Automotive Battery Al tha end of chapter students will be able to: ® Identify components of aulorotive battery. *& Understand warking and types of batteries. > Perform different tests on battery. Identify causes of failure and foctors affecting bottery life. M > Understand about charging af battery. 2.1 INTRODUCTION * The storage battery is the heart of the charging circuit (Fig. 2.1). It is an electrochemical device for producing and storing electricity. * Avvehicle battery has several important functions, which are as follows: 1. It must operate the starting motor, ignition system, electronic fuel injection system and other electrical devices for the engine during engine cranking and starting 2. It must supply ALL of the electrical power to the vehicle when the engine is not running. 3. It must help the charging system to provide electricity when current demands are above the output limit of the charging system 4. Tt must act as a capacitor (voltage stabilizer) that smoothes current flow through the electrical systern. 5. It must store energy (electricity) for extended periods * The type of battery used in automotive, construction and mater ial-handling equipment is a lead-acid cell-type battery. This type of battery produces direct current (dc) electricity that flaws in only one direction. * When the battery Is discharging (current flawing out of the battery), it changes chemical energy into electrical energy, thereby, releasing stored énergy. During charging (current flowing into the battery from the charging system), electrical energy is converted into chemical energy. « The battery can then store energy until the vehicle requires it 20Automotive Separators Cross-section of a typical automotive battery BATTERY TYPES AND CONSTRUC 2.2.1 Lead-Ai Battery e The lead-acid cell-type storage battery is built to withstand severe vibrations, cold weather, engine heat, corrosive chemicals, high current discharge and prolonged periods without use. To test and service batteries properly, you must understand battery construction. * The construction of a basic lead-acid cell-type battery is as follows: Battery elements, Battery case, cover and caps, Battery terminals, Electrolyte. 1. Battery Element * The battery element is made up of negative plates, positive plates, separators, and straps (Fig. 2.2). « The element fits into a cell compartment in the battery case. Mast automoti batteries have six elements Negative group 2 volts Positive group Negative plate Separator Positive plate . AV AUB Tau |___________Fig. 2.2: Battery element“Automotive Electrical & Electronics Systems 23 Automotive Battery Each cell compartment contains two kinds of chemically active lead plates, known as positive and negative plates. The battery plates are made of GRID (stiff mesh framework) coated with porous lead. These plates are insulated from each other by suitable separators and are submerged in a sulfuric acid solution (electrolyte). Charged negative plates contain spongy (porous) lead (Pb) which is gray in colour. Charged positive plates contain lead peroxide (PbO2) which has a chocolate brown colour. These substances are known as the active materials of the plates. Calcium or antimony is normally added to the lead to increase battery performance and to decrease gassing (acid fumes formed during chemical reaction). Since the lead on the plates is porous like a sponge, the battery acid easily penetrates into the material. This aids the chemical reaction and the production of electricity Lead battery straps or connectors run along the upper portion of the case to connect the plates. The battery terminals (post or side terminals) are constructed as part of ane end of each strap. To prevent the plates from touching each other and causing a short circuit, sheets of insulating material (micro porous rubber, fibrous glass or plastic- impregnated material), called separators, are inserted between the plates. These separators are thin and porous so the electrolyte will flow easily between the plates. The side af the separator that is placed against the positive plate Is grooved so the gas that forms during charging will rise to the surface more readily, These grooves also provide room for any material that flakes from the plates to drop to the sediment space below 2. Battery Case, Cover and Caps The battery case is made of hard rubber or a high-quality plastic. The case Must withstand extreme vibration, temperature change, and the corrosive action of the electrolyte. The dividers in the case form individual containers for each element. A container with its element is one cell. Stiff ridges or ribs are molded in the bottom of the case to form a support for the plates and a sediment recess for the flakes of active material that drop off the plates during the life of the battery, The sediment is thus kept clear of the plates so it will not cause a short circuit across them.