Battery Charging System

Battery charging systems are utilized in many applications including renewable energy storage, cell towers, electric grid support, and rail transportation. In each of these applications, voltage transducers are a critical component as they allow you to monitor and control the battery charging process. NK Technologies’ line of voltage transducers ensures your implementation is running optimally by providing solutions for voltage sensing, charging control, overcharge and undervoltage protection, and fault detection.

At its most basic function, voltage transducers can be used to measure the voltage of the battery charging system when the voltage transducer is connected to the terminals of the battery being charged. It continuously measures and monitors the voltage across the battery terminals, providing real-time feedback on the battery's state of charge and voltage level. This allows for charging control. Based on the voltage readings from the transducer, the charging system can adjust the current or voltage to ensure optimal charging conditions. For example, if the voltage transducer detects that the battery voltage is low, it signals the charger to increase the charging current until the desired voltage level is reached.

One crucial function of a voltage transducer in a battery charging system is to prevent overcharging. Once the battery reaches its full charge, the voltage transducer signals the charger to either reduce the charging current or switch to a trickle charging mode. This avoids overcharging, which can damage the battery. Conversely, the voltage transducer can also detect an under-voltage condition. This occurs when the battery voltage drops below a certain threshold, indicating that the battery is discharged. In such cases, the charging system can adjust the charging parameters to provide the necessary current and voltage to recharge the battery safely.

Voltage transducers can also be used to detect faults in the charging system or the battery itself. For example, if the voltage transducer detects an unusually high or low voltage reading, it may indicate a problem such as a short circuit, a faulty battery cell, or a malfunctioning charger.

Data logging and analysis can be enabled by feeding the voltage transducer’s analog output to an analog input card of a process control device, such as a Programmable Logic Controller (PLC), Distributed Control System (DCS), or a digital display capable of accepting an analog input. System operators can then track the charging process over time, identify trends, and diagnose potential issues with the battery or charging system. For example, in larger battery charging systems or applications where multiple batteries are being charged simultaneously, a voltage transducer paired with a PLC integration enables automated monitoring, control, and management of the charging process for each individual battery. A properly designed system can then remain online while individual battery cells can be evaluated and scheduled for maintenance or replacement.