E2417 Project

Battery Desulfator Report Part 1

2003/5/14

Group member: Curtis Lin Harry Jao

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Table of content: 1. Objective and Technical Function P. 3 2. Description of Car Battery P. 4 3. Complete chemical reaction for charging and discharging a car battery P. 5 4. Equipment list P. 6 5. Commercial product and Prototype 1’s layout P. 7 6. Details of parts list to build Prototype 1 P. 8 7. Prototype 2’s layout and Details of parts list to build Prototype 2 P. 9 8. Car battery pulse charging simulation test circuit by using current probe P. 10 9. Commercial product and Prototype 1’s output pulsing current’s waveform P. 11 10. Prototype 2’s output pulsing current’s waveform P.12 11. Reasons of using the design of Prototype 1 to do the final testing P.13 12. Expected and measured discharging time with and without using the desulfator

P.14 & P.15 13. Measured charging time with desulfator P.16 & P.17 14. Conclusion P.18

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List of Figures: Figure 1: Setup of battery desulfator and 12V car battery P. 3 Figure 2: Commercial and Prototype 1 car battery desulfator (from AMOX Inc). P. 7 Figure 2(a): The Prototype 1 circuit we built P. 8 Figure 3: Prototype 2 car battery desulfator (from website). P. 9 Figure 4: Car battery pulse charging simulation test by using current probe P.10 Figure 5: Car battery pulse charging simulation test by using the scope’s function

MATH = CH1 – CH2 P.10 Figure 6: Commercial product’s output pulsing current P.11 Figure 7: Prototype 1’s output pulsing current P.11 Figure 8: Prototype 2’s output pulsing current P.12 Figure 9: Expected shape of waveform for Battery discharge depth VS voltage P.14 Figure 10: Discharging (BLACK) battery with and without using Prototype 1 desulfator P.15 Figure 11: Charging Current & Voltage wrt. Time P.16 Figure 12: Battery charging current characteristic P.17 List of Tables: Table 1: Equipment list P. 6 Table 2: Parts list of Prototype 1 P. 8 Table 3: Parts list of Prototype 2 P. 9 Table 4: Compare BLACK battery discharge depth with and without desulfator P.14 Table 5: Charging GREEN battery (without Desulfator) P.16 Table 6: Charging BLACK battery (with Desulfator) P.17 Appendix: Appendix A: Milestone Chart Appendix B: Bar Chart (Table 8 to Table 10)

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Objective: To build a device that improves the sulfate problems in a 12 volts car battery. With the battery desulfator we built, the battery will have a longer lifetime for use. Technical Function: By generating a series of high amplitude current pulse (around 1 Amp) and charging it into the Lead acid battery, the function of battery desulfator that is used in conjunction (in parallel) with the conventional battery charger will activate the large lead sulfate crystals on the cathode plate and improve the charging chemical reaction efficiency of the battery. As a result of repetitive use of the battery desulfator, the lead sulfate crystal size is reduced and more sulfuric acid is returned to the battery solution. The car battery will have a longer lifetime for use.

Figure 1: Setup of battery desulfator and 12V car battery

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Description of Car Battery: A car battery is formed with six smaller batteries that line up in series. This causes the voltages of each battery to add. The general way a battery works is that when an electronic circuit is connected to the battery, electrons are allowed to flow. Inside the battery, there are 3 important things: 1. There are 2 connectors that come out of the battery. They are called the cathode

and the anode. 2. There is also a solution that the cathode and the anode sit in.

During the normal operation, a chemical reaction occurs between the solution and the anode that releases electrons that flow through the circuit.

3. These reenter the battery through the cathode where another chemical reaction

happens between the cathode and solution.

The electrons are incorporated in the products of this reaction. When run in reverse (with certain batteries), electrons are forced to the other direction in the reverse reactions.

The cathode is lead dioxide (PbO2), the anode is a sponge of lead (Pb), and the solution is sulfuric acid (H2SO4). When the battery is being used, the 2 connections react to form lead sulfate (PbSO4) by reacting with the sulfuric acid. Specifically, the two reactions are: Cathode: PbO2 + 4H+ + SO4(2-) + 2e- ! PbSO4 + 2H2O Anode: Pb + SO4(2-) ! PbSO4 + 2e- Why a battery dies? A battery dies because one or more of the chemical reactants is more or less used up, which means the battery plate is covered in heavy sulfation buildup (lead sulfate crystals). How to prevent a car battery dies? Use a Pulse Technologic products to remove (de-solve) these sulfate crystals and exposes the active material of the battery plates. More active material means stronger batteries.

