GB2559375A

GB2559375A - Battery sensing device

Info

Publication number: GB2559375A
Application number: GB1701779.9A
Authority: GB
Inventors: Vuopionpera Raimo; Marek Pavel; Kucheryavy Evgeny
Original assignee: Tty Saatio Sr
Current assignee: Tty Saatio Sr
Priority date: 2017-02-03
Filing date: 2017-02-03
Publication date: 2018-08-08
Also published as: GB201701779D0

Abstract

A sensing device 720 for monitoring the status of a battery 700 comprises a sensor housing 702 configured to be mounted on an exterior of a battery proximate to a visual indicator 712 of a state of the battery such that a sensor 728 detects an output of the visual indicator. The sensing device further comprising a controller 726 configured to digitize the output of the visual indicator. The sensing device may be used to detect a fluid level, for example water and/or electrolyte level. The sensor housing may comprise light emitters 732a, 732b such as LEDs to display the digitized output, these light emitters may illuminate when the battery reaches a predetermined state which may be when the battery requires servicing. An array of light emitters may be provided which may represent a range of states of the battery such as an okay state, an attention required state and a not okay state. The sensor may comprise an optical sensor which may have an infra-red light source. The sensor may comprise a proximity sensor or ultrasound sensor. The sensing device may be connected to an external device 736 which may transmit the digitized output to a cloud server 740.

Description

Battery Sensing Device

The present invention relates to a battery sensing device. More particularly the present invention relates to a battery sensing device for sensing a state of a battery.

Background

Batteries store electrical charge and are operable to supply an electrical current to one or more devices to which they are attached. One practical use of a battery is for industrial motive power. For example forklift trucks, golf carts, cleaning machines (used for example in shopping centres and/or industrial facilities), luggage trains, cranes, industrial trucks, automobiles etc. may use a battery for providing electrical power. Industrial batteries are a relatively high cost item. However, such batteries are not always treated properly, and badly treated batteries quickly lose their ability to store energy. Some known batteries are fitted with a visual indicator to indicate to a user or operator a state of the battery in a human readable way, for example using a colour indicator or height indicator. Such analogue systems require a user or operator to be in physical proximity to the battery to read and interpret the indicator, for each and every battery pack. Furthermore, it is not always easy for a user or operator to understand or interpret the analogue visual indicator. For example it may not be easily understood whether a battery in question is in a normal state or in a state requiring servicing. One example of a battery which may use such a visual indicator is a lead-acid battery.

Summary

In a first aspect there is provided a sensing device for monitoring a battery status, comprising: a sensor housing, the sensor housing configured to be mounted on an exterior of a battery, proximate to a visual indicator of a state of the battery; the sensor housing comprising a sensor, the sensor configured to sense an output of the visual indicator of the battery; the sensing device further comprising a controller configured to digitize the output of the visual indicator of the battery, so as to provide a digitized output from the sensing device.

According to some embodiments, the state of the battery comprises a fluid level of the battery.

According to some embodiments, the fluid level comprises a water and/or electrolyte level.

According to some embodiments, the sensing device comprises a standalone sensing device.

According to some embodiments, the sensing device comprises its own power source.

According to some embodiments, the power source comprises a coin battery comprised within the sensor housing.

According to some embodiments, the power source is replaceable in the sensor housing.

According to some embodiments, the sensing device comprises one or more light emitters on the sensor housing to display the digitized output in a visual form.

According to some embodiments, the one or more light emitters comprises one or more LEDs.

According to some embodiments, the one or more light emitters comprises only a single light emitter.

According to some embodiments, the single light emitter is configured to be illuminated only when the state of the battery reaches a predetermined state.

According to some embodiments, the predetermined state comprises a state at which the battery requires servicing.

According to some embodiments, the one or more light emitters comprises an array of light emitters.

According to some embodiments, the array of light emitters is configured to represent a range of states of the battery.

According to some embodiments, the range of states comprises an “okay” state, an “attention required” state, and a “not okay” state.

According to some embodiments, the sensing device comprises connection means for connecting to an external device.

According to some embodiments, the external device is configured to transmit the digitized output to a cloud server.

According to some embodiments, the sensing device is configured to be powered and/or charged by the external device.

According to some embodiments, the sensing device is configured to be powered and/or charged by the battery being monitored.

According to some embodiments, at least one parameter of the sensing device is configurable.

According to some embodiments, a sampling frequency of the sensing device is configurable.

According to some embodiments, the sampling frequency is configurable: in a range of 12 to 24 samples per day; or in a range of 6 to 12 samples per day; or in a range of 3 to 6 samples per day; or in a range of 1 to 3 samples per day; or a single sample per day; or fewer than one sample per day.

According to some embodiments, the sampling frequency is configurable wirelessly.

