bad. Overfilling dilutes the electrolyte and spillage may corrode battery terminals.
4.CYCLING: Repeated cycling from fully charged to fully discharged and back - may cause loss of active material from the positive plates. This reduces battery capacity and its useful life.
TEST RESULTS:
1. A fully charged battery will have specific gravity readings around 1.265. 2. Specific gravity readings below 1.225 usually mean the battery is run down and must be charged.
1 . If the battery has just been charged, turn on the headlamps for one minute to remove any surface charge. 2. Turn headlamps off and connect the voltmeter across the battery terminals. 3. Read the voltmeter. A fully charged battery will have an open-circuit voltage of at least 12.6 volts. A dead battery will have an open-circuit voltage of less than 12.0 volts.
Charge-indicator Condition
It is a built-in hydrometer to show the condition and state of charge of the battery. A green indication means the battery is over 65% charged. If indicator is dark, the battery is less than 65% charged- the battery should be charge. If the indicator is light yellow or clear, the electrolyte level is low- if it happen to a maintenance-free battery, replace the battery.
Heavy-Load test
1. 2.
3. 4.
5.
After the battery passes the state of charge test, check for the performance by battery capacity test or battery load test. This measures terminal voltage while the battery is discharging at high rate. To perform the test; The load is applied using a tester (Sun VAT-40) that includes a voltmeter, an ammeter and a carbon-pile resistor. Load the battery by turning the Load Increase control until the ammeter reads 3 times the amp- hour (AH) rating or onehalf the cold-cranking ampere (CCA) rating. After 15 seconds, read the voltage and remove the load. Battery voltage should read 9.6 volts or higher. If below the minimum, recharge the battery and retest it. If fails again, discard the battery
Battery Charging
A battery charger must be used if the alternator cannot charge the battery adequately due to long period of no use.
Slow Charging A slow charger feeds small amount of current into the battery. Charging time is longer (about 12 hours at 10 amps). The chemical action inside the battery is improved and the active materials are plated back on the battery plates better.
Fast Charging /Boost Charging A fast charger forces a high current flow into the battery for rapid recharging. Fast charging allow engine starting in a matter of minutes. A high charging current can be used below the gassing voltage. If exceeded, the battery starts to gas and leads to water loss in battery. Done for emergency case only because it can cause damage to battery
3. PLATE AREA: Small plates are charged faster than large plates. When sulfation covers most of the plate area, the charging system may not be able to charge the battery.
4. IMPURITIES: Dirt and other impurities in the electrolyte increase charging difficulty. 5. GASSING: Hydrogen and oxygen bubbles form at the plates during charging. As these bubble out, they wash away active material, cause water loss, and increase charging difficulty.
Charging rate
Jump-starting
Proper connections in jump starting a dead battery with a booster battery to prevent sparks. 1. First, connect cable(red) to the two positive terminals. 2. Then, connect one end of the jumper cable (black) to the negative terminal of the booster battery. 3. Connect the other end to a good ground away from the dead battery. 4. If a spark occurs, it won't be near the battery.
Battery Storage
1. 2. 3. 4. 5.
3.
4. 5.
Disconnect the ground cable from the battery Loosen the clamp bolt then pull the clamp from the terminal If the clamp sticks, use a battery-clamp puller Disconnect the positive cable from the battery Remove the battery
To install the battery: 1. Do not reverse the terminal connections 2. Reconnect the positive cable first then the ground cable
THE END
Any question?
Assignment
Differentiate between battery slow charging and fast charging, and give an advantages and disadvantages of each methods.