AEES - 2021-03 - Starter Battery

Automotive Electrical-Electronic Systems
POWER SUPPLY SYSTEM

1 STARTER BATTERY
2 ALTERNATOR & CHARGING SYSTEM
TRAN DANG LONG

HCMUT - 2021
1
©TRẦN ĐĂNG LONG – ĐHBK, 2021
Automotive Electrical-Electronic Systems
POWER SUPPLY SYSTEM

1 STARTER BATTERY
2 ALTERNATOR & CHARGING SYSTEM
TRAN DANG LONG

HCMUT - 2021
2
AUTOMOTIVE LEAD-ACID STARTER BATTERY
Goals of the Course
 Students can describe functions, assignments and roles of starter battery
 Students can describe safety issues related to starter battery
KNOW  Students can define major technical parameters of a starter battery
 Students can remember values of some major technical parameters
 Students can describe structure of a lead-acid battery
 Students can describe equivalent electrical circuit of a lead-acid battery
UNDERSTAND
 Students can describe operation principle of a lead-acid battery
 Students can describe discharge characteristics of a lead acid battery
 Students can describe charging methods for a lead-acid battery
 Students can calculate batteries in series and parallel connections.
 Students can troubleshoot common failures of starter battery
APPLY  Students can wire batteries in series and parallel
 Students can check a starter battery
 Students can measure operating parameters of a starter battery
3
POWER SUPPLY SYSTEM
LEAD-ACID STARTER BATTERY

A INTRODUCTION B STRUCTURE C OPERATING
PRINCIPLE
Functions & Roles
Structure & Accessories
Tech. requirements Chemical energy  Electricity
Categories & Selection
General layout Discharge characteristics
Equivalent circuit diagram
Technical terms Energy losses
D Technical use G DIAGNOSIS & MAINTENANCE

Safety instructions Troubleshooting
Wiring instructions Check – Maintenance – Replacement
Charging instructions
4
Key Takeaways
 Discharge characteristics of a lead-acid battery is
significantly dependent on total reaction rates:
 Temperature
 Total active surface area of electrode plates
 Specific gravity (wt.%, g/cm3) of H2SO4 electrolyte
 Diffusion rate of H2SO4 to reaction zones
 A starter battery MUST be adequately charged by alternator
5
Quizzes: 1. Describe roles and affects of starter battery to vehicle
performance?
2. How have technologies related to lead-acid starter battery
matured to match increasing automotive requirements so far?
Hints
 Automotive electrical requirements
• Elevated electrical demands during various operating statuses (e.g. ignition switch ON?
OFF?; vehicle standstill? driving?; engine standstill? starting? running?) to match primary
goals in fuel economy, gaseous pollutant emissions, specific power (W/kg), and driveability?
• Deep discharge - rapid charge cycle (i.e. deep-cycling) demand in modern vehicles (e.g.
Start-Stop technology)?
 Lead-acid battery technology

• Technologies to improve specific power (W/kg) and specific energy (Wh/kg)?
• Technologies to prolong service life against degradations?
 Automotive control technology

• Smart charging and monitoring solutions?
• Electrical energy management in modern vehicles?
6
INTRODUCTION
 History of development
 Functions & Assignments & Roles
 Technical requirements
 General layout diagram
 Technical terms and specifications
7
INTRODUCTION TO STARTER BATTERY / HISTORY
Bosch starter battery: 1951 version

8
INTRODUCTION TO STARTER BATTERY / FUNCTIONS
Chemical energy  Electricity

Battery  A device that stores and
releases electrical energy via
electrochemical reactions
9
INTRODUCTION TO STARTER BATTERY / ASSIGNMENTS
 supply electrical power to all consumers as engine is

standstill (1-4 kW);
 supply a huge electrical power to start engine
 supply additional electrical power to consumers as
lack of power from alternator;
 assist to stabilize system voltage.
10
INTRODUCTION TO STARTER BATTERY / ROLES
 Failures related starter battery

• Fail to crank engine, or too low cranking speed for starting
• Large voltage drop during engine start
• Rough idle, dead stereo system, warning lights (i.e. Check Engine, ESP) illuminated
after battery replacement
 Impacts from other automotive electrical systems

• Alternator: dead voltage regulator; no pre-excitation current; rectifier
diodes burnt or shorted; worn carbon brushes and slip rings;
serpentine belt slippage or broken
• Elec. consumers: high parasite currents while parking; high leak currents or
mechanical parts jammed causing overload to alternator 11
INTRODUCTION TO STARTER BATTERY / TECHNICAL REQUIREMENTS
 Capability to supply extremely high

currents instantly (200-400 A in 5-10 s)
with very low voltage drop for engine start
 High specific power (W/kg) và high specific

energy (Wh/kg)
 Harsh environment (strong temp. variation,

strong vibration, dust, salt, fuel, oil, water)
 Low or free-maintenance
 Easy to check and replace

12
INTRODUCTION TO STARTER BATTERY / GENERAL LAYOUT DIAGRAM
1. Power supply system with one battery
13
1. Power supply system with one battery
Quiz:
Describe general
features of automotive
electrical systems?
14
2. Co-operative operation
of battery and alternator
Quiz:
How many cases of co-operative operation
are there for battery and alternator in a car?
15
3. Vehicle
electrical
consumers
16
3. Vehicle electrical consumers