According to some embodiments, the sensing device is configured to substantially enclose the visual indicator of the battery, in use.

According to some embodiments, the sensor comprises an optical sensor, the optical sensor comprising a light source, and a light sensitive photo detector.

According to some embodiments, the light source comprises an infra-red light source.

According to some embodiments, the sensor comprises a proximity sensor.

According to some embodiments, the sensor comprises an ultrasound sensor.

According to some embodiments, the sensing an output of the visual indicator of the battery comprising sensing any one or more of: distance to a surface of the visual indicator; movement of the visual indicator; a colour of the visual indicator; a colour change of the visual indicator.

According to some embodiments, the sensor housing comprises an opening disposed therein.

According to some embodiments, an open-end of the opening is configured to be mounted proximate to the visual indicator in use, and the optical sensor mounted proximate to a closed-end of the opening.

According to some embodiments, the opening is configured to allow the visual indicator to move therein, in use.

According to some embodiments, the sensing device comprises a microcontroller configured to digitize the output from the sensor.

According to some embodiments, the sensing device is configured such that the sensing device does not extend into an interior of the battery.

According to some embodiments the sensing device does not directly measure the state of the battery.

According to some embodiments the sensing device is configured to be mounted to the battery without requiring a physical modification to the battery or components of the battery.

According to some embodiments the visual indicator of the battery comprises an analogue visual indicator.

According to some embodiments the battery comprises a lead-acid battery.

According to some embodiments the visual indicator is mounted on the exterior surface of the battery.

According to some embodiments, one or more further battery state sensors are integrated in the housing of the sensing device.

According to some embodiments, the one or more further battery state sensors being operable to monitor one or more of: battery voltage; battery current; battery temperature.

In a further aspect there is provided a method comprising: using a sensing device mounted on an exterior of a battery, proximate to a visual indicator of a state of the battery, to sense an output of a visual indicator of the battery; and digitizing the output of the visual indicator of the battery, so as to provide a digitized output from the sensing device.

In a further aspect there is provided a computer program comprising at least one computer executable component which when run on a computer executes the method defined in the previous aspect.

Brief Description of Drawings

Some embodiments of the present invention will now be described in more detail with respect to the following drawings in which:

Figure 1 shows an example of a battery, such as a lead acid battery.

Figure 2 shows an example of a battery including a visual status indicator.

Figure 3 schematically shows a battery sensing device according to an embodiment.

Figures 4A to 4C show alternative light emitting arrangements of a sensing device according to embodiments.

Figure 5 shows a schematic diagram of a battery sensing device and an external apparatus according to an embodiment.

Figure 6 shows a battery sensing device attached to a battery, according to an embodiment.

Figure 7 shows a battery sensing device attached to a battery, according to another embodiment.

Figures 8A to 8G show alternative arrangements of battery visual indicators.

Figure 9 shows a flowchart of a method according to an embodiment.

Detailed Description

By way of background Figure 1 shows certain parts of a battery 100. The battery 100 may be an industrial battery as previously described. For example the battery may be a traction battery. The battery 100 comprises a housing or casing 102. As is known in the art, within the battery housing 102 there are comprised positive and negative battery terminals. The battery also comprises an electrolyte. In at least some embodiments the electrolyte comprises a fluid. On an exterior of the battery housing 102 there is comprised a positive connector 104 for connecting to the positive battery terminal, and a negative connector 106 for connecting to the negative terminal of the battery. The positive and negative connectors 104 and 106 can then be connected via wires or cables to components to be powered to provide electrical current thereto.

Over time and in particular with extended use, the level of electrolyte within the battery may decrease. If the level of electrolyte decreases too much then the battery may not be able to hold a charge and will cease to operate effectively, or may not operate at all. The battery 100 therefore comprises a plug assembly 108 and a removable lid 110. Once the lid 110 (and/or plug depending on its design) is removed then the fluid level of the battery can be topped up by pouring fluid into the battery through the plug 108 and/or an opening in the housing 102. The fluid may be an electrolyte and/or water. Where the fluid is water, distilled water may most preferably be used. The battery may be considered a “flooded” or “open-top” battery. The battery of Figure 1 may be a lead acid battery.

Figure 2 shows a certain aspects of a battery 200. The battery 200 comprises a battery housing 202, and positive and negative battery connectors 204 and 206 respectively. In this example the plug assembly 208 comprises a visual indicator 212 for indicating a fluid level within the battery 200. In this example the visual indicator 212 is configured to move as the fluid level within the battery changes. A user can thus ascertain by looking at the visual indicator 212 whether the fluid needs topping up. For example the visual indicator may be attached to a float that is configured to float on or in the fluid in the battery. The indicator 212 may therefore rise and fall as the fluid level (and therefore the float) in the battery rises and falls respectively, or may move in an opposite direction to the float, for example if connected thereto via a “swing” mechanism. In Figure 2 a lid (for closing plug 208) is not shown for clarity. The plug 208 comprises an indent 214. The indent 214 may receive a projection of the plug lid so that they can be firmly attached to each other.

