Research on Rapid Charging of Sealed Lead Acid Battery

M.Hazfizul Md Ali a , Fadzil Adly Ishak b

Universiti Kuala Lumpur

Malaysian Institute of Aviation Technology
Lot 2891, Jalan Jenderam Hulu, Jenderam Hulu, 43800 Dengkil

a
hazfizul@gmail.com
b
fadziladly@gmail.com

keywords : Charging, Lead Acid Battery

Abstract : This project only focus on 2 types of Lead acid battery which are, Valve Regulated
Lead Acid (VRLA), AGM type and Gel Type which is new technology for Lead Acid
Battery. The most important of this research is the method of charging of the battery. This
research is focusing on the rapid charging of the battery. This rapid charging involve with the
application of Very High Current flow from the charger to the battery. The 2 types of
batteries is being compared which one of it is reliable for rapid charging usage. All the data
of charge and discharge is being recorded. This research is mostly focus on charging
compared to discharging. The comparison of VRLA wheatear AGM and Gel type which
involve with different manufacturer of the battery is concluded in this research.

I. INTRODUCTION

The lead-acid battery has been a successful article of commerce for over a century. Its
production and use continue to grow because of new applications for battery power in energy
storage, emergency power, and electric and hybrid vehicles (including off-road vehicles) and
because of the increased number of vehicles for which it provides the energy for engine
starting, vehicle lighting, and engine ignition (SLI).[1]

Lead acid is one of the very popular battery uses very widely todays. From Automotive,
Aviation and other Engineering Industries are using this battery because of the inexpensive
price and simple to manufacture. In terms of cost per watt hours, the Lead acid battery is least
expensive especially the Sealed Lead Acid Battery (SLA).

Normally, after the battery depleted, it need to be recharge of the next operation. The normal
charging method will take a long time before the battery is really full charge. The rapid
charging is a method that already use at Europe country for their electric car. In our country,
Malaysia, the rapid charging is currently use for hand phone charging station and the
possibility of the usage can be expanded since we are undergo the electric car project and
now, the electric aircraft project.

The objectives of this project is to identify the characteristic of Sealed Lead Acid Battery, to
perform and analyse the method of charging the Sealed Lead Acid Battery and to compare
which of the battery are suitable for rapid charging. The scopes of project only cover the
Sealed Lead Acid Battery and the Charging Method as per Fig 1.

The limitations of this project are the equipment and facilities for detailed experiment are
limited. The charger provided is constant voltage charging and the current flows allow only
maximum 10 Amp to charge the 12V Batteries. The load provided are medium, which is only
60 Watt. So, we couldn’t do the deep discharge.

The most affecting factor of this project is time. Because more time spends to get the battery,
so, less time are provided to perform the experiment and test. Time was taken a lot for the
commitment of study and other subject project.

II. BASICS OF VRLA TECHNOLOGY

Not to oversimplify or appear to be too repetitive, but as most who work with batteries on a
regular basis know, in a vented lead acid (VLA) flooded cell, during float and discharge,
oxygen gas is released from the cell and the hydrogen ions move in the electrolyte to the
negative plate. There it is reduced to hydrogen gas. Some of the oxygen gas does find its way
to the negative plate where it can be recombined with the hydrogen gas and reform into
water. But both the oxygen and the hydrogen gasses not recombined are released and leave
the cell via the openings in the flame arrestor. This action results in a slow water loss, but
eventually these cells have to be refilled with distilled or ionic water. Of course, one of the
advantages of a VLA cell is that this event can be monitored and controlled, assuring that the
cells remain filled with the correct amount of electrolyte, contributing to their extended
service life. [9]

Lead Charging
Acid Method
Battery

Fig 1: Scope of Project

With valve-regulated lead-acid (VRLA) cells, there are actually two distinct actions: a liquid
one in which the hydrogen ions are transported via the electrolyte and a gaseous one. Both
play an important role in the performance of the VRLA cell. In the gaseous phase, oxygen
gas migrates to the negative plate where it is reduced to oxygen ions (O2). In the meantime,
hydrogen protons (H+) are being transported in the electrolyte to the negative plate as well.
At the negative plate the oxygen and hydrogen combine again to form water. Known as the
internal oxygen cycle, this process is called recombination of the electrolyte and defines the
principle of VRLA methodology. It is based on the principle that “the oxygen evolution rate
at the positive electrode and the oxygen-reduction rate at the negative electrode balance each
other.”