Electrical load variation during driving
Quiz: Describe co-operative operation of battery

and alternator in modern vehicles having
Stop-Start function?
17
Quiz: Plot variation of voltage between battery terminals

in each operating state? Explain?
Engine stop Engine Engine stop

IGW off IGW on start Engine idling Driving IGW on
Time
18
4. Electrical energy management in modern vehicles
• Would a certain
operation be successful
with the current
battery status?
• Warn required
operation impossible
• Prevent overcharge
and extensive
discharge
• Reserve charge in stop
phase (Start-Stop)
Regulator with • Battery charge
variable charge indication
voltage
• Adjust idle
speed to load
varations
IBS – Intelligent
Battery Sensor
Status recognition:
• Load shedding
 SOC - State of Charge • Optimize charge
(switch off
 SOH - State of Health voltage to extend
unnecessary loads
 SOF - State of Function battery life
for power balance)
19
Modern Day Automotive Electrical Loads

Knowledge of the battery’s health and charge are very important in modern day
vehicles. Innovations such as stop-start, drive-by-wire, and the conversion of once
hydraulic systems to electrical systems add an even greater load to the vehicle’s
electrical battery system, which motorists are already relying on for the safety of
themselves and others around them. An IBS allows the vehicle to prioritize all of
these electrical loads on a scale from “comfort related” to “safety critical.” The
automobile can then shut these systems down in a logical order to warn drivers of
an impending battery problem, while keeping them safe.
Christopher Lohmeier and Tom Veik, Battery Management With an Intelligent Battery Sensor is Vital to the Success of Future
Automotive Designs [https://www.batterypoweronline.com/]
20

Stop-start technology has been implemented on hybrid vehicles for many years and is
now starting to be implemented as a standalone system on conventional internal
combustion engine (ICE) powered cars. One significant problem that still needs to be
addressed with stop-start technology, however, is the 12 V battery system. Just the
additional number of restarts on a normal trip through town would be enough to drain and
possibly destroy a conventional lead-acid battery, which is why most stop-start enabled
vehicles use absorbed glass mat (AGM) batteries. While AGM batteries enhance a car’s
ability to use stop-start technology, problems still persist with systems that need to continue
to run after the car shuts itself down, including the ECU, safety monitoring, lighting,
navigation, climate control and general comfort systems. All of these systems present a huge
drain on the car’s battery that can destroy it if not monitored closely. Current stop-start
models address this by either turning off the comfort systems while the car is stopped, or by
routinely restarting the engine to ensure the battery is kept charged throughout the stop. A
proper battery management sensor could better ensure that the battery was operated at
safe levels only. This would increase fuel economy even further by forcing the car to restart
when, and only when, it was absolutely necessary during a stop. It could even allow the
vehicle’s comfort systems to be intermittently pulsed on and off as needed without an
engine restart when the battery condition was in a known safe operating area, giving the
driver a more comfortable in-car experience.
Christopher Lohmeier and Tom Veik, Battery Management With an Intelligent Battery Sensor is Vital to the Success of Future
Automotive Designs [https://www.batterypoweronline.com/]
21
5. Power supply system using two batteries
22
5. Power supply system using two batteries
DC/DC converter
• Prevent discharge
while standstill
• Optimize charge
voltage to
minimize the
charge time
• Support the weak
general-purpose
battery
Quizzes: 1. Advantages of using two separate batteries?

2. Describe technical features of each battery?
3. Describe assignments of EN ECU?
23
6. 12/24 V power supply system in commercial-vehicles
Quizzes:
1. What is nominal system
voltage?
2. What is nominal start
voltage?
3. While is it necessary to
use different voltage
levels?
4. Describe operation of
battery changeover?
24
INTRODUCTION TO STARTER BATTERY / TECHNICAL TERMS
Technical terms & specifications Symbol Unit Notes
Cell electromotive-force (single cell 𝑒 V 𝑒 = 0.85 + 𝜌∗,

EMF) 𝜌∗, = 𝜌 , − 0,0007 25𝑜𝐶 − 𝑇
Electrolyte specific gravity 𝜌 g/cm3 𝜌 , : specific gravity at 𝑇 (oC); 𝜌∗, : equivalent specific
gravity at 25 oC; 35 wt.% H2SO4 solution: 𝜌 , = 1.265 g/cm3
Open-circuit voltage (Battery EMF) 𝐸 ,𝑈 V 𝐸 =𝑛 𝑒 𝑛: number of single cells; 𝐼 (A):
battery current; 𝑅 (): external
Terminal voltage 𝑈 ,𝑈 V 𝑈 =𝑅 𝐼 resistance (total load resistance)
𝑈 =𝐸 −𝑅 𝐼
Internal resistance 𝑅 m 𝑅 + 𝑅 +𝑅 +𝑅 +𝑅
Nominal voltage 𝑈 V ~𝐸 at 𝑆𝑂𝐶 = 100%
Gassing voltage 𝑈 V Charging voltage level that accelerate water decomposition;