Figure 3 is a schematic diagram of a battery sensing or monitoring device, according to an embodiment. Herein the phrases “battery sensing device” and “battery monitoring device” are used interchangeably. The battery sensing or monitoring device is shown generally at 320. The sensing device 320 comprises a housing 322. The housing 322 comprises attachment means or attachment point 324 for attaching the sensing device 320 to an exterior of a battery, or to a component of the battery (e.g. visual indicator plug). The attachment means enables the battery sensing device to be mounted proximate to a visual indicator that is indicative of a state of the battery. For example the attachment point 324 may enable the sensing device 320 to be attached to a fluid plug assembly of the battery to be sensed. The attachment means 324 may take any form. For example it may be a threaded male projection for engaging with a complementary female thread on the battery. Alternatively it may be a female thread for attaching to a complementary male thread on the battery. The attaching means 324 may also take any other form. For example it may be a projection for insertion into a recess or hole on the battery and/or battery plug, or a recess for engaging a projection on the battery and/or battery plug. In some embodiments the sensing device 320 may be a friction fit on the battery or on a component of the battery. Where the sensing device 320 is configured to attach to a fluid plug of the battery, then the attachment means 324 may mimic the attachment means of a plug lid which ordinarily would be attached to the plug. The sensing device may additionally or alternatively be of a form that mimics an outer form factor of a component (e.g. plug) to which it is to be mounted, enabling it to fit over the component like a sleeve. Generally speaking it will be understood that the sensing device 320 can be attached to a battery or component thereof in a number of different ways.

The battery sensing device 320 further comprises a controller 326. The controller may be in the form of a microcontroller. The controller may also be any other kind of programmable logic device, such as a micro or mini-computer or any other kind of programmable logic chip or microprocessor. This also applies to other controllers referred to elsewhere in the specification. The battery sensing device further comprises a sensor 328. In some embodiments the battery sensing device further comprises a power source 330.

As will be explained in more detail below, the sensor 328 is arranged to sense an output from a visual indicator located on the battery, the visual indicator configured to indicate a state of the battery. In some embodiments the sensor 328 comprises an optical sensor. Where an optical sensor is used, the sensor comprises a light source, and a light detector. The light detector may comprise a light-sensitive photo transistor. The light source may transmit visible light. In some embodiments the light source is an infrared light source. In other embodiments any other kind of sensor could be used. The sensor may be a distance or proximity sensor. For example the sensor may use an ultra sound source and receiver.

The controller 326 is arranged to receive and process signals from the sensor 328. The controller 326 may also drive and/or control the sensor 328, for example for triggering light emissions from the sensor (for example where an optical sensor is used). This may help with power saving features, as discussed in more detail below. The controller can then provide an output relating to the input from the sensor 328. That is the controller 326 may be considered to provide a digitised output of the information received from the sensor 328. As also explained in more detail below, in some embodiments the sensor 328 is arranged to sense output from an existing analogue visual indicator on the battery being monitored. Therefore it may be considered that the controller 326 (and therefore sensing device 320) is arranged to digitise information from an analogue visual indicator of a battery. The digitised output can be provided in any manner, and/or to any other device.

In the embodiment of Figure 3 the sensing device 320 comprises at least one visual output 332. In this example the visual output 332 is in the form of one or more light emitters. In some embodiments the one or more light emitters comprises one or more laEDs. This is explained in more detail below with respect to Figure 4.

In the embodiment of Figure 3 the sensing device 320 comprises a power source 330. In some embodiments the power source 330 comprises a button or coin battery. The power source 330 provides the necessary power to the controller 326, sensor 328 and light emitter 332. In some embodiments the power source 330 is removable and replaceable in the sensing device 320. Where the sensing device 320 has an integrated (or its own) power source then it may be considered a standalone sensing device 320.

Optionally, the sensing device 320 may comprise at least one further connection means or connection point 334. The connection means 334 enables the sensing device 320 to be attached to one or more further devices. In one embodiment the connection means 334 enables the device 320 to be attached to the terminal connection points of the battery being sensed, via one or more electrical leads. In such a case the power to the sensing device 320 may be supplied by the battery being sensed/monitored. In such embodiments the battery 330 may be omitted.

Figure 4A to 4C show possible alternative arrangements of the at least one light emitter 332 on the sensing device 320. It will be understood that other arrangements are also possible, and that Figures 4A to 4C merely show three possible implementations.