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The complete chemical reaction for discharging in a car battery: At the positive electrode (anode) lead (IV) ions gain electrons [2e- + Pb (4+) ---reduction--- ! Pb(2+)] At the negative electrode (cathode) lead atoms lose electrons [Pb ---oxidation--- ! 2e- + Pb(2+)]. The complete chemical reaction for discharging is PbO2+Pb+2H2SO4 ---redox--- ! 2PbSO4+2H2O+electr. energy The complete chemical reaction for charging in a car battery: At the positive electrode (anode) lead(II) ions lose more electrons [Pb(2+) ---oxidation--- ! 2e- + Pb(4+)] at the negative electrode (cathode) lead(II) ions get electrons [2e- + Pb(2+) ---reduction--- ! Pb]. The complete chemical reaction for charging is 2PbSO4+2H2O+electr. energy---redox--- ! PbO2+Pb+2H2SO4 Reduction: The accepting of electrons by a chemical reaction with a reducing agent

(a reactant that gives electrons to another reactant by a chemical reaction: H2, CO)

Oxidation: The loss of electrons by a chemical reaction with an oxidizing agent Redox-Reaction: (Electronen Exchange Reaction)

A reaction in which reduction and oxidation take place at the same time.

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Equipment list:

Table 1: Equipment list Instrument Manufacture Model

Oscilloscope Tektronix TDS210 Multimeter Fluke 8010A

Multimeter (Portable) Mastech M9502 Slide transformer Tokyo Rikosha RSA-20 Analog Ammeter Techman TP670

Current Probe AEMC instrument MN106 Battery Tester ULTRA Pro 95270

Slide Transformer Tokyo Rikosha RSA-20 12V Car battery Interstate GREEN 12V Car battery Magnacharge BLACK

4Ω 225W Power Resistor Renfrew 10½ CH4R0 Note: Two 12V car batteries are used in our project just in case if one of them does not

work. Magnacharge (BLACK) battery was picked up from Automotive Parts & Light Warehousing in building 1 Newton Campus. Interstate (GREEN) battery was picked up from Burnaby Battery Recycle Center.

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Procedure: Two types of battery desulfators are built in our project: Prototype1 uses the reference circuit from AMOX Inc (commercial product). Prototype2 uses the reference circuit from Alastair Couper (website).

1. Build the Prototype 1 and Prototype 2 battery desulfator. Prototype 1’s layout is shown in Figure 2. The layout of Prototype 2 is shown in Figure 3.

Commercial and Prototype 1:

R1

10kohm

R2

10kohm

50%2kOhmKey = a

R3

Q1IRF530N

D1

1N4742A

Q2MPSA56

R4

10ohm

R5

33ohm

D2

1N4004GP

D3

1N4004GPR6100ohm

D4

DIODE_VIRTUAL

D5

DIODE_VIRTUAL

C310uF

C4 100uF

L11mH

L295mH

L395mH

C50.224uF

LED_greenLED1

D6

1N4748A

R7

120ohm

R8

12kohm

C6

10nF

Vreg

U2LM7812CT

IN OUT

Q4MPSA06 D

S

2

3

IO1

+12V

U1A

40106BD

21

U1B

40106BD

43

U1C

40106BD

65

U1D

40106BD

89

U1E

40106BD

1011

U1F

40106BD

1213

S1

OL

S2

OLIO3

-12V

Figure 2: Commercial and Prototype 1 car battery desulfator (from AMOX Inc).

Note: We have replaced a 2k ohm resistor pot component called R7 (R7 was 120 ohm in commercial product) to our Prototype 1 from the commercial product. By adjusting the component R7, we are able to adjust the output pulsing current amplitude in Prototype 1.

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Figure 2(a): The Prototype 1 circuit we built

Details of Parts list to build Prototype 1: Table 2: Parts list of Prototype 1 (Figure 2)

Unit # Component Name Function Unit Price U2 LM7812CT 12V regulator, provides 12V source for

U1 1.26

U1 CD40106BD Hex Schmitt trigger, U1A drives U1B and U1B drives Q1.