| & Electronics Systems 24 Nigsiad Sioned erial as the container and i provides openings for the tw Automotive Elect + The battery cover is made of the same mat bonded to and seals the container. The cover battery posts and a cap for each cell. * Battery caps either screw or snap into the openings in the battery cover, The battery caps (vent plugs) allow gas to escape and prevent the electrolyte: from splashing outside the battery. They also serve as spark arresters (keep: sparks or flames away from igniting the gases inside the battery). * The battery is filled through the vent plug openings. Maintena nce-free batteries have a large cover that is not removed during normal service. * Caution: Hydrogen gas can collect at the top of a battery. If this gas Is” exposed to a flame or spark, it can explode 3. Battery Terminals * Battery terminals provide a means of connecting the battery plates to the electrical system of the vehicle. Either two round post or two side terminals can be used, * Battery terminals are round metal posts extending through the top of the battery cover. They serve as connections for battery cable ends. * Positive post will be larger than the negative post. It may be marked with red paint and a positive (+) symbol. * MNegative post Is smaller, may be marked with black ar green paint, and has a negative (-) symbol on or near it. t « Side terminals are electrical connections located on the side of the battery, They have internal threads that accept a special bolt on the battery cable end, Side terminal polarity is identified by positive and negative symbols marked on the case. 4, Electrolyte * The electrolyte solution in a fully charged battery sulfuric acid in water. Th sulfuric acid, a harge 'S a solution of concentrated is solution is about 60% water and about 40% * The electrolyte in the lead-acid storage battery has a specific gravity of 4.28, c +28), increase.‘automotive Electrical & Electronics Systems 25 Automotive Battery As a storage battery discharges, the sulfuric acid is depleted and the electrolyte is gradually converted into water. This action provides a guide in determining the state of discharge of the lead-acid cell. The electrolyte that is placed in a lead-acid battery has a specific gravity of 1,280. The specific gravity of an electrolyte is actually the measure of its density The electrolyte becomes less dense as its temperature rises, and a low temperature means a high specific gravity. The hydrometer that used is marked to read specific gravity at 80°F only. Under normal conditions, the temperature of electrolyte will net vary much from this mark. However, large changes in temperature require a correction In reading For EVERY 10° change in temperature ABOVE 80°F ADD 0.004 to specific gravity reading. For EVERY 10° change in temperature BELOW B0°F, SUBTRACT 0.004 from specific gravity reading. For example, if the hydrometer reads 1.280 and a thermometer in the cell Indicates an electrolyte temperature of 60°F, |.e. a normal difference of 20° from the normal of 80°F, To get the true gravity reading, subtract 0.008 from 1.280. Thus, the specific gravity of the cell Is actually 1.272, A hydrometer conversion chart is usually found on the hydrometer. From it, you can obtain the specific gravity correction for temperature changes above or below 80°F 2.2.2 Maintenance Free Battery Maintenance free battery incorporates several modifications over a conven- tional battery, the most significant feature is that it is sealed (except for a very small vent-hole) and requires no service attention other than ta be kept clean. The Delco-Remy Freedom maintenance free battery first appeared in America in 1971. In addition to being maintenance-free, this battery offers better cold weather starting power and improved resistance to heat and vibration damage. The antimony has been eliminated from the plate grids, which could remove four major causes of early battery failure such as overcharge, water usage, thermal-runaway and self discharge, Thermal runaway is a condition, which occurs in a conventional battery when. the battery operating temperature is high or when faulty regulation of the charging system Is combined with a rising electrolyte temperature. Qvercharge is the major cause of gassing in a conventional battery.Automotive Battery Automotive Electrical & Electronics Systems 2.6 Gang vent cap One piece cover Battery terminal Plate strap. ‘with call connector Container Element (With altemate negative and positive plates) Plate separators Fig. 2.3: Maintenance-free battery + In a maintenance free