In Figure 4A the sensing device 320 comprises only a single light emitter 332. This may be in the form of a single LED 332. The use of a single light emitter minimises the required power output of the device. Therefore the single LED option may be useful for minimising power consumption of the battery 330. In some embodiments the single LED 332 is only illuminated when it is sensed that the battery being monitored is in a “not okay” or “alarm” state i.e. the battery needs servicing such as a top up of electrolyte and/or water. A red LED may be used for this purpose. By only illuminating when servicing is required this again minimises power consumption of the device. Of course the opposite is also possible whereby the LED is illuminated when the battery is in an “okay” state, and is then extinguished when the battery moves to a “not okay” state. A green LED may be used for indicating an “okay” state.

Figure 4B shows an exampie where the sensing device 320 comprises two light emitters, that is light emitters 332a and 332b. One of the light emitters may be used to signal that the battery is in an okay state, and the other light emitter may be used to signal that the battery is in a not okay state. For example LED 332a may be a green LED indicating that the battery is okay or operating within normal parameters. Once it is determined that the battery state is not okay e.g. servicing is required, then LED 332b may be illuminated. LED 332b may be a red LED. In some embodiments, only one of LEDs 332a and 332b is illuminated at the same time.

Figure 4C shows an exampie where there are three light emitters, namely light emitters 332a, 332b and 332c. To this end it may be considered that the sensing device 320 comprises an array of LEDs. The first LED 332a may indicate that the battery is operating normally i.e. it is in an okay state. LED 332b may be used to indicate that the battery is still operable but will shortly require attention i.e. this may be considered an “attention required” state. LED 332c may be used to represent that the battery is in the “not okay" state i.e. requires immediate attention. Again, different colour LEDs may be used to represent the different states. For example LED 332a may be green, LED 332b may be orange or amber, and LED 332c may be red.

One or more light emitters (e.g. LEDs) may also be provided external from the device 320 itself. For example, where the battery being monitored is a traction battery, then an LED representing the state of the battery may be placed, for example in a cab or cockpit or on a control panel of the industrial equipment in which the monitored battery is present, or in an office of a supervisor. Therefore a user or operator does not need to come within proximity of the battery in order to determine its status. The visible light emitter provides a quick and easy way for a person to see a state of a battery, even from some distance and/or at a quick glance. This may apply when the battery or batteries" are" in' storage or in use.

As shown in Figure 4A to 4C, the device 320 has a generally circular outer periphery (in plan view). It will of course be understood that other shapes/cross sections are possible. For example the sensing device may be generally square, rectangular etc.

In some embodiments a light emitter on the sensing device may be used to indicate when a charge of a battery 330 of a standalone sensing device is running low e.g. below a predetermined threshold.

In some embodiments the sensing device may also be configured to provide and/or trigger an audible output, such as an alarm sound for indicating to an operator that the battery requires attention. To this end one or more speakers (not shown) may be provided.

Figure 5 shows another embodiment of a sensing device 520. Similar to the embodiment of Figure 3, the sensor device 520 comprises a housing 522, a sensor 528, and a controller 526. As previously described the controller 526 may be a microcontroller, or indeed any other type of controller. The sensor 528 and controller 526 may operate in the same or a similar manner as that explained with respect to Figure 3, and therefore this detail is not repeated for conciseness. The sensing device 520 is attached to an external device 536. The external device 536 is operable to receive information from the controller 526 of the sensing device 520. In some embodiments the external device 536 is located proximate to the sensing device 520 when in use. For example the external device 536 may also be located on the battery being monitored and/or on the vehicle in which the battery is located. The external device 536 comprises a radio portion 538. The radio portion 538 enables the external device 536 to transmit information using standard transmission technology, such as wired or wireless technology. For example the external device 536 may wirelessly communicate information to a server, such as a cloud server 540. The external device 536 may be connected to the sensing device 520 via a wire 535. Thus, by this system the battery status information can be transmitted to a cloud server, where the information can be processed and/or used. Operators at or in communication with the cloud server can then monitor the status of one or more (and possibly many) batteries in use, enabling them to efficiently determine and arrange servicing of those batteries. Battery state information sent to the cloud server 540 may include information such as battery voltage, battery current, battery temperature, battery water level, battery electrolyte level etc. Such information may be presented in a graphical form enabling an operator in communication with the cloud server to see how these parameters vary over time.

Although in Figure 5 the sensing device 520 and external device 536 have been shown separately, it will be understood that in other embodiments they may be integrated into a single, unitary device.

It will also be understood that elements of the embodiments of Figures 3 and 5 may be combined in any way. For example the sensing device 520 may also include a battery 330 in the sensing device 520. Additionally or alternatively a battery 537 may be provided in the external device 536 for powering the external device and/or the sensing device 520. The sensing device 520 may also comprise at least one lighting element 332, Although not shown in Figure 5 the external device 536 may also comprise one or more lighting elements/LEDs for showing the status of the external device 536 and/or the battery being monitored. The external device 536 may also comprise its own controller.