𝑈 = 14.714.4 V (decrease with increase of temperature)
for batteries with 𝑈 = 12 V
Nominal capacity@20-hour Rate 𝐾 Ah 𝐾 = 𝐼 20h: a battery can discharge a constant current 𝐼
(A) at 252 oC (77 oF) for 20 h until 𝑈 reach 𝑛 1.75 V
State of Charge 𝑆𝑂𝐶 % (~1.12 g/cm3, “completely exhausted”, 𝐷𝑂𝐷 = 100%)
Depth of Discharge 𝐷𝑂𝐷 % Operation with 𝐷𝑂𝐷 > 50% causes rapid degradations
(irreversible damages) of electrode plates in start batteries
25
Technical terms & specifications Symbol Unit Notes
Cold cranking amps 𝐶𝐶𝐴 A Continuous discharging current at –18 oC (0 oF) for 30 sec.
(SAE J537 CCA Test) or 10 sec. (EN 50 342 CCA Test) while
𝑈 > 𝑛 1,2 V. Practically, 𝐶𝐶𝐴 ≅ 5. . 10𝐼
Reserve capacity 𝑅𝐶 minute Discharging duration of a 100%-𝑆𝑂𝐶 (fully-charged)
battery under a constant current of 25 A at 27 oC (80 oF)
until 𝑈 reaches 𝑛 1.75 V
Nominal discharge current 𝐼 A 𝐼 = 𝐾 /1h
Starting current 𝐼 , A 𝐼 , ≅𝐼 = 4𝐼
Nominal charging current 𝐼 . ,𝐼 A 𝐼 . = 0.1𝐼
Temperature range − oC Temperature ranges for charging, discharging, and storage
Specific energy − Wh/kg
Energy density − Wh/L
Specific power − W/kg
Self-discharge rate − %/month Rate of capacity loss during storage due to self-discharging
Life cycle − cycle 𝑆𝑂𝐶 = 100% 𝐷𝑂𝐷 = 100%
26
Quizzes:
1. Determine at 25 oC?
2. Determine integer value of to obtain = 6, 12, and 24 V at 25oC?
3. Plot with respect to ?
4. Determine , and threshold voltages corresponding to , , and
of batteries having = 6, 12 and 24 V at 25 oC?
5. Practical meaning of CCA in starter battery?
6. How does operation with frequent stop-and-go (i.e. repeatedly driving
only short distance) affect lead-acid battery‘s service life?
7. Explain technical specifications of a commercialized lead-acid battery?
How to determine the max. starting current available?
27
28
CONSTRUCTION
 Single cell
 Battery
 Categories
 Accessories
 Battery selection
 Equivalent electrical circuit
29
LEAD-ACID BATTERY CONSTRUCTION / SINGLE CELL
Complete
Pasted cell, 2.1 V
Grids with porous,
Pb + Sb active
(8-10%) materials
Terminals
(Posts)
Diluted H2SO4
Plate groups (35-37 wt.%)
after
“formed” (+)
(–) brown
grey Pb PbO2
Plate separators Closed

(porous plastic case
insulator)
Complete element 30
LEAD-ACID BATTERY CONSTRUCTION
31
Advantages?
32
Important Notes
1. Assembly layout  length of starting cable in a vehicle

2. Positive terminal/post (+)  larger ; last out – first in
3. Negative terminal/post (–)  smaller ; ground system; first out – last in
4. Vent cap  pouring distillated water (10-15 mm above plates)
5. Capacity indicator  Full-charged – Charging needed – Water fill-in/Replacement
33
LEAD-ACID BATTERY / CATEGORIES
1. CATEGORIES OF APPLICATIONS
Technical features at Starter battery Deep-cycle battery
same Ah
Plate construction Thinner plates, higher number Thicker plates, higher life cycle
of plates, higher total active
surface area
Maximum discharge Much higher -

current
Maximum discharge Much higher -

power
Discharge capability 𝐷𝑂𝐷 = ~50% 𝐷𝑂𝐷 = 70 ÷ 80%
Applications Starting battery in automobiles, Electric vehicle, electrical power

marine vessels storage system (UPS, solar power
system, …)
34
2. Battery versions
Completely
Technical features at Conventional Low-maintenance Maintenance-free
maintenance-free
same Ah battery battery battery
battery
Self-discharge rate at 𝑆𝑂𝐶=65%@6 - 𝑆𝑂𝐶=90%@6 months Much slower rate

𝑇 of new battery months 𝑆𝑂𝐶=65%@18 months
Water loss 4.0-6.0 g/Ah < 4.0 g/Ah < 0.2 g/Ah < 0.1 g/Ah, increase
with elevating temp.
Electrolyte level check Regularly 15 months/25k-km - 25 months/40k-km
Starting power - - - 30% > conventional

battery
Degradation of starting Starting power drops below rated value Starting power stays higher rated value after
power compared to after 40% of service life; 1/3 loss after 75-80% of service life
new battery 75% of service life
Service life - - - 20% > conventional

battery
Vehicle model Old Old Modern Modern, with Start-

Stop function
35
Quizzes:
Identify the following batteries?
 Conventional & Low-maintenance
 Maintenance-free
 Completely maintenance free
36
37
Enhanced Flooded Battery
85k VS. 30k

Số lần dùng cho khởi động
38
Absorbent Glass Mat battery technology
39
• Avoid high
temperature
locations due
to low thermal
capacity
AGM
Benefits at a glance
40
41
42
43
Quizzes:
Name technologies to enhance battery’s service life:
• Reduce electrode wearing and corrosion?
• Reduce water loss during charging?
• Prevent short-circuit between positive and negative
plates due to debris from plate damages?
44
LEAD-ACID BATTERY / ACCESSORIES
#1 – Battery safety terminal
45
#1 – Battery safety terminal
Quizzes:
1. Describe assignments of Battery Safety Terminal (BST)?
2. How is BST activated by Multiple Restrain System (MRS)?
3. To which battery post is a BST connected? and which electrical systems are de-
energized as BST is activated?
4. How to know a BST already activated? Is it possible to be rebuilt?
46
#2 – Battery temperature sensor
 Optimal operating temperature: 5 .. 21 oC

