Explain how to carry out the cell balance test?

What is cell balancing?

Cell balancing is the process of equalizing the voltages and state of charge among the cells
when they are at a full charge. No two cells are identical. There are always slight differences
in the state of charge, self-discharge rate, capacity, impedance, and temperature
characteristics. This is true even if the cells are the same model, same manufacturer, and
same production lot. Manufacturers will sort cells by similar voltage to match as close as
possible, but there are still slight variations in the individual cells impedance, capacity, and
self-discharge rate that can eventually lead to a divergence in voltage over time.
On the discharge side, the weak cells tend to have lower voltage than the other cells, due to
either higher internal resistance, or a faster rate of discharge that results from the lower
capacity. This means that if any of the weak cells hits the cell under voltage protection limit
while the pack voltage is still sufficient to power the system, the full capacity of the battery
will never be used as the pack protector will prevent over discharge which would damage the
cell by stopping the discharge of the whole pack when one cell voltage goes below the cell
under voltage threshold usually around 2.7 V.

Why cell balancing is required:

To prevent the cause of
Thermal runway
Cell Degradation
Incomplete charging of Pack
Incomplete use of Pack energy
NiCad cells are very sensitive to
overcharging and over discharging. Extreme
care must be taken when carrying out thus
process.
When a NiCad cell is overcharged even
slightly above its recommended value, the
efficiency and life cycle of the cell gets
reduced. If cell balancing is not accurate
even slight overcharging will reduce the
battery life.
As the batteries in a pack get older few cells
might be weaker than its neighbouring cells.
These week cells will be huge problem
since they will charge and discharge faster
than a normal healthy cell.
When the battery pack is being discharged,
 the weaker cells will discharge faster than
the healthy cell and they will reach the
minimum voltage faster than other cells.
Thus leading to unused capacity of pack
energy.

Tools required to carry out cell balance test :

Battery Analyser

Pc Software

Battery Test System

Battery Balancer

Types of battery cell balancing:

There are 4 types of cell balancing
1) Passive cell balance: Passive cell balancing method is the simplest method of all. It
can be used in places where cost and size are major constraints. The following are the
two types of passive cell balancing.

a) Charge shunting: In this method a dummy load like a resistor is used to

discharge the excess voltage and equalize it with other cells. These resistors are
called as bypass resistors or bleeding resistors. Each cell connected in series in a
pack will have its own bypass resistor connected through a switch

b) Charge limiting: The charge Limiting method is the

most inefficient method of all. Here only the safety and lifetime of the battery is
considered while giving up on the efficiency. In this method the individual cell
voltages are monitored continuously.

2) Active cell balance: In active balancing the excess charge form one cell is transferred
to another cell of low charge to equalize them. This is achieved by utilizing charge
storing elements like Capacitors and Inductors. There are many methods to perform
Active cell balancing. The most used methods are,

a) Charge shuttles: This method utilizes capacitors to transfer charge from high
voltage cell to low voltage cell. The capacitor is connected through SPDT
switches initially the switch connects the capacitor to the high voltage cell and
once the capacitor is charged the switch connects it to the low voltage cell where
the charge from the capacitor flows into the cell. Since the charge is shuttling
between the cells this method is called as charge shuttles.

b) Inductive converter: Another method of Active cell balancing is by using

inductors and switching circuits. In this method the switching circuit consists of a
buck boost converter. The charge from the high voltage cell is pumped in the
inductor and then discharged into the low voltage cell by using the buck boost
converter.
 3) Lossless balancing: Lossless balancing is a recently developed method that reduces
losses by reducing the hardware components and providing more software control.
This also makes the system simpler and easier to design. This method uses a matrix
switching circuit which provides the capability to add or remove a cell from a pack
during charging and discharging.

4) Redox Shuttle: The idea behind Redox shuttle is to try achieving the same effect on
lithium cells by altering the chemistry of the electrolyte of the lithium cell. This
modified electrolyte should prevent the cell from getting overcharged.

Safety prrecautions:
 NiCad batteries are generally not dangerous during normal operation and are built
sturdily enough to withstand puncture from typical damage scenarios. However, if for
some reason they are ruptured, they can be quite hazardous.

 The potassium hydroxide in NiCad batteries is an alkali solution that is dangerous and
highly corrosive to skin.

 Contact with the eyes can result in permanent eye damage.

 It is toxic if ingested. Avoid breathing the fumes in a closed area since that can lead to
irritation in the mouth, throat, and lungs.

 Long-term exposure to potassium hydroxide fumes can cause liver and kidney
disorders, and it has been identified by OSHA as a possible carcinogen.

 Anyone handling NiCad batteries should avoid contact with the inner components and
wash hands thoroughly after handling. If you have a spill, make sure to wear
protective clothing including vinyl or PVC gloves, eye goggles, and a face shield.

 Never attempt to clean up a hazardous material spill unless you have received proper
training.

Conclusion:
In conclusion, the battery cell balance is an important test to ensure that the battery is
performing at maximum capacity as well as maximum efficiency. If cell unbalance is present
then the cell balance test must be carried out.

Reference:
https://circuitdigest.com/article/cell-balancing-techniques-and-how-to-use-them
https://www.aviationpros.com/engines-components/article/10387569/nickelcadmium-
batteries-basic-theory-and-maintenance-procedures
https://www.batterypoweronline.com/blogs/why-proper-cell-balancing-is-necessary-in-
battery-packs/
NAME: VISAN NAIDU A/L KALAISELVAN ( 53106118040 )
AHMAD JUMAL RASHEED ( 53106118519 )
RAYNER RONWALD JAMES PAPANJI ( 53106118211 )
CLASS: 4 AEM 8
ASSIGNMENT NO: 1
TITLE OF ASSIGNMENT: CELL BALANCING TEST
SUBMISSION DATE: 12 FEB 2020