In embodiments where a sensing device 520 is in communication with an external device 536, controlling means (e.g. a microcontroller) may be provided in either or both of the sensing device 520 and external device 536.

Figure 6 shows an example of a “stand-alone” sensing device 620 attached to a fluid (e.g. water/electrolyte) plug 608 of a battery 600. As described with respect to Figure 2, the battery 600 comprises a visual indicator 612 of a state of the battery. In this example the visual indicator 612 comprises an analogue visual indicator which may rise and fall with changing fluid/electrolyte level in the battery. In this example, the sensing device 620 is arranged to monitor the battery by sensing a position of the visual indicator 612.

As previously explained, the sensing device 620 comprises a power source 630, a controller 626, at least one light emitter 632, and a sensor 628. In this example the sensor 628 comprises an infrared sensor, which can emit an infrared beam 629 which can be fired at the visual indicator 612. The beam 629 is then reflected back to a light receiver of the sensor 628, enabling a position of the visual indicator 612 to be determined. This information can then be sent to the controller. The controller may control the at least one light emitter 632 as previously described.

The schematic diagram of Figure 6 is shown in cross-section through the sensing device 620 and plug 608. In embodiments the sensing device 620 may substantially enclose the visual indicator 612, such that the visual indicator 612 is not visible when the sensing device 620 is attached. To this end the sensing device 620 comprises an opening 621 for housing the visual indicator. The opening 621 comprises an open end 623 through which the visual indicator 612 can enter the interior of the sensing device. The opening 621 also comprises a closed end 625 The sensor 628 is mounted proximate to the closed end 625.

The sensing device 620 is provided with a projection 624 for engaging with a corresponding recess 614 on the fluid plug 608. This enables the sensing device to be securely fitted to the plug. The projection 624 may be a friction fit, such as a push fit, in the recess 614. In this example the sensing device 620 also comprises a hinged connection 627 to the plug 608. This allows the sensing device 620 to pivot back and forth between open and closed configurations on the plug 608, without having to be completely detached therefrom.

In some embodiments, when it is detected that the battery needs servicing the plug 608 can be removed from the battery housing 602, to reveal an opening into the interior of the battery housing 602. For example fluid can be poured into the battery through said opening. In some embodiments the plug 608 and sensing device 620 can be removed together, effectively as one piece. Alternatively they can be separately removed in turn. In some embodiments fluid can be poured into the battery 600 through an opening in the battery housing, via the plug 608 (i.e. the plug 608 does not need to be removed).

Figure 7 shows an example of a sensing device 720 of the type shown in Figure 5 (i.e. connected to an external device), connected to a plug 708 of a battery 700. Features in common with earlier embodiments are given a different leading reference numeral. For example sensing device 720 is equivalent to sensing device 520. For conciseness a full description is not repeated for all features previously described.

As discussed, the embodiment of Figure 7 relates to an embodiment where the sensing device 720 is connected to an external device 736. The external device 736 comprises a radio portion 738 and a power source 737. The external device 736 can communicate with a server 740, which may be a cloud server. As previously discussed, the external device 736 may comprise its own power source 737, enabling the externa! device 736 to power the sensing device 720. Additionally or alternatively the external device 736 is powered by the battery 700 being monitored. This is represented schematically in Figure 7 where leads 742 and 744 are provided from the external device 736 for connecting to the connection posts 704 and 706 of the battery 700. These connections from the external device 736 to the connecting posts 704 and 706 of the battery 700 may additionally or alternatively be used to obtain further information on the state of the battery, such as current, voltage etc. This information may also be conveyed to the cloud server 740. In some embodiments the external device 736 may also comprise a controller 739, such as a microcontroller.

In the example of Figure 7 the external device 736 also comprises light emitters 732a and 732b connected to controller 739. In one example the LED 732a indicates a “power on” state of the external device 736. For example this may be a green LED. The light emitter 732b may indicate an “alarm” state. For example this may be a red LED. This may indicate for example if the battery needs to be serviced.

As previously discussed the visual indicator of the state of the battery may take many forms. The visual indicator may be considered part of the battery that is being monitored. For example in some embodiments when the battery is purchased it may include the visual indicator. In at least some embodiments the visual indicator of the state of the battery comprises an analogue visual indicator. In some embodiments the visual indicator comprises a mechanical arrangement. In some embodiments the visual indicator is configured to be directly in contact with the state of the battery that is being monitored. For example if the parameter of the battery that is being monitored is a fluid level, then the visual indicator (of a component thereof) may be in direct contact with the fluid.

Figures 8A to 8G show some examples of visual indicators and sensing arrangements which may be utilised in conjunction with the present invention.