 Temperature has strong effects on rates of charging, water decomposition, and electrode wear
 In modern vehicle charging voltage (𝑈 ) is adjusted to ensure full-charge, enhance service life,
and reduce fuel consumption
• Low temperature  increase 𝑈 for quick full-charge
• High temperature  decrease 𝑈 for preventing water losses and electrode wear
 Completely maintenance-free battery: 𝑈 = 16 V@<<0 oC and 13.5 V@>>30 oC
 Symptoms of bad battery temperature sensor (always connected at negative post (–))
• 80k .. 100k miles in lifetime
• Strong 𝑈 fluctuation  engine surging
• Low 𝑼𝑩  battery is discharging and is not fully-charged
• Battery is not charged; high battery temperature  Battery Warning Light and Check Engine
Light illuminated
47
#2 – Battery temperature sensor
Quizzes:
1. How is charging process affected by
temperature?
2. Requirements for a charging system using
a battery with temperature sensor?
3. Symptoms of bad battery temperature
sensor?
Bộ tiết chế MAHLE có chân S cho cảm
4. Replacement procedure for battery
biến nhiệt độ ắc-qui
temperature sensor?
 The S terminal in most of voltage

regulators in alternators senses battery
voltage to adjust charging voltage for
counteracting voltage drop over charge
line (B) under high load currents
48
#3 – Battery sensor
• Optimize charge voltage

• Idle speed control
• Load shedding + a
warning message in the
instrument panel
 Better fuel efficiency & Longer battery life

49
 Connected to the battery
negative terminal
 In sleep mode, automatically
wake-up every 14 sec. and carry
out required measurements
within approx. 50 ms for power
saving
 Measurement ranges:
 Voltage: +6 .. +16.5 V
 Current: –200 .. +200 A
 Starting current:
0 .. +1000 A
 Temperature:
–40 .. +105 oC
 Software in the
ECU and that of
IBS must match
50
• A battery sensor is a fragile device and can also be damaged when
servicing or removing the battery.
• A failed IBS is known to cause variety of electrical problems including
a no-start.
• The most common problem is when the dirt, moisture or battery acid
get into the sensor and damage or short it.
• If there is a fault related to the battery sensor, the first step is to
check it visually for corrosion, cracks, physical damage, loose battery
terminals or battery cable connections, corroded pins at the
connector or broken wires. If there are any added electrical
accessories that are connected directly to the negative terminal
bypassing the battery sensor, this may also cause problems.
 Direct diagnosis of the IBS is impossible and a scan tool is required

 Defective IBS leads to EMERGENCY MODE that boosts the idle speed in order to sufficiently charge the battery
 In some vehicles, if the sensor has been disconnected or the battery has been replaced, the Stop-Start feature
might not work for some time, until the ECU re-learns the parameters of the battery
 Many electrical problems, including issues with the battery current sensor can be caused by loose or corroded
battery terminals or moisture/corrosion around the battery sensor. To function properly, the battery sensor
must be clean and dry, and the pole terminal must be tight.
51
Quizzes:
1. Describe functions of battery sensor in modern vehicles?
2. Describe advantages of using battery sensor in automotive power
supply system?
3. Describe principles of battery voltage, current and temperature
measurements?
4. Describe practical meaning of , , and ?
5. Denote important notes in using battery sensor?
6. Summarize symptoms of bad battery sensor?
7. Describe replacement procedure for battery sensor?
52
#4 – Battery warning light / Conventional
Quizzes:
1. Function of battery light?
2. Operation principle?
3. How does battery light
indicate co-operative
operation of battery and
alternator?
4. What may cause battery light
off while ignition switch is on?
5. What may cause battery light
on while driving with more
steering effort and engine
over temperature?
53
#4 – Battery warning light / Conventional
The charging system warning light should show for a few seconds when you start the car, but if
the battery light shows while you’re driving the vehicle, that light signals a problem. Among
other signs that the alternator or other parts of the charging system aren’t working are dim
headlights or the clock losing time.
If the car’s dashboard battery light comes on, you might be able to make it home or to a service
facility for a repair. The car will continue running as long as some juice is left in the battery, but
if the charging system isn’t working or you have a bad alternator, your car’s engine will stop
running once the battery is drained. If you turn off the engine, you won’t be able to restart it if
the battery doesn’t have enough charge left to power the engine’s starter motor.
If the battery light is on and you’re still driving the car, turn off as many electrical accessories as
you can, such as the stereo, air conditioning or heater, and avoid using electrical controls such
as power windows.
Reducing the amount of electricity the car is consuming will increase the distance you can drive
before the battery is discharged. Get to a mechanic as quickly as possible, and have the battery,
wires and charging system checked out to find the cause of your problem and what you need to
repair or replace.
https://www.cars.com/articles/why-is-the-battery-light-on-1420663031640/
54
#4 – Battery warning light / Modern
 Multifunctional voltage regulator +
Conventional instrument panel
 Voltage regulators with PWM or LIN
interface + Instrument panel controlled
via CAN bus (Control Area Network)
 Battery Light is illuminated while engine
running as 𝑈 < 13.5 V due to top
reasons
• Corrosion at battery terminals
• Loose car battery cables
• Bad ground strap
• Weak battery
• Bad alternator
• Bad alternator belt
• Too many accessories
 Chance to fix the issue before battery is
completely drained of its stored energy 55
#4 – Battery warning light
Quizzes:
1. Compare operation principles of
conventional and modern battery
lights?
2. Compare effectiveness in diagnosis
of conventional and modern battery
lights?
3. What should a driver do if battery
light is on while driving?
56
LEAD-ACID BATTERY / SELECTION
1. Matching engine displacement
57
1. Matching engine displacement
Quizzes:
Summarize technical specifications of batteries
commonly used on vehicles in Vietnam?
 Motorcycles
 Passenger cars
 10-16 seat buses
 City buses, shuttle buses
 Light-duty trucks
 Heavy-duty trucks
58
2. Matching electrical demands
? ? ?
Quiz: Determine operating conditions and

