LEAD CRYSTAL Battery cycle life calculation

In order to calculate the different amounts of cycles the lead crystal

batteries would be able to perform at different DOD's the following
steps where taken to come to a useable formula to assist with the
calculations. A third party testing facility in Shanghai China then
confirmed our data
Different size and capacity batteries where chosen and subjected to
extreme cyclic tests at 60 and discharged to 100% and 80% so that
we could build a base line for our formula below
After careful examination of various batteries tested during our R&D
phase we came to a conclusion that electrolyte H2O loss would be the
main contributing factor that can cause the battery to stop
performing. We conducted the following tests in order to calculate the
rate of evaporation that occurs at 100% DOD to be able to find a
formula that could easily be used to calculate cycles at different
DOD's and environmental temperatures

100% DOD Runtime test

This test was conducted at variable environmental temperatures and
cycled daily a 100%, the temperature, runtime in minutes and amount
of cycles was recorded for 1 year
As can be seen from the below curve graph the battery after
performing 316 cycles was still able to supply a rated capacity of
above 100%. The test was stopped and the volume of the battery was
measured to establish the amount of electrolyte (H2O) loss during the
test procedure conducted during the year.
Measured:
Voltage
Charge time
Discharge time Temperature
Capacity rate
Cycles
(not in this graph)
Weight at start
after each cycle
at the end

4903 821 0 051 0 8 1

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Discharge*+me 647

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100% DOD test at 60

This test was conducted by placing a battery in an oil bath and
heating the oil to 60 and current environmental humidity, the
temperature of the oil was carefully controlled by temperature
sensors to maintain a constant during the test duration.
Reason for test: To determine how many charge and discharge cycles
the Lead Crystal Battery can perform at 100% DOD and at 60, before
the capacity falls below 80% of rated capacity
Test Parameters:
1. Discharge at a constant current of 10A to final voltage of 1.8V/cell
(100% DOD)
2. Charge with a constant voltage of 2.35V/cell and limited current of
0.2CA C10 (20A) for 4 hours, Charge with a constant voltage of 2.25
and variable current 0.1CA to 0.05CA C10 until a total charge time of
18 hours have been reached.
3. Repeat point 1 and 2 until the capacity is below 80% of rated
capacity C10 rate
4. Environmental temperature must be kept constant at 60 +- 1

As can be seen from the above graph the LEAD CRYSTAL Batteries
remained stable at extreme temperature for more than 170 cycles, the
capacity started falling after the H2O content in the electrolyte was
completely depleted due to vaporization
With the results of the above tests and the measured recombination
rate of the battery during normal operation, we where able to obtain
accurate data of electrolyte loss with a 99% accuracy.
The measured data of electrolyte H2O loss was used to simulate in
our laboratory using heating, weighing and vaporization equipment,
the results that was achieved by the real time test performed.
The results were then adjusted to indicate the vaporizing effect at
various DOD's and environmental temperatures. Our calculations was
used to generated a multiplication factor that can be used with fairly
accurate estimation to determine the cycles of the LEAD CRYSTAL
Batteries at various DODs

Theoretical calculation formula for lead crystal batteries at (25) and

different depth of discharge, based on the rate of electrolyte
evaporation and cyclic results at 100% DOD performed on a 12 volt
7.2Ah, 100Ah, 170Ah and 2 volt 1000Ah batteries at 20, 40
and 60.

No.

Depth of
discharge
(DOD)

Cycles

Multiplication (100%
DOD as reference point)

100%

540 - 628

80%

1290 - 1507

2.39

70%

1587 - 1846

2.94

60%

1944 - 2260

3.6

50%

2494 - 2901

4.62

40%

2916 - 3392

5.4

30%

4298 - 4998

7.96

20%

5184 - 6031

9.6

10%

6480 - 7539

12

The above table shows the multiplication factor in the part marked
Multiplication (100% DOD as reference point) this number is
the rate that the electrolyte evaporates slower than the
base rate of 1.
How to use to calculate for example the number of cycles at
50% DOD Take the number of cycles shown next to 100%
and multiply with the number that corresponds with the
50% DOD rate 4.62. Multiply: 628 x 4.62 = 2901 Cycles.
We gave two (2) base numbers to calculate with, the first
number is for when various factors like humidity, and
temperature fluctuations and users equipments charge
profile is unknown.