In Figure 8A the visual indicator 812 comprises a rod 811. The rod 811 comprises at least one light coloured portion 850 and at least one dark coloured portion 852. In some embodiments the light coloured portion is white, and the dark coloured portion is black. As a fluid level in the battery varies, then the rod 811 moves up and down, as represented by arrow 854. The sensor 828 can sense the position of the indicator 812 by detecting a colour and/or colour change of the indicator as it moves. This information can be sent to the controller (not shown) which can then determine the state of the battery. A similar but alternative arrangement is shown in Figure 8B in which the rod 811 is connected to a wheel 813, such that up and down movement (shown by arrow 854) of the rod is converted into rotary movement (shown by arrow 855) of wheel 813. The wheel comprises at least one light coloured portion 850 and at least once dark coloured portion 852. Again, the sensor 828 can detect the colour/colour change as the state of the battery varies (e.g. fluid level), which information can be sent to the controller for processing.

Figure 8C shows a further alternative arrangement. This arrangement is similar to that of Figure 8B except the light and dark coloured portions 850 and 852 being sensed by the sensor 828 are disposed on a circumferential edge of the wheel 813, rather than on its circular face.

Figure 8D shows an arrangement whereby the sensor 828 senses either the appearance or disappearance (e.g. presence or lack of presence or movement there between of those two states) of the visual indicator 812.

Figure 8E shows an example where the sensor 828 comprises a digital measuring stick. Therefore in this embodiment the sensor 828 is not an optical sensor. In the example of Figure 8E the digital measuring stick 828 is physically attached to the visual indicator 812 in the form of rod 811. Therefore the digital measuring stick can determine movement 854 of the indicator 812 e.g. as fluid level in the battery rises and falls.

Figure 8F shows an example where the sensor 828 measures a distance X between the sensor 828 and the visual indicator 812. In this manner the sensor can sense movement 854 of the visual indicator 812 (e.g. in the form of rod 811) as it moves e.g. as it rises and falls along with fluid level in the battery being monitored.

Figure 8G shows another alternative where the sensor 828 senses a colour change between light and dark regions 850 and 852 on a visual indicator 812. In this example vertical movement 854 of rod 811 is translated into horizontal movement 857 of the visual indicator 812.

Therefore generally speaking it will be understood that the visual indicator and sensing means, and their interrelationship, can take many forms. It will however be appreciated that in at least some embodiments the sensor is operable to digitise an output from an analogue visual indicator of the battery.

Where the sensor of the sensing device comprises an optical sensor, output of the sensor comprises a voltage corresponding to an amount of reflected light. In a case of a position indicator, the amount of reflected light depends on a distance of the indicator’s surface from the sensor. In a case of a colour changing indicator, the amount of reflected light depends on the indicator’s color. An ADC (analogue to digital) converter (integrated to microcontroller) may be used to obtain a digital value for further processing. Also simpler logic (e.g. a voltage comparator) can be used, in some embodiments.

Figure 9 is a flowchart showing a method according to at least some embodiments.

At step S1 an output of a visual indicator of a state of a battery being monitored is sensed.

At step S2 the output of the visual indicator is digitised by the sensing device. This may provide a digitised output from the sensing device. In at least some embodiments the digitisation step is carried out by a microprocessor of the sensing device, operating on signals received from a sensor of the sensing device.

In at least some embodiments the sensing device may be considered an integrated sensing device in that it integrates a number of components. For example the sensing device may integrate both the sensing unit (e.g. optical sensor), and microprocessor (e.g. digitiser) in the same housing. The integrated sensing device may further comprise its own power source (e.g. battery). The integrated sensing device may further comprise other battery state sensors, such as sensors configured to measure temperature and/or current and/or voltage etc. Therefore it will be appreciated that a number of components/sensors may be integrated within the sensing device housing.

In at least some embodiments the sensing device is configurable. For example parameters of the sensing device may be configured/updated overtime. Such configurations may be carried wirelessly over the air. Alternatively a computer may be connected by a cable to the sensing device in order to carry out the configuration changes/updates.

In at least some embodiments a sampling frequency of the sensing device is configurable. The sampling frequency may be considered how often the sensing device samples the battery to determine its state. Adjusting the sampling frequency may allow for power saving, and therefore increased time between battery replacement in the sensing device and/or charging of the sensing device. This may be particularly useful where the sensing device is a stand-alone sensing device in that it comprises its own power source (e.g. coin battery), so as to maximise longevity of the sensing device.

In one particular embodiment, the stand-alone sensing device may comprise a single LED output (e.g. as shown in Figure 4A), and be configurable to (or configured or preconfigured with) a relatively low sampling frequency. Such an embodiment may require minimal power from the sensing device’s own battery.