technical requirements for battery
applied to Start-Stop function?
59
2. Matching
electrical
demands
60
EXTENDED QUIZ: SELECT BATTERY PACKS FOR ELECTRIC VEHICLE
1. Compare energy density, specific power, and
unit price of various types of batteries (lead-
acid, Ni-Cd, NiMH, Li-Po, Li-ion and LiFePO4)?
2. Compare energy density of batteries and
hydrocarbon fuels (gasoline, diesel, ethanol,
LPG, CNG, H2)?
3. Major technical problem in electrical vehicle?
4. Technical, economical, and environmental
issues should be considered in mass
production of batteries for electric vehicles?
5. Propose a method to select battery pack for a
14-seat electric vehicle with a rated voltage
of 72 V and a travel distance of 80 km per
charge with 28 km/h on level road?
Hints
• Define general layout of electric powertrain
Marshell DN-14 Nimo Design • Apply law of energy conservation
61
LEAD-ACID BATTERY / EQUIVALENT CIRCUIT DIAGRAM
Quizzes: 1. Under which electrical conditions can battery discharge?

2. Under which electrical conditions can battery is charged?
3. Why does battery get hot during charging and discharging?
4. When is battery voltage drop the most?
62
OPERATING PRINCIPLE
 Chemical energy  Electricity
 Discharge characteristics
 Discharge losses
 Effective discharge capacity
 Effect of temperature
63
LEAD-ACID STARTER BATTERY / OPERATION PRINCIPLE
64
LEAD-ACID STARTER BATTERY / OPERATING PRINCIPLE
 Electrolytic dissociation
Physical
• Electrolyte: H2SO4  2H+ + SO42–
& Chemical Processes
 Electrochemical reaction
• (–) post: Pb + SO42–  PbSO4 + 2è
• (+) post: PbO2 + SO42– + 4H+ + 2è  PbSO4 + 2H2O
 Mass transport
• Diffusion: H2SO4 and H2O
 Charge motion  Electric current

• External circuit & metallic parts: è (–)  (+)
• Electrolyte: SO2– (+)  (–)
H+ (–)  (+)
 Heat source & Heat transfer

• Joule heating: 𝑅𝐼
• Heat conduction
65
Substances Discharging Charging Notes
(–) Pb   Sediment generation over charge-discharge cycles

(+) PbO2    Electrode wear  Wear decay
white color, low conductivity; reduces active surface areas and increases
PbSO4   diffusion resistance  reduces 𝐶 (i.e 𝜌 ) vicinity to electrode plates
 Instant voltage drop during discharging
H2SO4   𝜌 decreases while discharging and increases during charging
H2 O    Variation of 𝐸𝑀𝐹 = 𝑁 0.85 + 𝜌 , − 0,0007 25𝑜𝐶 − 𝑇
66
Quizzes:
1. Calculate electrical current generated by a
reaction rate of 1 mol/s?
2. Impacts of PbSO4 on reaction rate and 𝑅 ?
3. Variation of 𝐸 during discharging?
4. Variations of material amounts during
charging and discharging?
5. How do the following factor affect to
reaction rate during discharging:
• Total active surface area?
• H2SO4 concentration in adjacent to
electrode plates?
• H2SO4 diffusion rate to adjacent
electrode plates ?
• Temperature?
67
DISCHARGE CHARACTERISTICS OF LEAD-ACID BATTERY
Quiz:
A B Determine discharge power
C
and effective discharge
capacity?
D
Typical discharge characteristics

of lead-acid battery Cathode Anode
• A = 100%;
• A-B quick reduction of H2SO4 concentration  quick drop
• B-C stable H2SO4 diffusion rate (balance)  slow drop
• C-D very low H2SO4 concentration, severe sulfation  quick drop
• D = 100%
68
1. Voltage drop & Losses

𝐸 , 𝑹𝒗 is adjusted to achieve 𝑰𝒃 = 𝒄𝒐𝒏𝒔𝒕
𝑉=𝑅 𝐼 + 𝛿𝐸
Cathode Anode
𝐸 , Initial EMF
𝑉 Voltage drop
𝑅 Internal resistance
𝛿𝐸 EMF drop
Discharge time
•
• , where ,
𝑜
• increases with decrease of , due to consumption and low diffusion

69
1. Voltage drop & Losses Quizzes:

1. and vs. ?
𝐸 , 𝑹𝒗 is adjusted to achieve 𝑰𝒃 = 𝒄𝒐𝒏𝒔𝒕
2. Which part has a higher
𝑉=𝑅 𝐼 + 𝛿𝐸 contribution to voltage drop
at low and high ?
3. Calculate heat generation
Cathode Anode
𝐸 , Initial EMF during discharging?
𝑉 Voltage drop 4. Why does a battery usually
𝑅 Internal resistance get explosion as shorted?
𝛿𝐸 EMF drop
5. A shorted-battery may not
Discharge time get explosion. Why?
•
• increases with increase of PbSO4 (polarization resistance)
• increases with decrease of due to consumption and low diffusion
70
• starter battery
2. Discharge capacity • power backup system
• UPS system
• Peukert’s law
Quiz: Relationship between discharge

capacity and discharge current?
3.25 A
195 A 65 A
7 min. 30 min. 20 h
Gel Battery (12V 65Ah)
71
3. Discharge capacity recovery
Quiz:
Why does gradually
increase as discharging is
interrupted?
 Diffusion rate VS. Elec.chem.