battery, lead calcium (PaCa) is used for the grid material. Therefore with the inherent assistance of the higher EMF given by this construction as it approaches full-charge, it is possible to reduce loss of water under overcharge conditions by aver 80%. * There still exists some gassing, and to encounter this gas, reservoir is formed in the container to collect the water, which returns after cooling te the main electrolyte mass, * This battery Incorporates a built-in, temserature-compensated hydrometer which indicates the relative density and leval of the electrolyte. In fact, various colours are displayed to indicate the states of charge, * The appearance of a green-coloured signal means the battery is charged and usable, whereas a green/black or black signal indicates that recharging Is necessary. * When a light-yellow signal appears, it indicates an internal fault so that the battery must not be charged or tested. Also when the battery is in this state the engine must not be started with jump leads. : should be installed in the vehicle and the alternato. correct operation. removed and bench-charged, b higher, which cannot be Provided byAutomotive Electrical & Electronics Systems 27 Automotive Battery. Other design improvements included over a conventional battery are strengthened grid supports, sealed terminal connections and stronger retention supports, These features together with a better efficiency enable this battery to be smaller and lighter than the conventional type. ‘Built-in fectractable carrying handle Negalive plate Acid absorbent low resistance glass microfibar separator Positive plate __ Fig. 2.4: Recombination electrolyte battery pee rae Fig. 2.4 illustrates a battery made by chloride, called a ‘Torque Starter’. The Recombination Electrolyte (R.E.) is used in this maintenance-free battery to reduce the formation of oxygen and hydrogen when the battery is being charged. Each plate is wrapped with a glass micro-fiber separator that absorbs, in its pores, the entire liquid electrolyte. Therefore, there is no free acid in the cell unlike conventional batteries. As the battery approaches its fully charged state, the oxygen generated at the positive plate passes through the separator pores to the negative plate, After initially reacting to form lead sulphate, the plate then changes to lead due to further charging. As a result of this action, the negative plate never attains the right potential for the liberation of hydrogen, so that no water is formed. As no free oxygen or hydrogen is released, the battery is totally sealed, except for a small pressure valve set, which opens if the battery is abused, The R.E. battery can deliver 20% more power than an equivalent conventional battery. Under the Cold Cranking Test the battery can deliver a current of 420 A, These features combined with better resistance to vibration and lightweight construction make the R.E. battery more attractive than the conventional type.Automotive Battory Automotive Electrical & Electronics Systems 28 2.2.3 Low-maintenance Type * Use of improved materials and advanced constructional Orrelimin f riadicall educed tt topping a battery peria y elther red liminated the requirement 9! f ; The batteries without techniques have with distilled water to replace lass due te evaporation this maintenance are becoming attractive. These batteries incorporate the | improved control of the charging rate, especially the voltage output, given by an alternator system as compared with a dynamo system. Gassing has been, reduced by changing the grid material from lead-antimony alloy to an alloy of lead-calcium, | « This type of lead-acid battery (Fig. 2.5) requires less attention than the { conventional type. When operated under normal temperatures and charged under suitable conditions, the electrolyte level of this battery requires | checking only once per year, or after 80,000 km running. * The construction of a low maintenance battery is similar to a conventianal type, except the change in the grid material from lead-acid antimony alloy to lead-ealcium. Since the performance characteristics are based on proven designs, the battery can be used on vehicles as an alternative to the traditional type. Negative Through the partition Vent terminal intereell connector orl Positive terminal Intercell Partition Positive plate Negative plate Heat welded id container seal Seperate i Polypropylene container nance batterya automotive Electrical & Electronics Systems 29 Automotive Battery Hybrid Battery = Hybrid battery is a revolutionary and unique concept in the field of two- wheeler batteries. Hybrid battery is a combination of latest Ultra-capacitor technology with VRLA battery. + Both these components being completely maintenance