BY A-3 GROUP

OVERVIEW
 DEFINATION OF BATTERY
 CONSTRUCTION OF BATTERY
 TYPES OF BATTERY
 WORKING PRINCIPLE
 ELECTROCHEMICAL REACTION
 CAPACITY RATING
 OVERVIEW
 FACTORS AFFECTING CHARGING
 CAUSES OF BATTERY FAILURE
 TESTING PROCEDURE
 HYDROMETER
 SAFETY PRECAUTIONS
BATTERY
 Convert stored chemical
energy into electrical energy

 Batteries only store power,

they do not create it.
Battery Construction
 COMPONENTS
 Positive plate : Lead peroxide (PbO2).
 Negative plate : Spongy lead (Pb)
 Electrolyte : Diluted sulphuric acid
(H2SO4 + H2O)
 Separator : Hard rubber and PVC
commonly used.
 Keeps positive and negative plates
electrically apart
 Cell connector : For inter-cell
connections. Heavy lead bar is used.
 Container : Acid resistant materials.
Hard glass, hard rubber, plastic.
 Cover : Covers each cell. Hard rubber is
used.
 Grid : Holds the active materials in
position. Mesh like structure of alloy of
lead and antimony
 Sealing compound : makes acid tight
joint between cover and case.
 High temperature and acid resistant
 Blend of specially processed
bituminous substance
TYPES OF BATTERY
 PRIMARY CELLS
 SECONDARY CELLS
 WET CHARGED
 DRY CHARGED
 LOW MAINTENANCE
 1. PRIMARY CELLS

 Destroys one of the metals after a

period of time.
 Cannot be recharged
 Small batteries for flashlights and
radios are primary cells.
 2. SECONDARY CELLS
 The metals and acid mixture change as
the battery supplies voltage.
 The metals become similar.
 The acid strength weakens.
 Can be recharged by applying current
to the battery in the opposite
direction.
 3. WET-CHARGED
 Filled with electrolyte and charged
when it is built.
 During storage, a slow chemical
reaction will cause self- discharge.
 Periodic charging is required.
 4. DRY- CHARGED
 The battery is built, charged, washed,
dried & sealed.
 Shipped without electrolyte.
 It can be stored for 12 to 18 months.
 When put into use, it requires adding
electrolyte .
 5. LOW- MAINTENANCE
 Most batteries for vehicles are low-
maintenance batteries.
 Such batteries are built to reduce
internal heat and water loss.
 The addition of water should only be
required every 15,000 miles or so.
 Like VRLA, AGM & gel type.
WORKING PRINCIPLE
 Positive plate called anode
 Negative plate called cathode
 Both plate are immersed in electrolytic
solution
 When both plate are connected by an
external load current flow from anode
to cathode
ELECTROCHEMICAL REACTION
 A lead acid storage battery can be
partially discharged and recharged
many times. There are four stages in
this discharging and charging cycle as
mentioned below:

 Discharging
 Charging
DISCHARGING
 In this cycle electrolyte becomes diluted and the
plates become sulphated. The electrolytes divided
into H2 & SO4. H2 combines with O to form H2O
& Pb & SO4 combines to form PbSO4.
 Pbo2+Pb+h2So4-pbso4+ pbso4+2h2o
CHARGING
During charging, the chemical action is
reversed. SO4 leaves the plates & combines with
H2 to become H2So4. O2 combines with Pb to
form PbO2. Gassing occurs as the battery near
full charge & hydrogen bubbles out at the –ve
plates, oxygen at the +ve.
• PbSo4+ PbSo4+2H2OPbO2+Pb+H2So4
FACTORS AFFECTING CHARGING
 There are five factors affect battery
charging by increasing its internal
resistance:
 1. TEMPERATURE
 2. STATE OF CHARGE
 3. PLATE AREA
 4. IMPURITIES
 5. GASSING
 TEMPERATURE
 As the temperature decreases the
electrolyte resists charging.
 A cold battery will take more time to
charge; a warm battery, less time.
 Never attempt to charge a frozen
battery
 STATE OF CHARGE
 The condition of the battery's active
materials will affect charging.
 A battery that is severely discharged
will have hard sulphate crystals on its
plates.
 The vehicle's charging system may
charge at too high of a rate to remove
such sulphates.
 PLATE AREA
 Small plates are charged faster than
large plates.
 When sulphating covers most of the
plate area, the charging system may
not be able to restore the battery.
IMPURITIES
 Dirt and other impurities in the
electrolyte increase charging difficulty.
 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.
CAUSES OF BATTERY FAILURE
 ELECTROYTE LEVEL
 OVERCHARGING
 UNDERCHARGING
 CORROSION
 CYCLING
 TEMPERATURE
 VIBRATION
 TESTING PROCEDURE
 All batteries require routine
maintenance to identify and correct the
problems caused by physical abuse and
low electrolyte levels.
 MAINLY TWO PROCESS ARE THERE
1.Visual Inspection
2. State of Charge Test
VISUAL INSPECTION
 VISUAL INSPECTION
 Check for cracks in the battery case and
for broken terminals
 Check for corrosion on terminals and
dirt or acid on the case top
 Check for a loose battery hold-down
and loose cable connections.
 Check the level of electrolyte.
 Check for cloudy or discoloured
electrolyte caused by overcharging or
vibration
 Check the tension and condition of the
alternator drive belt. A loose belt must
be tightened
 STATE OF CHARGE TEST
 Checks the battery’s chemical
condition
 Two methods:
1. Hydrometer
2. Digital voltmeter
 TEST RESULTS
Sp. Gravity Battery condition
readings
1.265 Fully charged
1.225 Run down
1.190 Sulphation begins
1.155 Severe discharge
1.120 Completely discharged
DIGITAL VOLTMETER
 Checks open circuit voltage
 Fully charged battery have 12.6 volts
 Dead battery gives 12.0 volts
CAPACITY RATINGS
 Capacity is the amount of electrical
energy the battery can deliver when
fully charged.
 Determined by the
 size & number of plates
 the number of cells & the strength
 volume of electrolyte.
The most commonly used ratings are :-