In the valve regulated cell, the water is diffused back into the mat or gel. However, it is
important to note that the internal oxygen cycle generates water from the oxygen and the
hydrogen protons, not the hydrogen gas. This is important because it shows that hydrogen gas
is not removed by the internal oxygen cycle, 5-10% of the hydrogen ions are still reduced to a
gaseous state, and this small amount of hydrogen is released through the pressure sensitive
release valves.
In the VRLA process, the electrolyte is mobilized in one of two ways, depending upon the
type of VRLA being considered.

1. The Absorbed Glass Mat (AGM) VRLA utilizes a microporous felt known as a glass mat
to immobilize the electrolyte. The electrolyte then fills the smaller pores of the mat by
capillary action, but a good portion of the larger pores remain unfilled. Specific gravity also
plays a role here, but we’ll deal with that in a moment.

2. The Gelled Electrolyte (GEL) forms by the addition of silica dioxide (SiO2) to the sulfuric
acid (SO4) and water (H2O). In this type, the gel shrinks which open crevices that run
through the electrolyte. Void space is available around the electrodes, allowing fast transport
of the oxygen gas.

III. RAPID CHARGING

When rapidly charging the battery, a large charge current is required in a short time for
replenishing the energy which has been discharged. Therefore, some adequate measures such
as the Control of charge current is required to prevent overcharging when the rapid charging
is complete. Basic requirements for rapid charging are as follows:

 Sufficient charging should be made in a short time for fully replenishing the
amount discharged.
 Charge current should be automatically controlled to avoid overcharge even on
prolonged charging.
 The battery should be charged adequately in the ambient temperature range of
32°F (0°C) to 104°F (40°C).
 Reasonable cycle life of charge/discharge should be secured.
 Typical methods to control charging so as to satisfy the above requirements
follow.
 Two-step constant voltage charge control method
 IV. METHODOLOGY

The flowchart of the project is shown on fig 2. All the methods of this project are mostly
focus on research, test and experiment of battery. The project undergoes a lot of internet
research, test and experiment of the battery, discussion with advisors and finally report of
work. All the data during test and experiment are recorded every 5 minutes interval. The data
then being analyse and compared.

The experiments begin with discharging the battery and see the discharge state of the battery.
The discharge use 60 Watt load and connected with ammeter in series. The reading of the
current, voltage and temperature are taken in 5 minutes interval. Then, the charging process
begins. It begins with knob 1 charging of the charger which give current about 1.3 to 3 amps,
depends on the battery. The temperature, voltage and current readings are taken in 5 minutes
interval. Then, the battery is being discharged. The battery is continued to be charge but with
knob 5, which give current about 6 to 10 amps. The temperature, voltage and current readings
are taken in 5 minutes interval.
 Start

Brainstorming

Discussion

Research

Data Process

Test and Experiment

Data Analyse

Report

End

Fig 2: Flowchart of project

 IV. RESULT AND DISCUSSION

The results for knob 1 charging taken are temperature, voltage and current are in Graph 1, 2
and 3 below.

40
35
30
25
20 G-Wheel
Osima
15 Koyoko
10
5
0
0

20
40
60
90

0
0
0
0
0
0
0
0
0
0
0
0
0
0
10

12

18
21

27

33

42

48
15

24

30

36
39

45

51
Graph 1: Temperature Comparison

The temperature Graph 1 shows that when charging, all the battery temperature increased.
After the battery close to full charge, the temperature starts to maintain. The G-Wheel battery
gives the lowest temperature increment in this experiment followed by Koyoko Battery.

3.5

3 G-Wheel Koyoko

2.5 Osima

1.5

0.5

0
0 10 20 30 40 50 60 70 80 90 10 0 11 0 12 0 13 0 1 4 0 1 5 0 1 6 0 17 0 18 0

Graph 2: Current Comparison

The Graph 2 shows that the current are sudden increase to the optimum limit of charging
current of the battery specifically. The Osima only 1.5 amps, koyoko max 3 amps while G-
Wheel is 1.3 Amps. Then, the current are gradually goes down because the battery is about to
full charge. It means that the battery voltage are achieving 12 volts.