reaction rate
 An engine start attempts
shorter than 5-10 s.
 Wait for 10-15 s between
starting attempts.
72
4. SOC – State of Charge / DOD – Depth of Discharge

𝑂𝐶𝑉 = 𝑁 0.85 + 𝜌 , − 0,0007 25𝑜𝐶 − 𝑇
[V]
, [g/cm3]
[%] PbSb PbCa
100 12.65 12.80 1.261.27
75 12.45 12.65 1.211.22
50 12.24 12.44 1.161.17
25 12.06 12.19 1.121.13
0 <11.89 <11.97 <1.10
Quiz:
What terminal voltage indicates that a starter
battery should be charged immediately?
73
5. Self-discharging
Quiz:
Why is it necessary to regularly charge lead-acid battery in
vehicle or back-up generator while in rest for long time?
74
• Plate damage, corrosion

6. Life cycle • Water decomposition
• Short-circuit due to debris
Quizzes: 1. Life cycle vs. ?

2. Limit value of for automotive starter battery?
75
• Plate damage, corrosion

6. Life cycle • Water decomposition
• Short-circuit due to debris
Quiz:
How does
starting power
decrease with
respect to
useful life?
76
7. Temperature impacts
Effective discharge capacity Effective discharge power
Quizzes: 1. How does temperature affect on 𝐸 ?

2. Why does temperature has a positive effect on effective capacity and power?
77
Electrical demand for cold-start
Quiz: Why is it difficult to

start engine in cold weathers?
Consequences? Solutions?
 CCA-Cold Crank Amps.

 Gasoline engine: fuel
enrichment to
compensate low fuel
evaporation rate
 Diesel engine: intake-air
heating using glow-plugs
 Modern engine: heat
recovery system
78
Quizzes:
1. Explain the plot?
2. Summarize in a table impacts of temperatures
on performance and life cycle via:
 Effective discharge capacity?
 Voltage drop?
 Effective discharge power?
 Electrode wear?
 Water decomposition?
 Self-discharge rate?
3. Which driving conditions can causes strong
heat generation?
4. Advantages and disadvantages of smart idle?
79
1) Fully-charged & No-load 𝑬𝑴𝑭 𝑼𝒊 2) Low discharging currents
B A B A 𝑼𝒊
𝑬𝑴𝑭
𝑪𝑯𝟐 𝑺𝑶𝟒 𝑪𝑯𝟐 𝑺𝑶𝟒 𝑼𝑩

𝑪𝑯𝟐 𝑺𝑶𝟒 𝑪𝑯𝟐 𝑺𝑶𝟒 𝑼𝑩
“diffusion”
A ~ reaction zones friction pressure friction pressure

B ~ adjacent zones
𝑼𝑩 ~ pressure w/o friction
closed no electric load small opening light electric load
for the same flow rate
𝑼𝒊 ~ friction losses no flow rate no current low flow rate low current
3) High discharging currents 4) Stop discharging  Discharging recovery

B A B A
𝑬𝑴𝑭 𝑼𝒊
𝑬𝑴𝑭 𝑼𝒊
𝑪𝑯𝟐 𝑺𝑶𝟒 𝑼𝑩
𝑪𝑯𝟐 𝑺𝑶𝟒 𝑪𝑯𝟐 𝑺𝑶𝟒
𝑪𝑯𝟐 𝑺𝑶𝟒
“diffusion”
𝑼𝑩
friction pressure SOC ~ H2SO4 left friction pressure

DOD ~ H2SO4 lost
wide opening heavy electric load closed no electric load
high flow rate high current no flow rate no current

80
Quiz:
Summarize major technologies to improve capacity,
power and service life of lead-acid battery?
Hints
• EMF drop reduction
• Reaction rate promotion
• Heat losses reduction
• Thermal stability enhancement
81
TECHNICAL USE
 Safety instructions
 Ground connection
 Wiring instructions
 Charging instructions
82
LEAD-ACID STARTER BATTERY / SAFETY INSTRUCTIONS
IEC 60095-1 colored symbols for safety labeling
[Ref.] BOSCH BATTERIES - Optimal starting power for all vehicles

83
LEAD-ACID STARTER BATTERY / GROUND CONNECTION
NOTES
• All ground connections should be fully tightened
• Turn off all consumers before work
• Remove (–) post for repair or working in adjacent to (+) post
• Isolate (+) post while working at (–) post (remove, connect)
• Always remove (–) post first, and connect last
84
LEAD-ACID STARTER BATTERY / GROUND CONNECTION
Honda CIVIC R18 ground kit