Cold Cranking Amperes (CCA)

Reserve Capacity (RC)
Amp-Hours (AH)
Cold Cranking Amperes (CCA)
 The discharge load a fully charged battery at
0˚F (-1 7.8˚C) can deliver for 30 seconds
while maintaining a voltage of at least 1.2
volts per cell (7.2 volts total for a 12-volt
battery).
 Measured in amperes(A).
 Batteries used on various vehicles have CCA
ratings ranging from 350 to 560 amps.
Reserve Capacity (RC)
 The length of time a fully charged battery at
80˚F (26.7'C) can be discharged at 25 amps
while maintaining a voltage of at least 1.75
volts per cell (10.5 volts total for a 12-volt
battery).
 Measured in minutes
 energy for ignition, lights, and accessories if
the vehicle's charging system fails.
 Batteries used on various vehicles have RC
ratings ranging from 55 to 115 minutes.
Amp-Hours (AH)
 This method of rating batteries is also called
the 20-hour discharge rating.
 The current the battery can provide for 20
hours at 80˚F (26.7˚C) while maintaining a
voltage of at least 1.75 volts per cell (10.5
volts total for a 12-volt battery).
 For example, a battery that can deliver 4
amps for 20 hours is rated at 80 amp-hours
(4 x 20 =80).
 SAFETY PRECAUTIONS
 Wear gloves and safety glasses.
 Remove rings, watches, other jewellery.
 Newer use spark producing tool.
 Newer lay tools on the battery.
 When removing cables, always remove the
ground cable first.
 Protect your body from electrolyte.
 If you have to mix battery electrolyte, pour
the acid into the water.
MODERN CAR BATTERIES
 Low maintenance
 Completely sealed
 No need of topping up.
 Charges quickly
 No risk of acid leak.
 Can be used in any orientation
 Environment friendly.
 More efficient
VRLA batteries
 Valve Regulated Lead Acid battery.
 Plates are similar to conventional lead
acid battery.
 Have pressure relief valve.
 Have range of 2-40 psi.
 No loss of electrolytes.
 Can be used in any orientation.
TYPES OF VRLA
Sealed VR wet battery
AGM battery
Gel battery
Sealed VR wet type
 Same as lead acid battery.
 Acid in liquid form.
 Loss in form of H2 and O2 is minimal.
 Gasses released only when pressure rises
above safe limits.
 Gasses recombine within battery itself.
 Not permanently sealed but they are
maintenance free.
AGM battery
 Absorbent Glass mat
 Electrolytes held in glass mats.
 Very thin Glass fibre are woven on a mat.
 Mats are soaked in acid and wrung out.
 Fibre don’t absorb and react with acid.
 Can take Shock and vibration.
 No risk of acid spillage.
 Recharges quickly.
DISADVANTAGE
 Cannot tolerate overcharging.
 Have shorter life.(6-8 YEARS)
 Costly.
Gel battery
 Jellified electrolyte.
 H2SO4 mixed with fumed silica.
 Fumed silica is universal thickening agent.
 Flame pyrolysis of silicon tetrachloride.
 No spillage and electrolyte evaporation.
 Greater shock and vibration resistant.
 Heavier.
ELECTRIC VEHICLE BATTERIES

Mercedes Benz-SLS AMG Coupe Electric Drive

BATTERY FEATURES
 No starting.
 Designed to give power over sustained
period of time.
 Deep cycle batteries are used.
 Commonly used Lithium-ion batteries.
 >4000 cycles , life upto 8 years.
Lithium-ion battery
 Negative plate – Carbon.(Graphite)
 Positive plate – Lithium Metal oxide.
 LiCoO2
 Electrolyte - lithium salt + organic
solvent.
 Each cell produces 3.2-3.6V
CONSTRUCTION
 Stacked in modules.
 10-16 modules.
 Each module have 50-500 cells.
 Cooling system is provided
liquid-cooled 400 V lithium-ion battery rated to 60 kWh
 The 548 kg battery pack.
 Made up 864 li-ion cells.
 Divided into 12 modules, each
comprising 72 lithium-ion cells.
DISADVANTAGES
 Electrolites are flammable.
 Positive electrode may produce oxygen.
 Heat is generated with use.
 Risk of explosion.
THANK YOU