0.9

R7 2kΩ pot

Controls the out put pulse amplitude at 1A. Reduce R7 value will increase the out put pulse amplitude.

1.03

The R7’s value is 120 ohm to achieve an output pulsing to be 1 Amp. R3 2kΩ pot Determine the start voltage for the

whole circuit. It controls Q4 & Q2. When Q4 & Q2 are ON, U2 will output 12V.

1.5

S1,S2 1.6A MXXX-002 Protect the circuit been damaged by rapid current.

1.5

D5 1N4742A 12V Zener Diode 1.22 Q1 IRF530N Switching the pulse. 2.39 C5 0.224µF Protect Q1. Increase C5 will increase

the out put pulse amplitude but it also increases junction temperature on Q1.

0.84

D1~D4 1N4004 Diode 0.88 L1,L2 95 mH Transformer 0.54 LED1 Red 3mm LED Indicate circuit starts function when

light on. 0.74

Total is about 12.8 Canadian dollar

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Prototype 2:

U1

1

DIS7

OUT3

RST4

8

THR6

CON5

TRI2

GND

VCC

LM555CN

R1470kohm

R2

22kohm

R3

330ohm

R4

330ohm

C1

100uF

C2

33uFC3220nF

C4

47nF L1200uH

L21.0mH

D1GI818

M1IRF9530

D

SG

+12V

-12V

Figure 3: Prototype 2 car battery desulfator (from website).

Details of Parts list to build Prototype 2.

Table 3: Parts list of Prototype 2 (Figure 3) Item Component Description Cost (Canadian $) Q1 IRF9Z34 P channel MOSFET 2.73 U1 LM555CN Timer IC 0.63 D1 GI826CT Fast recovery diode, >6 A, 100 V 1.16 C1 30 µF, 16 V Electrolytic 0.35 C2 0.022 µF Disk ceramic 0.57 C3 0.047 µF Disk ceramic 0.81 C4 100 µF, 16 V Electrolytic, low impedance type 0.66 R1 470 k. 1/4 W 0.23 R2 22 k. 1/4 W 0.23 R3 330 . 1/4 W 0.23 R4 330 . 1/4 W 0.23 L1 220 µH (nominal) Ferrite inductor, 6+ A peak 3.12 L2 1000 µH Ferrite choke, 100 mA 4.68

Total is about 17.86 Canadian dollar

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2. Use the slide transformer as a car generator. Connect the battery and the prototype circuit in parallel with the slide transformer (see figure 4). Observe the output pulsing current and measure the rise time period.

Figure 4: Car battery pulse charging simulation tested by using current probe Note: Current probe equipment is expensive. We can use the testing circuit in Figure 5

instead.

Figure 5: Car battery pulse charging simulation tested by using the scope’s function MATH = CH1 – CH2

Note: XMM1 represent Ammeter and XMM2 represent Voltmeter.

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Data and Result: By using the setup in Figure 4, we got the following waveforms for Prototyp1 and output pulsing current for Prototype 2. AEMC current probe will display Current (A) instead of voltage on the oscilloscope.

Figure 6: Commercial product’s output pulsing current

Ref B is the enlargement of Ref A (Expected Waveform from commercial product)

Figure 7: Prototype 1’s output pulsing current

Ref B is the enlargement of Ref A

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Figure 8: Prototype 2’s output pulsing current

Ref B is the enlargement of Ref A

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Reasons of using the design of Prototype 1 instead of Prototype 2: As we described earlier in Technical Function part, we need an output pulsing current that equals to 1 Amp as most commercial products specified. The waveform in Figure 6 is our expected waveform from connecting the commercial product to the car battery using the setting as shown in Figure 4. From Figure 7, we can see Prototype 1’s output pulsing current amplitude is 1A and the rise time for the first pulse is only 680nS with 1A. Pulsing current amplitude drops constantly after the first pulse peak. Note: By adjusting the component R7, we have different output pulsing current

amplitude in Prototype 1. See Figure 2 at page 6 and more details in Table 2 at page 7.