1. Ground  Chassis
2. Chassis  Engine mount
3. Ground  Alternator
4. Ground  Cylinder head
5. Ground  Throttle body
6. Ground  Transmission
85
LEAD-ACID STARTER BATTERY / WIRING INSTRUCTIONS
Output Wiring method

performance Series Parallel

Nominal 𝑈 𝑈
voltage

Total current 𝐼 𝐼

Total power

Total energy

Total capacity 𝐴ℎ 𝐴ℎ

Requirements Same 𝑨𝒉 Same 𝑼𝑵
• Be aware of short-circuit
• Double checks before wiring
86
LEAD-ACID STARTER BATTERY / WIRING INSTRUCTIONS
Quizzes:
For each of battery packs:
1. Define battery output voltage?
2. Define current in external circuit?
3. Define total capacity?
4. Define total energy?
5. Define charging voltage needed?
6. Define rated charging current?
7. Requirements for batteries in series?
8. Requirements for batteries in parallel?
*. Propose some wrong wirings could
lead to battery explosion?
87
LEAD-ACID STARTER BATTERY / CHARGING INSTRUCTIONS
SOC = 100%
Charging voltage
Weak Strong
EMF gassing gassing
Charging current
Charging time
Charging method:
• 13.6  14.2 V for = 12 V; 27.2  28.4 V for = 24 V
• Used normal chargers, and in vehicles (charging voltage is regulated by alternator)
• Charging current is automatically reduced with increasing SOC  No controller required
• A low and stable charging current  Fully-charged battery (SOC = 100%).
• Strong gassing may occur if battery is overcharged  Water loss  Low electrolyte level
88
Quizzes:
1. Equivalent electrical circuit of charging with:
 Constant voltage?
 Constant current?
 Constant current & voltage?
2. Variation of voltage and current in each of
charging methods?
3. Efficiency and power losses during charging?
4. How to confirm a full-charge in each of
charging method?
5. How does overcharge affect to battery?
TigerPWR battery
jump starter
1300A peak
8L Gas engine
Bosch BML 2415 battery charger 6.5L Diesel engine
12/24V – 15/10A
89
Quizzes:
1. Charging method used in vehicles?
2. How to know if a car battery is being charged?
3. How does a car battery get damaged if
 repeatedly driving short distance?
 repeatedly driving long distance?
3. Functions of battery temperature and battery
sensor in modern vehicles?
90
DIAGNOSIS & MAINTENANCE

 Troubleshooting
 Check & Maintenance
 Replacement
91
STARTER BATTERY DIAGNOSIS & MAINTENANCE
1. Troubleshooting
Common symptoms:
 High rate of water loss
 Usual in low charge level even using new battery
 Full-discharge over a night even fully-charged before
 Battery light illuminates while engine running or driving
 Battery light does not illuminate when ignition switch is turned on
 Although normal driving and no warning from battery light, engine
suddenly stops and unable to restart due to low cranking speed
 Engine is suffered rough idle with Check Engine light on after
battery replacement
92
2. Battery damages
 Exterior
• Damaged case
• Burned posts
• Corroded posts
 Interior
• Sulfated electrode plate
• Broken, corroded electrode plate
• Short-circuit among plates
• Water loss
 Avoid excessive discharge

 Avoid overcharge for long time
 Always keep in full-charge
 Use correct battery version for application
93
3. Check & Maintenance

 Cleaning
• Clean cover with NaHCO3 solution
• Clean posts with iron brush or NaHCO3
solution
 Visual check
• Cracks on case
• Electrolyte leakage
• Dirt, deposit on cover surface
• Water on cover surface
• Corroded posts
• Fully-tightened to frame
• Fully-tightened terminals
94

Hydrometer (conventional batteries)
Built-in hydrometer
(low-maintenance & maintenance-free batteries)
 Capacity check
 Basing on open-circuit voltage
 Basing on electrolyte specific gravity
 Using built-in charge indicator
95

 Jump start with
 Working battery (strictly
follow jump start procedure)
 Mini jump starter
 Battery charger with jump
starter function
• Jump start cable cross sectional area > 16 .. 25 mm2

• Turn of all electrical consumers
• Wiring steps: 1 – 2 – 3 – 4
• Start engine right after the wiring step 4
• Remove cables in reverse order after start
• Keep engine running for ~15 min. for charging
96
 Parasite current test

• Usual out of charge over a night
• Permissible parasite current: 35 .. 50 mA
• Turn-off, remove key, leave for a while to
complete rest, measure battery current
and remove each fuse to determine
sources of high parasite currents 97
4. Battery replacement in modern vehicles
BATTERY MEMORY SAVERS Relearn process after battery
via OBD-II connection via cigarette lighter
replacement causing KAM erased
1. Stop completely, engage parking brake, put
automatic transmission in P position, turn off all
electrical consumers
2. Start engine and run at ~2500 rpm until
operation temperature is reached
3. Running in idle for 5-10 min. (clean throttle
• ECU automatically adjust parameters of idle speed control, body if necessary)
fuel trim, ignition timing, adaptive shifting… during driving
and stores them in Keep Alive Memory (KAM) 4. Turn on air conditioner at max. level and keep
engine running in ~5 min.
• KAM can be erased using scan tools or when power is
interrupted (battery terminal removed, dead battery, battery 5. Release parking brake, push brake pedal, put
or cable replacement, broken cable, loose terminals) automatic transmission in D position, keep
• Use a memory saver to energize KAM via OBD-II connector or engine running for >1 min.
cigarette light plug (depend on vehicle type) while replacing 6. Relearn is completed after ~50 km of driving
battery 7. Input radio security code, re-calibrate
• Only replace with the same battery version (𝐾 ? Start-Stop? acceleration pedal sensor and steering angle
assembly layout?) sensor if required
98

