Design Article
Selecting the right battery
Pushek Madaan and Rajiv Badiger, Cypress
6/19/2012 8:00 AM EDT
Part 1: Selection criteria and charger implementation
As more devices become mobile, efficient battery usage has become essential. Engineers tend to give utmost importance to the current consumption of the device. They devise numerous ways to reduce the power consumption because the longer the battery lasts, the greater perceived market value for the product. One important aspect to consider here is the battery itself.
Selecting an appropriate battery for a particular application is important because the battery determines the number of hours for which the device can work without the need for recharging, the amount of weight it adds to the system, and how much it adds to the BOM (bill of materials) cost. Along with the selection of battery, proper design of charging circuitry is also crucial because improper design can reduce the battery life or can even lead to battery failure (i.e., dangerous leakage or explosion). Failure leading to produce recall can cause massive losses and damage a manufacturer’s reputation.
This article discusses the following topics:
1. Different types of rechargeable batteries
2. Comparison and selection criteria of different types of batteries
3. CC-CV charging method (Part 2)
4. Implementation using a microcontroller (Part 2)
Types of rechargeable batteries:
Rechargeable batteries come in various shapes and sizes, ranging from a coin cell to a battery weighing on the order of tons. These batteries can be classified based on their chemical properties. Some of the most commonly used batteries are:
1. Nickel Cadmium (Ni-Cd) battery
2. Nickel-Metal Hydride battery (NiMH)
3. Lead Acid battery
4. Lithium Ion battery
Nickel Cadmium (Ni-Cd) battery:
Ni-Cd batteries are one of the oldest battery technologies on the market and have distinct advantages like low cost for low power applications, sturdiest for rough environments, and the ability to be recharged many times. These batteries pack nickel hydroxide (Ni(OH)2) electrode as the cathode (positive) and cadmium hydroxide (Cd(OH)2) as the anode (negative) in electrolytic solution comprising of potassium hydroxide (KOH).
One Ni-Cd cell gives 1.2V during discharge. These batteries have a flat discharge rate that falls rapidly at the end of the cycle as shown in Figure 1. Thus, it is difficult to estimate the amount of charge left. The advantage of this kind of battery is that it can withstand deep discharges without damaging the cell.
Along with the advantages mentioned, Ni-Cd comes with disadvantages as well, resulting in shrinking market share. Some of the major disadvantages include:
• Memory Effect: If the battery is repeatedly overcharged after partial discharging, it loses its capability to hold the maximum energy. This condition is referred as the memory effect. Thus, it is advised to either go for precisely controlled charging or regularly do a deep discharge such that the battery can recover its capacity. However, care must be taken since excessive deep discharge can permanently damage the cells.
• Cell Reversing: A battery consists of many cells connected together where each cell differs from the others slightly in terms of capacity. Thus, when one cell completely discharges before the other cells, the remaining cells will still force current through the discharged cell. This is known as cell reversing and results in undesirable and irreversible chemical reactions which permanently damage the cell.
• Over-Charging: When fully charged, the positive electrode (nickel) generates oxygen while the negative electrode (cadmium) generates hydrogen gas. These gases must be properly vented out from the system or operating conditions can become hazardous. To address this problem in sealed Ni-Cd batteries, the negative electrode (cadmium) is built with higher capacity. This causes the positive electrode to reach its fully charged state before negative electrode does. Thus, the oxygen released by positive electrode gets absorbed by the negative electrode and oxidizes.
As more devices become mobile, efficient battery usage has become essential. Engineers tend to give utmost importance to the current consumption of the device. They devise numerous ways to reduce the power consumption because the longer the battery lasts, the greater perceived market value for the product. One important aspect to consider here is the battery itself.
Selecting an appropriate battery for a particular application is important because the battery determines the number of hours for which the device can work without the need for recharging, the amount of weight it adds to the system, and how much it adds to the BOM (bill of materials) cost. Along with the selection of battery, proper design of charging circuitry is also crucial because improper design can reduce the battery life or can even lead to battery failure (i.e., dangerous leakage or explosion). Failure leading to produce recall can cause massive losses and damage a manufacturer’s reputation.