Some example sampling frequencies include a range of 12 to 24 samples per day; or a range of 6 to 12 samples per day; or a range of 3 to 6 samples per day; or a range of 1 to 3 samples per day; or a single sample per day; or fewer than one sample per day. Of course other sampling frequencies may be provided. The very low sampling frequencies (e.g. a single sample per day or fewer than one sample per day (e.g. one sample every two days)) may be particularly useful when the battery is in storage rather than operational on equipment. Therefore in some embodiments the configuration of the sensing device can be changed/updated to reflect the changing operation status of the battery being monitored. For example a relatively low sampling frequency may be used when the battery being monitored is in storage, and then the sampling frequency may be changed to a relatively higher sampling frequency when the battery is subsequently installed in a vehicle for use. In some embodiments the sampling frequency may be altered dependent on the state of the battery being monitored. For example, the sampling frequency may be increased as it is determined that a battery being monitored is approaching a “not okay” state. In some embodiments the change in configuration may take place in an automated fashion. In some embodiments logic is implemented in the sensor device (e.g. in the controller), configured to detect the change of state. For example after a certain period of time the device enters a power saving mode and begins sampling with a low or lower frequency. In some embodiments this may also be a gradual process where the sampling frequency is lowered over time, to or towards a certain lowest possible frequency. Moreover there may be programmed logic to wakeup the sensor device to an active mode if certain changes (like detection of flowing current, or change of direction of current in the battery being monitored) are detected to have occurred.

As mentioned above it will also be understood that other aspects of the sensing device may be configurable.

It will be understood and appreciated the battery sensing or monitoring device according to embodiments of the present invention can be easily fitted or retro-fitted to an existing battery. Therefore the battery sensing device may be considered non-intrusive to the battery. For example there may be no need to drill holes in the battery being monitored, or to replace internal parts of the battery being monitored or previously installed systems thereof. Therefore the battery sensing device can be simply placed on or over existing items of the battery being monitored. For example the battery sensing device can be simply placed on or over an existing visual indicator of a state of the battery. The battery sensing device can also be easily removed from a battery being monitored.

In at least some embodiments it may be considered that the battery sensing device indirectly monitors the state of the battery. That is the battery sensing device is not itself directly monitoring the parameter of the battery that is being monitored. Rather the existing visual indicator of the battery directly monitors the state of the battery, and the battery sensing device monitors the visual indicator in order to obtain the battery status information. As mentioned above the battery sensing device may then be operable to digitise status information and to provide that digitised information as an output. As mentioned above this means that the battery sensing device can be fitted to the battery being monitored in a nonintrusive fashion.

In some embodiments the actual physical design of the housing of the sensor is such that it can be easily clipped onto an existing optical level indicator plug. For example, it can replace an existing lid of an optical electrolyte level indicator or it is dimensioned in such a way that one can just easily place it over an existing indicator plug so that the sensor is placed correctly over the optical indicator. In some embodiments the sensing device is configured to recognize when it is not properly attached to or relative to the indicator. An output may be provided to an operator indicative of the faulty attachment (such as firing of a light emitter on the device). This may help to avoid faulty alarms. The housing of the sensing device can be formed of any material. In some embodiments the housing of the sensing device is made from plastic (or primarily from plastic). In some embodiments the sensing device comprises a corrosion resistant material and/or coating, to provide corrosion resistance for example against the types of acids used in batteries.

An appropriately adapted computer program code product or products may be used for implementing the embodiments, when loaded on an appropriate data processing apparatus. The program code product for providing the operation may be stored on, provided and embodied by means of an appropriate carrier medium. An appropriate computer program can be embodied on a computer readable record medium. A possibility is to download the program code product via a data network. In general, the various embodiments may be implemented in hardware or special purpose circuits, software, logic or any combination thereof. Embodiments of the inventions may thus be practiced in various components such as integrated circuit modules. The design of integrated circuits is by and large a highly automated process. Complex and powerful software tools are available for converting a logic level design into a semiconductor circuit design ready to be etched and formed on a semiconductor substrate.

It is also noted herein that while the above describes exemplifying embodiments of the invention, there are several variations and modifications which may be made to the disclosed solution without departing from the scope of the present invention.

Claims

Claim

1. A sensing device for monitoring a battery status, comprising: a sensor housing, the sensor housing configured to be mounted on an exterior of a battery, proximate to a visual indicator of a state of the battery; the sensor housing comprising a sensor, the sensor configured to sense an output of the visual indicator of the battery; the sensing device further comprising a controller configured to digitize the output of the visual indicator of the battery, so as to provide a digitized output from the sensing device.

2. A sensing device as set forth in claim 1, the state of the battery comprising a fluid level of the battery.

3. A sensing device as set forth in claim 2, the fluid level comprising a water and/or electrolyte level.

4. A sensing device as set forth in any preceding claim, the sensing device ™ comprising a standalone sensing device.

5. A sensing device as set forth in any preceding claim, the sensing device comprising its own power source.

6. A sensing device as set forth in claim 5, the power source comprising a coin battery comprised within the sensor housing.