The Graph 3 shows the voltage of all the batteries. When start charging, the battery are
sudden increase to close to 12 volts. Koyoko battery from 4.6 Volts to 12.8 volts, Osima
battery from 9.8 to 13.2 volts while G-Wheel battery from 6 to 10.8 volts. Then, all the
battery are constantly increase in voltage until it fully charged state.

16
14
12
10
Gwheel
8
6 Koyoko

4 Osima

2
0
0
10
20
30
40
50
60

80
90
0
0
0
0
0
0
0
0
0
0
70

10
11
12
13
14
15
16
17
18
19

Graph 3: Voltage Comparison.

The results for knob 5 charging taken are temperature, voltage and current in Graph 4, 5 and
6 below.
 50
45
40
35
30
25
20 G-Wheel
15 Koyoko
10 Osima
5
0
0 10 20 30 40 50 60 70 80 90 10 0 11 0 1 2 0 13 0 1 4 0 18 0

Graph 4: Temperature Comparison

Graph 4 shows the temperature comparison of the batteries when charged at knob 5 which
current 6.5 to 9 amps to the batteries depends to the charger and the battery. The temperature
for these three batteries is increasing higher than knob 1 charging. The behaviour of the
temperature rise are constantly increase. But the Osima Battery increase much higher
compared to G-Wheel and Koyoko.

Graph 5 shows the state of current comparison between these three batteries. The G-Wheel
battery receive higher current compared to the others because of its capacity and capability is
higher. The graph shows that the higher current applied to the batteries, the much more faster
the charging process will be completed.
 10
9 G-Wheel
Koyoko
8
Osima
7
6
5
4
3
2
1
0
0 10 20 30 40 50 60 70 80 9 0 1 0 0 11 0 12 0 1 3 0 14 0 18 0

Graph 5: Current Comparison

16
14
12
10
8 G-Wheel Koyoko

6 Osima

4
2
0
0 10 20 30 40 50 60 70 80 90 0 0 0 0 0 0
10 11 12 13 14 18

Graph 6: Voltage Comparison

The graph 6 shows the voltage comparison of these three batteries. The voltage ‘jump’ higher
than knob 1 charging at the first 5 minutes and then it stabilize until full charge. The voltage
then drop after charger is disconnected and let to be stabilized.
 V. ANALYSIS

The process of Charging and Discharging of these 3 types of battery which are:-

1. Types : Valve Regulated Sealed Lead-Acid Rechargeable Battery

Manufacturer : Gwheel

Specification : 12V, 12 AH/20 HR

2. Types : Dry Charge Absorbed Glass Matt (AGM) Battery

Manufacturer : OSIMA

Specification : 12 V, 7 AH/10HR

3. Types : Gel/Nanogel battery

Manufacturer : KOYOKO

Specification : 12V, 7 AH/10HR

These three types of battery is lead acid battery which has been chosen for replacement of
lithium battery for this research. The research is about applying large current to charge the
battery rapidly. But, due to the limitation of the battery that according to manufacturer
recommendation, we do not exceed the temperature limit because it will only give a negative
effect to the battery, damage, and capacity reduced and so on.

The current supplies to the battery were according to the charger, the chargers itself have
determine the maximum allowable current to charge the battery. That is why; the current
applied to each of the battery during charging is different. Maximum allowable current flows
from the charger for 12V battery are 10 Amp. GWheel battery is start from 9 A, Osima, 6.5 V
and Koyoko is 8.5 V. With the maximum current that the charger can applied, the battery are
charge quite rapid. For Osima battery, which is AGM battery, they are in full charge state in
40 minutes. For Koyoko, it only took 50 minutes to be in full charge state. Then, the batteries
were disconnected from charger and let to be stabilizing for 3hours and the last reading is
taken. To know the actual voltage of the battery left after charging, at least 3 hours interval
for the battery to be stabilize. The 3 hours give the battery to cool down and the voltage of the
battery is decreasing until one stable state.