This article discusses the following topics:
1. Different types of rechargeable batteries
2. Comparison and selection criteria of different types of batteries
3. CC-CV charging method (Part 2)
4. Implementation using a microcontroller (Part 2)
Types of rechargeable batteries:
Rechargeable batteries come in various shapes and sizes, ranging from a coin cell to a battery weighing on the order of tons. These batteries can be classified based on their chemical properties. Some of the most commonly used batteries are:
1. Nickel Cadmium (Ni-Cd) battery
2. Nickel-Metal Hydride battery (NiMH)
3. Lead Acid battery
4. Lithium Ion battery
Nickel Cadmium (Ni-Cd) battery:
Ni-Cd batteries are one of the oldest battery technologies on the market and have distinct advantages like low cost for low power applications, sturdiest for rough environments, and the ability to be recharged many times. These batteries pack nickel hydroxide (Ni(OH)2) electrode as the cathode (positive) and cadmium hydroxide (Cd(OH)2) as the anode (negative) in electrolytic solution comprising of potassium hydroxide (KOH).
Figure 1: Discharge rate of Ni-Cd battery
One Ni-Cd cell gives 1.2V during discharge. These batteries have a flat discharge rate that falls rapidly at the end of the cycle as shown in Figure 1. Thus, it is difficult to estimate the amount of charge left. The advantage of this kind of battery is that it can withstand deep discharges without damaging the cell.
Along with the advantages mentioned, Ni-Cd comes with disadvantages as well, resulting in shrinking market share. Some of the major disadvantages include:
• Memory Effect: If the battery is repeatedly overcharged after partial discharging, it loses its capability to hold the maximum energy. This condition is referred as the memory effect. Thus, it is advised to either go for precisely controlled charging or regularly do a deep discharge such that the battery can recover its capacity. However, care must be taken since excessive deep discharge can permanently damage the cells.
• Cell Reversing: A battery consists of many cells connected together where each cell differs from the others slightly in terms of capacity. Thus, when one cell completely discharges before the other cells, the remaining cells will still force current through the discharged cell. This is known as cell reversing and results in undesirable and irreversible chemical reactions which permanently damage the cell.
• Over-Charging: When fully charged, the positive electrode (nickel) generates oxygen while the negative electrode (cadmium) generates hydrogen gas. These gases must be properly vented out from the system or operating conditions can become hazardous. To address this problem in sealed Ni-Cd batteries, the negative electrode (cadmium) is built with higher capacity. This causes the positive electrode to reach its fully charged state before negative electrode does. Thus, the oxygen released by positive electrode gets absorbed by the negative electrode and oxidizes.
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Sanjib.Acharya
6/19/2012 1:21 PM EDT
This is a very nice overview of the different battery technologies.
What does the "efficiency" in the table providing a summary of the different types of batteries indicate? Efficiency of charging-discharging?
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katgod
6/20/2012 12:52 PM EDT
Good question and based on the numbers I think your guess of charge - discharge is a good one.
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Frank Eory
6/19/2012 4:19 PM EDT
Good article, but the material seems a bit dated. NiCd is in steep decline -- are those batteries even allowed in Europe anymore? And NiMH has mostly been superseded by Lithium ion for nearly all consumer portable applications.
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Hughston
6/21/2012 12:24 PM EDT
I thought Europe banned them in the mid 90s for environmental reasons.
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SimulinkJocky
6/20/2012 9:01 AM EDT
There is quite a lot of information out there pointing out that the real NICAD memory effect is largely gone in modern designs. Damage from overcharging is NOT the memory effect.
The use of a smart charger for both NI-MH and NICAD can eliminate overcharging. I hope you're going to go into that next week.
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docdivakar
6/20/2012 3:58 PM EDT
@Frank Eory & IFindNickNamesAnnoying: you are both correct, NiCd have been phased out in EU countries now, under the "batteries directive" the sale of except for medical use, alarm systems, emergency lighting, and portable power tools. This last category is to be reviewed soon.