There are some precautions when replacing the battery if a vehicle has a battery current
sensor. For instance, some manufacturers advise to disconnect the battery sensor first,
before disconnecting the negative battery terminal. It's also important to use the
replacement battery of the correct type.
For example, some vehicles with the Stop/Start system have an Absorbed Glass Mat (AGM)
12-volt battery, which is sensitive to overcharging. When replacing, an owner's manual may
recommend using only the AGM battery.
In some vehicles, a new battery might need to be "registered" with the battery management
system using a scan tool (e.g. BMW). If the battery replacement is not registered, the battery
(power) management system might not function properly. In some Ford vehicles, the battery
management system might need to be reset after the battery has been replaced.
It is also important where to connect the wire clamps when boosting or charging the battery
with a battery sensor. Considering all this, it might be a good idea to change the battery at a
dealership. At least, check your vehicle owner's manual or do some research before
replacing the battery.
https://www.samarins.com/glossary/battery-sensor.html
99
Quiz:
Important notes when replace battery
in modern vehicles?
100
5. ASE certification test

1. A vehicle's battery continues to discharge while sitting overnight. Technician
A says to perform a parasitic battery drain test. Technician B says this could
be a slow drain caused by a faulty alternator. Who is correct?
A. Technician A B. Technician B
C. Both A and B D. Neither A or B
2. Two technicians are discussing a battery that discharges overnight, even after
it's been fully charged the day before. Technician A says this could be a slow
drain caused by a faulty alternator. Technician B says this is most likely
caused by a parasitic drain. Who is correct?
101
3. A vehicle’s battery continues to discharge overnight. The vehicle was repaired,

and a battery drain test was performed. The reading on the multimeter above
indicates the parasitic drain. Which of the following is correct?
A. This is acceptable. B. This indicates 35mA of current.
C. This indicates 35A of current. D. Both A and B.
4. Technician A says a fully charged lead acid automotive battery has a specific
gravity of 1.265 at 80° F. Technician B says the battery's specific gravity is
affected by temperature. Who is correct?
102

5. All of the following are true about battery replacement EXCEPT.
A. Use a computer memory saver.
B. Remove the negative terminal first.
C. Replace the positive terminal last.
D. Use a battery terminal puller if the terminal is stuck to the post.
6. All of the following are true statements about a fully charged

lead acid battery EXCEPT.
A. It acts as a capacitor smoothing current.
B. It powers accessories while the engine is running.
C. The electrolyte has a specific gravity of 1.265.
D. It powers the starter while the engine is cranking.
103

7. A vehicle's battery is being tested for capacity. Technician A says during a
battery capacity test the voltage should not drop below 9.6 volts at 70° F.
Technician B says a battery's voltage reading should increase as temperature
decreases. Who is correct?
8. Technician A says that the charge indicator of a maintenance free battery is a

hydrometer measuring the density of the electrolyte solution. Technician B
says that as the battery is discharged the electrolyte solution’s specific gravity
gets closer to 1.0. Who is correct?
104

AEES - 2021-03 - Starter Battery

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Automotive Electrical-Electronic Systems

POWER SUPPLY SYSTEM

TRAN DANG LONG

POWER SUPPLY SYSTEM

TRAN DANG LONG

LEAD-ACID STARTER BATTERY

D Technical use G DIAGNOSIS & MAINTENANCE

 Lead-acid battery technology

 Automotive control technology

Bosch starter battery: 1951 version

Chemical energy  Electricity

 supply electrical power to all consumers as engine is

 Failures related starter battery

 Impacts from other automotive electrical systems

 Capability to supply extremely high

 High specific power (W/kg) và high specific

 Harsh environment (strong temp. variation,

 Easy to check and replace

1. Power supply system with one battery

1. Power supply system with one battery

3. Vehicle electrical consumers

Quiz: Describe co-operative operation of battery

Quiz: Plot variation of voltage between battery terminals

Engine stop Engine Engine stop

4. Electrical energy management in modern vehicles

4. Electrical energy management in modern vehicles

Modern Day Automotive Electrical Loads

4. Electrical energy management in modern vehicles

5. Power supply system using two batteries

5. Power supply system using two batteries

Quizzes: 1. Advantages of using two separate batteries?

6. 12/24 V power supply system in commercial-vehicles

Technical terms & specifications Symbol Unit Notes

Cell electromotive-force (single cell 𝑒 V 𝑒 = 0.85 + 𝜌∗,

Gassing voltage 𝑈 V Charging voltage level that accelerate water decomposition;

Technical terms & specifications Symbol Unit Notes

Nominal charging current 𝐼 . ,𝐼 A 𝐼 . = 0.1𝐼

Temperature range − oC Temperature ranges for charging, discharging, and storage

Specific energy − Wh/kg

Energy density − Wh/L

Specific power − W/kg

Life cycle − cycle 𝑆𝑂𝐶 = 100% 𝐷𝑂𝐷 = 100%

Plate separators Closed

1. Assembly layout  length of starting cable in a vehicle

Maximum discharge Much higher -

Maximum discharge Much higher -

Discharge capability 𝐷𝑂𝐷 = ~50% 𝐷𝑂𝐷 = 70 ÷ 80%

Applications Starting battery in automobiles, Electric vehicle, electrical power

Self-discharge rate at 𝑆𝑂𝐶=65%@6 - 𝑆𝑂𝐶=90%@6 months Much slower rate

Electrolyte level check Regularly 15 months/25k-km - 25 months/40k-km

Starting power - - - 30% > conventional

Service life - - - 20% > conventional

Vehicle model Old Old Modern Modern, with Start-

Enhanced Flooded Battery

85k VS. 30k

Absorbent Glass Mat battery technology

 Optimal operating temperature: 5 .. 21 oC

 The S terminal in most of voltage

• Optimize charge voltage

 Better fuel efficiency & Longer battery life

 Direct diagnosis of the IBS is impossible and a scan tool is required

Quiz: Determine operating conditions and

Quizzes: 1. Under which electrical conditions can battery discharge?