7. A sensing device as set forth in claim 5 or claim 6, the power source being replaceable in the sensor housing.

8. A sensing device as set forth in any preceding claim, comprising one or more light emitters on the sensor housing to display the digitized output in a visual form,

9. A sensing device as set forth in claim 8, the one or more light emitters comprising one or more LEDs.

10. A sensing device as set forth in claim 8 or claim 9, the one or more light emitters comprising only a single light emitter.

11. A sensing device as set forth in claim 10, the single light emitter configured to be illuminated only when the state of the battery reaches a predetermined state.

12. A sensing device as set forth in claim 11, wherein the predetermined state comprises a state at which the battery requires servicing.

13. A sensing device as set forth in claim 8 or claim 9, wherein the one or more light emitters comprises an array of light emitters.

14. A sensing device as set forth in claim 13, the array of light emitters configured to represent a range of states of the battery.

15. A sensing device as set forth in claim 14, the range of states comprising an “okay” state, an “attention required” state, and a “not okay” state.

16. A sensing device as set forth in any preceding claim, comprising connection means for connecting to an external device.

17. A sensing device as set forth in any preceding claim, the external device configured to transmit the digitized output to a cloud server.

18. A sensing device as set forth in any preceding claim, the sensing device configured to be powered and/or charged by the external device.

19. A sensing device as set forth in any of claims 1 to 17, the sensing device configured to be powered and/or charged by the battery being monitored.

20. A sensing device as set forth in any preceding claim, at least one parameter of the sensing device being configurable.

21. A sensing device as set forth in any preceding claim, a sampling frequency of the sensing device being configurable.

22. A sensing device as set forth in any preceding claim, the sampling frequency being configurable: in a range of 12 to 24 samples per day; or in a range of 6 to 12 samples per day; or in a range of 3 to 6 samples per day; or in a range of 1 to 3 samples per day; or a single sample per day; or fewer than one sample per day.

23. A sensing device as set forth in claim 21 or 22, the sampling frequency being configurable wirelessly.

24. A sensing device as set forth in any preceding claim, the sensing device configured to substantially enclose the visual indicator of the battery, in use.

25. A sensing device as set forth in any preceding claim, the sensor comprising an optical sensor, the optical sensor comprising a light source, and a light sensitive photo detector.

26. A sensing device as set forth in claim 25, the light source comprising an infrared light source.

27. A sensing device as set forth in any preceding claim, the sensor comprising a proximity sensor.

28. A sensing device as set forth in any preceding claim, the sensor comprising an ultrasound sensor.

29. A sensing device as set forth in any preceding claim, the sensing an output of the visual indicator of the battery comprising sensing any one or more of: distance to a surface of the visual indicator; movement of the visual indicator; a colour of the visual indicator; a colour change of the visual indicator.

30. A sensing device as set forth in any preceding claim, the sensor housing comprising an opening disposed therein.

31. A sensing device as set forth in claim 30, an open-end of the opening configured to be mounted proximate to the visual indicator in use, and the optical sensor mounted proximate to a closed-end of the opening.

32. A sensing device as set forth in claim 30 or claim 31, the opening configured to allow the visual indicator to move therein, in use.

33. A sensing device as set forth in any preceding claim, comprising a microcontroller configured to digitize the output from the sensor.

34. A sensing device as set forth in any preceding claim, the sensing device configured such that the sensing device does not extend into an interior of the battery.

35. A sensing device as set forth in any preceding claim, wherein the sensing device does not directly measure the state of the battery.

36. A sensing device as set forth in any preceding claim, wherein the sensing device is configured to be mounted to the battery without requiring a physical modification to the battery or components of the battery.

37. A sensing device as set forth in any preceding claim, wherein the visual indicator of the battery comprises an analogue visual indicator.

38. A sensing device as set forth in any preceding claim, wherein the battery comprises a lead-acid battery.

39. A sensing device as set forth in any preceding claim, the visual indicator mounted on the exterior surface of the battery.

40. A sensing device as set forth in any preceding claim, one or more further battery state sensors being integrated in the housing of the sensing device.

41. A sensing device as set forth in claim 40, the one or more further battery state sensors being operable to monitor one or more of: battery voltage; battery current; battery temperature.

42. A method comprising: using a sensing device mounted on an exterior of a battery, proximate to a visual indicator of a state of the battery, to sense an output of a visual indicator of the battery; and digitizing the output of the visual indicator of the battery, so as to provide a digitized output from the sensing device.

43. A computer program comprising at least one computer executable component which when run on a computer executes the method defined in claim 42.