BattRecon Servicing and Restoration Devices for Forklift, Golf Cart, Auto, Marine and Telecom Batteries

What is Battery Optimization and The Daily (Periodic) Equalization System?

 Battery optimization is the automatic minimization of the battery’s internal resistance on a daily, weekly or other periodic basis. 

Battery Repair, Regeneration or Restoration, is the process of allowing the battery’s performance to deteriorate until a recognizable loss of performance is observed, then attempting to restore that lost performance.  

As you can see from a chart of actual battery data below, the "Regeneration" battery used as illustrated by the yellow trace will accumulate sulfates within the    battery causing the battery operational run time to diminish. The "Optimized" battery illustrated by the red trace using the BattRecon Daily Equalization System, will maximize the number of lead molecules that are kept in the "Free State" after each charge, greatly reducing electrical costs, eliminating the wasteful weekly equalization charge, and significantly reducing battery service labor and training requirements. 

 During each charge and discharge cycle of the battery, there are lead molecules that have not been freed of their sulfate molecules by the re-charging process.  This means that every re-charging cycle leaves more and more lead molecules as un-useable since they remain occupied and are not returned to the "free" status.  As the battery is used, more and more occupied lead molecules are insulated from the acid reducing the run time of the battery. 

 The conventional battery operational cycle begins with a battery in an optimized condition, whether new or recently returned from a service event.  As the battery is used on a daily basis a small amount of “Daily” sulfation remains on the plates.  As recommended or mandated by battery manufacturers/service providers, the battery typically endures an additional periodic overcharge as part of an equalization strategy.  While daily charging replenishes a useful discharge of the battery, the equalization charge is an additional charge cycle without a corresponding productive use.

 The initially optimized battery, even  using the best operational techniques currently available to the industry, are being removed from service for de-sulfation.  More efficient chargers result in a longer service interval between de-sulfation service intervals, than the less efficient chargers.   In any case, the current battery charger technologies do not fully optimize the battery as the BattRecon Daily (Peridoic) Equalization System does.

As an example of the conventional operational cycle, the battery performance may degrade at a linear rate from a 5-hour runtime on day one, to a 3-hour runtime on day 270 (a 40% reduction in runtime).  This is shown by the yellow trace in the graph above, caused by the increase in resistance from accumulated sulfation. 
During this assumptive 270-day cycle, the battery has been delivering less useful power while consuming about the same grid electricity per charge, which can be viewed as a 40% increase in the operator's electrical costs.  While the battery may have provided the required workload using 5 charges per week in the early months of operation, the same battery attempting to provide the same rate of productivity would now require almost twice as many charge cycles in the last month of operation before an additional service event. This increased number of charge and discharge cycles per week to accomplish the same amount of work, reduces the useful cycles lowering the life expectancy of the battery.  The fewer the number of charge cycles used to accomplish the desired workload, the longer the battery life.

If the operator uses the conventional equalization strategy, the battery would also endure twice as many non-productive charges in the later months of operation.  By contrast, the DES system would use about 2 or 3 minutes of BattRecon DES time after each charge cycle, and maintain the battery in a optimized state eliminating the need to equalize charge the battery.  The BattRecon DES would also significantly reduce or eliminate the frequent battery de-sulfation service events and reduce watering of the battery. 

 Fully optimized batteries use about 25% less re-charging electricity, on average, and are always at their optimum performance increasing lift truck, or golf cart productivity.  Optimized batteries use less charging and discharging cycles per week to accomplish the same workload, thus extending their life cycles about 25% on average.  The automatic application feature reduces or eliminates technician labor and training.  The “CLOUD BASED” system means that a centralized operator can be located thousands of miles away and: “SCAN - COMMANDand CONTROL” the battery charger, the BattRecon process, or perform a Load Discharge Test upon the batteries.

The heart of the Battery Optimization Process is a new technique referred to as “ECO-PULSE,” which is an electronic signal automatically applied to the battery before and after a normal battery re-charging cycle.  To operate, simply connect your charger to the Optimization Station, thereafter, connect your battery to the Optimization Station when re-charging the battery.  Once a battery is connected to the Optimization Station,  it senses the battery and first applies a Patented 5-minute ECO-PULSE process to the battery, followed by the normal battery charge, then a final 5-minute ECO-PULSE process.  Once the cycle is completed, the battery is considered Optimized.


                 BattRecon: We Invented Battery Optimization!

U.S. Patent # 8,330,428 B2