From Figure 8, we can see Prototype 2 output pulsing current amplitude is 2.6A. The rise time for the first pulse is only 10nS with 1A. There are too many spikes after the first pulse peak. By studying the waveforms in Figure 6, Figure 7, and Figure 8, we decided to use Prototype 1 to do our final testing. It is because the output pulsing current in Prototype 1 is 1 Amp which is the same as what we expected from commercial products. The output pulsing current in Prototype 2 is 2.6A and has too many spikes after the first pulse peak. The current pulsing amplitude over 1A could vibrate down those crystal sulfate deposits on the plate to the bottom. Our goal is to de-solve the crystal sulfate deposits and to have more sulfuric acid returned to the battery solution, but not to break the crystal sulfate deposits down.

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3. To proof the pulse current charging on the battery can electrically de-sulfate the crystallization of the battery’s plate, we will discharge the car battery first by connecting a 4Ω power resistor in parallel with the battery. Two 12V car batteries were tested Interstate (GREEN) and Magnacharge (BLACK).

Table 4: Compare (BLACK) battery discharge depth with and without desulfator

Measured without using

desulfator

Measured with using desulfator

Discharge % Expected Voltage

(V) Voltage

(V) Time

(Minute) Voltage

(V) Time

(Minute) 1% 12.91 X 0 X 0 10% 12.8 12.76 0 12.87 0 20% 12.66 X 0 X 0 30% 12.52 X 0 X 0 40% 12.38 12.3 0 12.4 0 50% 12.22 12.22 20 12.22 60 60% 12.06 12.06 65 12.06 170 70% 11.90 11.9 105 11.9 295 80% 11.70 11.7 210 11.7 440 90% 11.42 X X X X 100% 10.50 X X X X

• Note: Battery will drop about 0.5V right after connecting with the power resistor and

this is why we see an immediately drop of battery at time zero in Table 4. We stopped collecting data at 80% maximum discharge when the voltmeter read 11.70 volts. Meanwhile, battery voltage rose 0.5 V right after disconnect the power resistor.

Discharge Depth VS Voltage

56789

1011121314

0% 20% 40% 60% 80% 100% 120%Discharge Depth %

Vol

tage

(V

)

Figure 9: Expected shape of waveform for Battery discharge depth VS voltage

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Discharging with and without using desulfator

0

20

65

105

210

0

60

170

295

440

0

0

0

00

1000

0

0

11.6

11.8

12

12.2

12.4

12.6

12.8

13

0 100 200 300 400 500 600 700 800 900 1000

Time (min)

Vol

tage

(V

)Discharging without using desulfator

Discharging with desulfator

Expected Dsicharging a good conditionbattery with desulfator

Figure 10: Discharging (BLACK) battery with and without using Prototype 1 desulfator

• Note: From the graph above, it proves that (BLACK) Battery with the use of Prototype

1 desulfator has longer discharging time than before. Current through Power Resistor Ir = V/R= 12/4 = 3A Measured = 2.88A Calculation for a perfect condition of a 12V car battery: Calculate (BLACK) battery capacity for 80% discharge: Assume (BLACK) battery is in good condition, we expect output 48AH (or 1000minutes) for 80% discharge. Expected: 80% x 60AH=48AH ; 48AH/2.88A = 16.66Hours = 1000 minutes Measured: Before using desulfator, (BLACK) battery has: 2.88A (210 minutes / 60min/hr) = 10.08AH. After using desulfator, (BLACK) battery has: 2.88A (440 minutes / 60min/hr) = 21.12AH

• Note: From Figure 10 we know that (BLACK) battery has not totally improved the sulfate problems due to the data that we measured (440minutes) and expected (1000minutes). The problem might be the battery is too old.

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4. Then we charged the battery again until it was full with the same setting as

Figure 4. We recorded the voltage and current changing.

Battery Voltage Bulk charge Float Charge Current 12V 14.5V 13.65V 2A

Table 5:Charging GREEN battery (without Desulfator) 2003/May DD/Time

Initial Battery Voltage

Charge Voltage

(V)

Charge Current

(A)

Final Battery Voltage

Total period (Hr)

07/14:20 10.5 14 0.8 X 0 07/17:30 X 13.24 4 X 1.17 07/20:30 X 13.2 2.5 X 6.17 08/07:30 X 13.8 2 X 17.17 08/13:20 X X X 12.9 23

Charging current and voltage (with desulfator) wrt. Time for GREEN battery

0

2

4

6

8

10

12

14

16

0 5 10 15 20Time (hour)

Cu

rren

t (A

), V

olt

age

(V)

Charing current wrt.time

Charging voltage wrt.time

Figure 11: Charging Current & Voltage wrt. Time

• Note: Automotive batteries can be seriously damaged if the battery has been over-

discharged for a few times. In order to verify the expected value, we let the (GREEN) battery discharged 100% and then recharged fully. During recharging the (GREEN) battery, the internal resistance is huge. As we can see from Table 5, when the input voltage is 14V, the charging current is only 0.8A. From figure 11, we can see the relationship between the voltage and current due to the charging period. Less charging hours are needed if we increase the charging current.