free, the user can have a hassle free ride. Furthermore Ultra-capacitor circuitry is a long life component which could last for more than the fife of the vehicle. * This feature reduces the future cost of battery to a great extent as the user has to replace only VRLA battery after 2 years which costs several times less than the tatal cost of the battery. « Nochange in the original vehicle is required to use the hybrid battery. Ultra capacitor + VRLA battery = Hybrid battery | Fig. 2.6: Hybrid battery Main Features: = Ultra-capacitor circuit is capable of giving full crank for starting the vehicle. « The purpose of VRLA battery Is to provide back-up for Ultra-capacitors. © Long life ultra-capacitor circuit * Zero maintenance. * Eco-friendly ultra capactior circuitry. = Distilled water not required. + Easy installation and testing. Comparison between “Hybrid Batteries” and “Conventional Lead-Acid Battery”: Parameter Hybrid Batteries | Conventional Lead-Acid lee | Battery Components _| Ultra-eapacttors + VRLA Battery [Lead-Acid Battery. "| Life © Ultra-capacitors: More than | 1 to 2 years if maintained 10 yrs | properly. = VRLA battery: 1 to 2 years_| Warranty + Ultra Capacitors: 3 years | 1 year. a Ls VRLA battery:1 year | contd.Automotive Battery Maintenance | + Ultra-capacitor: Not Water top-up, eccastonal required charging, contact cleaning. * VRLA battery : Occasional : Chargina Initial Nat required. Required. | Charging - a Eco-friendly 70% less lead and acid Contains lead and acid only. Applications: + Hybrid batteries can be installed on vehicles which uses respectively similar conventional lead-acid batteries. Specifications: (Ultra-capacitor and VRLA Battery combined) Parameter Hybrid 9 | Nominal voltage > i2v DC Battery used 12V, 1.3 Ah VALA 12 V, 3.4 Ah VRLA (maintenance free) | (maintenance free) Equivalent capacitance 8.33 Farad 1 Farad Min. stored eneray 600 Joules | 1200 Joules Max. with-stand voltage | 15 V DC [15 voc Max. storage temperature | 40°C 40°C Max. working 50°C 50°C | temperature Cyéle life for Ultra- 5,00,000 cycles 50,000 cyel capacitors : as Life time for Ultra- 90,000 hrs ‘h z 90,01 capacitor poe oo its Instructions while Installing On the Vehicle: * Clean battery terminals, remove Precipitation due to acid «Place hybrid battery in the space Provided on the vehicle, * Connect vehicle wires to the battery terminals and fae proper spanner. nd fasten the nuts with 4 Caution: «Ensure proper polarity (+f). * Do not short terminals. + No distilled water required.— | automotive Electrical & Electronics Systems an Automotive Battery, » When starting the vehicle in the morning or after long halt, use kick-start | aption instead of button-start. + If the vehicle does not start in first cranking, please use kick to start the venicle, | For automotive use only. BATTERY RATINGS AND SPECIFICATIONS ee i + Battery ratings were developed by the Society of Automotive Engineers (SAE) and the Battery Coundl International (BCI), They are set according to national test standards for battery performance. They let the mechanic | compare the cranking power of one battery to another. The two methods of | rating lead-acid storage batteries are the cold-cranking rating and the reserve capacity rating. FEREI Cold-Cranking Rating | The cold-cranking rating determines how much current in amperes the battery can dellver for thirty seconds at Q°F while maintaining terminal voltage of 7.2 volts or 1.2 volts per cell, This rating indicates the ability of the battery to crank @ specific engine (based of starter current draw) at a | specified temperature * For example; one manufacturer recommends a battery with 305 cold-cranking amp for a small four-cylinder engine but 2 450 cold-cranking amp battery for 2 larger V-8 engine. That means, a more powerful battery is needed to handle the heavier starter current draw of the larger engine | ri Reserve Capacity Rating | «© The reserve capacity rating Is the time needed to lower battery terminal voltage below 10.2 V (1.7 ¥ per cell] at @ discharge rate of 25 amp. This Is with the battery fully charged and at 80°F. Reserve capacity will appear on the battery as a time interval in minutes For example, if a battery is rated at 90 minutes and the charging system fails, the operator has approximately 90 | minutes (1 - 1/2 hours) of driving time under minimum electrical load before the battery goes completely dead. | « The capacity of a battery is measured in ampere-hours. The ampere-hour capacity is equal to the product of the current in amperes and the time in hours during which the battery is supplying current. The ampere-hour capacity varies inversely with the discharge current. The size of a cell is determined generally by its ampere-hour capacity.