In the US, part of the battery price charged goes toward recycling. But we all know many states are lacking in recycling e-wastes and consumers are also complicit in adhering to recycling.
MP Divakar
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Erny48
6/21/2012 2:31 AM EDT
A good article, but shouldn't it include
Lithium Iron Phosphate batteries, they seem to be the rising chemistry for a lot of applications?
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Nexing
6/21/2012 7:18 AM EDT
Another vote for the Lithium Phosphate LiFePO4 and LiPO
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elctrnx_lyf
6/21/2012 4:51 AM EDT
Li-Ion and more advanced technologies are already overtaking many applications of NiMH and NiCd also.
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Nexing
6/21/2012 7:32 AM EDT
Amazingly this article -so far- misses what probably is the most needed information; How user's usage, 1st charge and charging practices vary accordingly different battery types.
At 2012 most users have yet to learn that lithium ion batteries are best not discharged below 20-30% capacity, very different from the NiMH requirement of full discharge...
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Hughston
6/21/2012 12:57 PM EDT
Why do you leave that much reserve capacity in the battery? Is it to extend battery life? Is it because the internal impedance goes up too much? I remember when the voltage gets down near 3V, the battery is going fast.
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Nexing
7/4/2012 11:30 PM EDT
http://blog.bestlaptopbattery.co.uk/876/
Look at the inverse correlation between the level of Depth Discharge and discharging cycles at that article.
Besides, part II of this article finally did not answered most questions left unresolved here. This link http://blog.bestlaptopbattery.co.uk/ might prove to be more useful than what we are commenting into.
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Hughston
6/21/2012 12:52 PM EDT
Here are a few other good characteristics of lithium ion batteries: flat discharge curve, typical voltage just about right to linear regulate for logic, and it's easy to detect charge termination. Low self discharge is important for many low power applications.
You don't have to use CC/CV charge methods for these batteries. You can pulse charge them.
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Mike K.
6/25/2012 3:32 PM EDT
As mentioned above there are regulatory requirements to consider when selecting a battery technology. There are issues with batteries based on cadmium, lead, and lithium (and mercury, of course) in a variety of markets, not just the EU. Some are environmental, some are transport-related.
If you're going to do an article about "Selecting the right battery" in 2012, consideration of environmental performance, recyclability, potential shipping constraints, and legality are of critical importance.
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Hughston
7/9/2012 11:38 AM EDT
I was looking at my neighbor's outdoor solar lights last night and I was surprised to see NiCad batteries in what is supposed to be a green product. I assume they have the cheapest charging method, which would be trickle charge.
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Mike K.
7/9/2012 3:20 PM EDT
Hah! Who said solar anything is "green"? Most solar cells use Cd in the elements too. They lobbied for, and received, an exemption from the scope of EU RoHS.
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mcjw
6/26/2012 8:29 PM EDT
I was expecting to see what the difference is between 1000-cycle Li-ion and 300-cycle Li-ion, in cost, technology, and design. Since many products have internal batteries, this is important.
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Tim Foo
6/27/2012 9:41 AM EDT
The focus of the aricle is on recharable batteries.
There is a whole peletora of non-rechable batteries that are available off-the shelf. These includes:
Carbon Zinc 1.5V
Alkaline Manganese 1.5V
Lithium Iron Disulphide 1.5V, long shelf life, high power density
Lithium Manganese 3V, long shelf life, high power density
Lithium Thionyl Chloride 3.6V, long shelf life, very high power density
Silver Oxide 1.5V, typically button cells only
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anne-francoise.pele
7/16/2012 11:25 AM EDT
Part Two of this two-part article is now available here: http://www.eetimes.com/design/smart-energy-design/4376071/Implementing-battery-charger-using-Li-ion?Ecosystem=smart-energy-design
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anne-francoise.pele
7/16/2012 11:25 AM EDT
I invite you all to look for Part 2 next week. It will explain how to implement a battery charger using Li-Ion technology as the example.
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