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Old 05-26-2016, 05:56 PM   #1
AccuXperT
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Default My new invention: Battery-Analyzer for Segway-Batteries

-> Presentation of my development of a diagnostic tool for Segway batteries :

Foto 1 - Made in Germany - Kleineres Download vom Forum.JPG

-> Motivation :

During the development work on several battery-projects I had been looking for an opportunity to show the vital data of Segway batteries. It is known that the battery communicates over a system-bus with the Segway base and various data exchanges. After months of research of this data stream could be successfully interpreted. In a first version the presentation of relevant data of the battery was carried out on a computer screen, but this in daily use as a somewhat inflexible turned out.

To my opinion, it should be a portable device the size of a multimeter. So I came to the design of the "mobile visualizer", which combines many advantages in itself. A shapely, professional handset with TFT color display and keypad, which is traveling flexible Unlike other devices thus there is the advantage of complete independence from the mains, because the device work without power supply and batteries manages.

This project I want to introduce in detail below.

-> Principle of Operation :

The "mobile visualizer" or first Mobile Battery Analyzer - briefly MBA - was designed as an innovative device, which is connected via a 3 meter spiral cable and a safe adapter with the Segway battery.

Settings via the keypad and selected entries are made, are stored internally, a non-volatile memory (EEPROM) is used to thereby save the last setting for the next session. The approach has been from the outset great importance to security and network independence, the device is powered directly from the Segway battery.

After activating the device on the system-bus to the battery occurs in connection, reads the relevant data of the battery and displays it on a backlit TFT color display. The data are to cast 8 screens - provided, wherein the composition of the values ​​of the 8 screen can be freely selected by the user.

The (usually to the Segway-Base) sent Status of battery is permanently visualized, which can be estimated in advance, whether the base will accept a battery as error-free or not. Additionally warns an acousto-optic alarm the user about a critical operating condition and indicates a possible error situation.

-> The following values ​​from a original Segway battery ​​are visualized on the TFT color display :

- Status bytes (corresponding to the constantly data current from battery to Segway-Base)
- Battery status (OK / FAIL)
- Display of the battery fault code in Case of status = FAIL
- Status system-bus (OK / FAIL)
- 23 cell voltages, accuracy +/- 0.5%
- Maximum cell difference in mV (drift)
- Average cell voltage in mV (AVG)
- Cell with the highest voltage, indicating the cell number
- Cell with lowest voltage, indicating the cell number
- Total voltage in V (measurement by battery BMS), accuracy +/- 0.5%
- Total voltage from MBA internal ADC, accuracy +/- 0.5%
- Positiv current in mA (discharging), accuracy +/- 1%
- Negativ current in mA (charging), accuracy +/- 2%
- Maximum value pos. current
- Maximum value neg. current
- Total battery temperature in °C
- Temperature of 4 individual sensors in °C
- State of charge (S.O.C.) in %
- Capacity in Ah (charging / discharging to 4A through sockets on base adapter)
- Voltage of the internal 12V supply (ADC control value)

-> Other features and functions of the Mobile Battery Analyzer (MBA) :

- TFT-lighting with optional selectable power saving function
- On cast 8 screens displaying the data from the battery
- A screen can be assembled as desired by the user
- Stay made by the user changes permanent condition (EEPROM)
- Remains the last choice permanent condition (EEPROM)
- Audible and visual alarm function with undervoltage / overvoltage
- Audible and visual alarm function status = FAIL (with error code display)
- Data transfer to PC / Laptop via Q-record message
- Quick Start function
- Self-test function
- Device function in the range 32 ... 88V
- Carry out a possibility of battery fast charge / a Battery Capacity Test
- Possibility deeply discharged batteries to regenerate / recover
- Possibility to connect older batteries, for example, Rev.AC
- Unit by 2 relays uncoupled = no discharge when device plugged but off is
- High quality membrane keyboard with abrasion resistant printing and tactile feedback
- Professional hand housing

-> Security for equipment and battery :

There are several protections provided to both the MBA, as well as an adapted battery to best protect.

Decoupling the supply lines through internal relays :

Two internal relay if necessary disconnect from the adapted battery. In the event of a critical operating condition after alarm message automatically, or when the MBA is turned off by the user (pressing the Shift key for more than 1s).

There is another security mechanism: The relay connection is not even established when certain minimums are not met!
Before the controller of the MBA actuates a relay permanently, the amount of voltage to be switched by internal MBA ADC is checked. Not this in the predetermined voltage range, the relay is not energized and instead issued a warning, possibly Display of the faulty voltage value. Such measurements are performed for the first time with operating the red Power-On button.

-> Additional documentation: A first video on the functionality of the MBA can be found in my international YT Channel :

https://youtu.be/u9UsTmNTf44

-> Some project photos :

The operational Visualizer with 3 m spiral cable and battery adapter :

Foto 2 - Visualisierer mit 3m-Spiralkabel - Kleineres Download vom Forum.JPG

Typical application with original Segway battery (Rev. AF) :

Foto 3 - Anwendungsbeispiel mit AF-Akku - Kleineres Download vom Forum.JPG

The TFT shows individual cell voltages (here as a selection cell 17 ... 23) and the absolute cell voltage in mV difference (drift) :

Foto 6 - TFT zeigt einzelne Zellenspannungen und Zellen-Differenz - Kleines Download.JPG

Detail-Photo one of eight screens: a screen specifically for capacitance measurements. The TFT displays, in addition to capacity and current, all important values during discharging the battery. With an electronic load to the two sockets from the Base Adapter (red / blue), the capacity of a Segway battery can be determined.
The photo was taken during a measurement with typical 2,5A test current at 0,42Ah :

Foto 7 - TFT zeigt Kapazität und Strom an - Kleineres Download vom Forum.JPG
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Old 05-26-2016, 06:03 PM   #2
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Impressive!
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Old 05-28-2016, 01:29 AM   #3
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Very nice work. Will you be selling these?

jeff
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Old 05-28-2016, 03:39 AM   #4
AccuXperT
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Quote:
Originally Posted by jgbackes View Post
Very nice work. Will you be selling these?

jeff
But not now, perhaps later. Maybe I sell the software sources and the schematics to someone who makes me a good offer ...
With the knowledge of the software and the total control of the system bus a reliable fast charger could be built, as via the system bus the individual cell voltages, the cell temperature, and especially the timing of balancing is transmitted - and of course custom error codes if something goes wrong.
A safe Segway fully recharge in 2 hours is an option to the many users are interested - I have been practicing this for over 2 years with no apparent restriction or loss of capacity.

We will see...
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Old 06-08-2016, 03:54 PM   #5
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Exellent work!..

It takes long time to get this data.....😊
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Old 06-08-2016, 07:12 PM   #6
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Quote:
Originally Posted by dorrington View Post
Exellent work!..
Thank you, Sir!
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Old 10-26-2016, 04:16 AM   #7
felix_fetche
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Great job!

I need to buy one from you,

Can i contact you?

I have a workshop in Baia Mare, Romania.

I just start the business with cells refill and also reviving from deep discharge.
Your tool may be very useful in my business.
Best!

https://www.olx.ro/oferta/reparatii-...tml#103bb79ed8
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Old 10-26-2016, 04:20 AM   #8
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BTW,

With this tool can act to specific cell to charge if is low, or to discharge if is high?
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