CCT® test by customers

Different case study test from customers

Fieldtests from a major manufacturer / distributor

Field test on electrically operated industrial cleaning machines. Benefits were measured over the first 10% aging phase

Three BEAT50 units were fitted to a 36V floor cleaning machine and operating hours were logged and compared to the same type of floor cleaning machine without the CCT treatment.

3.6a  3.6b

Conclusions

An immediate increase in operational running time was noted verse a standard operating unit.

After only a number of operating days the cleaning machine with the BEAT units fitted was able to function for 40% longer on a single charge verse the standard cleaning machine, this increase in operating capacity continued before finally settling at a 100% increase in operating capacity.

Field-test from a major manufacturer in Northern Europe.

Benefits on new batteries at a logistics centre in Northern Europe

Two 24V electric forklifts (order pickers) were equipped with CCT (treated) and two without (untreated) at a logistic centre in Northern Europe during the wintertime. Charge time, in hours, charge current, in kWh, together with increased capacity, in operating hours, were measured and compared.

The order pickers were each equipped with new batteries. Typical annual operation hours for these order pickers are between 800 and 1,200. Batteries were charged for 8 hours until fully charged, which on new batteries typically gives 4 operating/driving hours. The complete test consisted of all together 100 charge hours and subsequently, approximately 50 hours of operation time. The batteries were charged with a 24V-50A charger.

Test results
CCT Treated Untreated Difference
Total charge 159,4 Kwh 189,47Kwh 18 %
To fully charged 86,7 hours 100,5 hours 14 %
Operating time/hours: 152,62 hours 130,45 hours 17 %

 

After just 100 hours of charge and approximately 50 hours of operation, the batteries showed the following improvements:

Improvements
Less energy used to charge CCT treated batteries: -18 %
Less time used to charge the CCT treated batteries: -14%
Increased operation hours/output for CCT treated batteries: +17%

 

Test by an Asian battery manufacturer (off grid storage batteries)

Performed on newer batteries in warm climate (55°C), benefits measured over the first 15-20% aging phase at partial state of charge

The main objective was to test the performance of 12, 2V-400Ah VRLA battery cells with CCT:

  • in a Life Cycle Test program;
  • in a temperature controlled chamber set at a temperature of 55°C;
  • at a partial state of charge;
  • and compare the results to battery cells tested without CCT.

The battery cells underwent initial capacity testing, and then each cell was charged as per the procedure used for the capacity test.

  • The cells were placed in a temperature controlled chamber maintained at a temperature of 55°C;
  • The cells were discharged at a rate equal to C/3 for 3 hours (or down to 1.75V), which is followed by a charge of a constant voltage of 2.33V per battery cell (Equivalent to 2.4V per cell at 35°C), limited to a charging current equal to only 40% of its rated capacity;
  • Frequently throughout the test program a capacity test was conducted. If the capacity obtained, at 27°C (when tested), was higher than 80% of its initial capacity, an additional test cycle was initiated;
  • The test was repeated until the capacity of the first battery cell group fell below 80 % of its initial capacity.
  • The battery cells were analysed to study both the positive and negative electrodes by using SEM and XRD.

Conclusions:

A summary of the results for the CCT treated battery cells:

  • In every cycle the treated battery cells are showing higher charge voltage for a given time of 9 hours, which means better charge acceptance.
  • During Life Cycle Tests the discharge voltage after two hours is higher; reveals better backup time.
  • The discharge voltage is higher for the CCT treated battery cells, showing better back up time with similar conditions as compared to non-treated battery cells.
  • The capacity of CCT treated battery cells is approximately 15% higher compared to non-treated battery cells.
  • The test data shows that CCT enhances the service life of a battery under partial state of charge conditions at high temperature applications. It extends the service life of VRLA batteries.

Major Asian automotive manufacturer

Test during the first ageing phase of a battery, benefits measured over the first 20% of the ageing phase.

Results from a major Asian automotive manufacturer’s own test program run over 3 months of real life urban cycle simulations during the first 20% of the ageing phase of the batteries. Eight 75Ah, flooded lead-acid batteries were tested in a Life Cycle Program over 50 charge and discharge cycles, and compared. (Four batteries were treated, and four were not).

  • The charging and discharging of the batteries was done as per USABC Dynamic Stress Test (DST);
  • The charging was done at CV mode;
  • Storage capacity of the batteries was estimated by discharging at a constant discharge rate of 15A until the voltage dropped to 10.5V;
  • During discharge, the voltage of each cell and the discharge current were measured at suitable intervals;
  • The charge continued until the charge current stayed constant for at least three hours;
  • The batteries were then allowed three hours of rest time before the next cycle started.

Conclusions:

  • Uniformity:Batteries with the BEAT units exhibited uniformity in battery terminal voltages during charging voltage, and not much variation of terminal voltage between batteries was observed.
  • Storage capacity: Batteries with BEAT units exhibited storage capacity of 21,060 coulombs (average value), and batteries without BEAT units exhibited storage of 16,920 coulombs (average value). An improvement of approximately 25% more capacity for treated batteries.
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