The battery becomes fully charged when the current to the battery starts to decrease and
stabilize. But because of high current applied, the current are stabilize at quite high amp, the
temperature were also high, and the voltage of the battery were close to allowable voltage for
charging. The knob 5 is where the maximum current selection that can be applied to the
battery.

The knob 1 selection of the charger is for normal charging of the batteries. It supply for G-
Wheel Battery is maximum 1.37 A, Osima Battery is maximum 1.7A and 3A maximum for
Koyoko Battery. The purpose of doing Knob 1 selection charging is to determine the
charging rate, full-charge state and the temperature. The charging process took longer time to
accomplish because small amount of current applied. But the good thing is the batteries
temperature were only increase a bit.

Mostly it will took 3 to 6 hour for these battery to be fully charged. The charger is using
Constant Voltage/Potential Charging which means, the charger will continuously charge until
the current flows to the battery are stable and the voltage of the batteries achieve their
maximum value according to the manufacturer. The Knob 1 charging are slow and for this
project, it is use to make comparison between low ampere and high ampere of current apply
to the batteries.

Based on the experiment, it clearly proven that the higher the ampere of the current let to
charge the batteries, the shorter time the batteries will be full charged. But, the heat dissipate
from the battery is also increased.
 VI. CONCLUSION

The Rapid Charging to the Lead Acid Battery are possible, specifically on this three types of
battery. As we know, A VRLA battery (valve-regulated lead–acid battery) more commonly
known as a sealed battery is a lead–acid rechargeable battery. Because of their construction,
VRLA batteries do not require regular addition of water to the cells, and vent less gas than
flooded lead-acid batteries. The reduced venting is an advantage since they can be used in
confined or poorly ventilated spaces. VRLA batteries are commonly further classified as:
Absorbed glass mat (AGM) battery and Gel battery ("gel cell")

These are the type of battery use in the experiment. An absorbed glass mat battery has the
electrolyte absorbed in a fiber-glass mat separator. A gel cell has the electrolyte mixed with
silica dust to form an immobilized gel.

Rapid Charging are possible for these type of battery. But, it heat up the battery and may
exceed it allowable limit by manufacturer. Large amount of current can be applied but in a
control manner. Because of excessive heat, the battery will gassing and drying. In this
experiment, the rapid charging are constant in voltage but varies in current. Until the battery
is fully recharged, the current was supplied to the battery. From the result, we can predict that
rapid charging on VRLA will charge the battery fast, but it will reduce the life of the battery
and affect the capacity of the battery. So, for Valve Regulated Sealed Lead Acid battery,
unlimited current is not recommended. Limit the initial current with respect to depth of
discharge and a maximum temperature rise of 10ºC. If rapid charging wants to be performing,
control the current flow and monitor the temperature.

The research, test and experiment need better equipment for the test to be precise such as
high amp charger and high current rating of multimeter/ammeter. The time provided must be
manage very well because this research need to spend a lot of time continuously to the battery
during charging and discharging process. Do the high voltages charge to the battery. This is
one of the rapid charging method that couldn’t be tested in this project.
 REFERENCES

[1] Alvin J. Salkind, Anthony G. Cannone, and Forrest A. Trumbure (2002), Handbook of
batteries.

[2] Electrochemistry of the lead cell, Rechargeable Battries Applications Handbook

[3] Flooded Lead Acid, Rechargeable Battries Applications Handbook

[4] Technical Manual Sealed Valve Regulated (SVR) Gelled Electrolyte Lead Acid Batteries,
MK Battery and American Workshop.

[5] The Discharge-Charge Cycle, Section 3, Inspecting, testing and Charging, Technical
Manual Yuasa Battery

[6] Depth of Discharge (2012), para 2,

http://batteryuniversity.com/learn/article/discharge_methods

[7] 4.1.3 Battery capacity, Section 4, para 2, page 159, Sealed –Lead Acid Cells and
Batteries, (2002), rechargeable Battery Applications Handbook.

[8] Para 2, November 2012,

http://batteryuniversity.com/learn/article/absorbent_glass_mat_agm

[9] Para 4, page 3, November 30, 2012, VRLA batteries: AGM vs gelled Electrolyte
Revisited.