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Table 6: Charging BLACK battery (with Desulfator)

2003/May DD/Time

Initial Battery Voltage

Charging Voltage

(V)

Charging Current

(A)

Time (Hours)

Final Battery Voltage

11/16:50 11.70 V 14.7 1.97 0 X 11/17:50 X 14.7 1.58 1 X 11/18:55 X 14.7 1.57 2.08 X 11/20:40 X 14.7 1.19 3.83 X 12/09:40 X 14.7 0.75 16.83 X 12/17:50 X 14.7 0.62 24.17 12.68

Charging current (with desulfator) wrt. Time for BLACK battery

0

0.5

1

1.5

2

2.5

0 5 10 15 20 25 30

Time (Hour)

Cha

rgin

g C

urre

nt (

A)

Figure 12: Battery charging current characteristic

• Note: Due to the internal resistance, voltage and current will change while charging the battery. So we set the slide transformer output at 14.7 volts (constant) and

observe the relation between current and time. When battery is getting close to full charge, less current get through into the battery. We expect to see the charging period extend if the battery has been desulfates more times.

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Conclusion: By generating a series of high amplitude current pulse (around 1 Amp) and charging it into the Lead acid battery from the battery desulfator used in conjunction (in parallel) with the conventional battery charger, we will are able to activate the large lead sulfate crystals on the cathode plate and improve the charging chemical relation efficiecy of the battery.

Therefore, having a battery desulfator hooked up in conjunction with car battery, every time when the engineer is turned, the battery desulfator starts functioning an the lead sulfate crystal size is reduced. More sulfuric acid is returned to the battery solution. The car battery will have a longer lifetime for use. In our project, we built two types of circuit, Prototype 1 and Prototype 2 (see Figure 2 at page 6 and Figure 3 at page8). In our final testing, we decided to use Prototype 1 instead of Prototype 2. It is because Prototype 1 gives a 1 Amp output pulsing current and Prototype 2 gives a 2.6 Amp output pulsing current. In 1 Amp output pulsing current, we are able to vibrate and de-solve the lead sulfate crystals. However, higher output pulsing current will result break down the lead sulfate crystals (see more explanation in page 12). In Prototype 1, we have replaced a 2k ohm resistor pot component called R7 (R7 was 120 ohm in commercial product) from the original commercial design. Therefore, by adjusting the component R7, we are able to adjust the output pulsing current amplitude in Prototype 1. As we see Table 4 at page 13 and Figure 10 at page 14, we see the discharging time almost doubled when a desulfator is connected. Although it is not as good as we predicted for a “perfect condition” of battery used in the testing, we can still say that the battery desulfator works.

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Appendix A: Mile Stone Chart:

Table 7: Milestone Chart of the project

Activity Person/Persons Target

Completion Date

Completion Date

1. Select a suitable 12v car battery with acid density measurement Harry & Johnny 1/20/2003 1/20/2003

2. Finding project parts and components that are available in the lab

Curtis 1/20/2003 1/20/2003

3. Winding coils for the project. (220uH, 95uH)

Harry 1/20/2003 1/20/2003

4. Multisim simulation of 12V Battery Desulfator

Curtis 1/20/2003 2/24/2003

Note: Mistake found in the circuit on 2/10/2003. Re-simulate with multisim. 5. Multisim simulation of 24V Battery Desulfator Johnny 1/20/2003 1/20/2003

6. Build circuit 2 (Fig. 1: 12V Battery Desulfator) on the bread board

Curtis & Johnny

1/27/2003 1/27/2003

7. Build circuit 1 (same as commercial circuit) on the bread board

Harry 1/27/2003 1/27/2003

8. Test Circuit 2 with oscilloscope waveform measurement

Curtis & Harry 2/03/2003 2/10/2003

9. Disordering Curtis & Johnny

2/03/2003 2/03/2003

10. Calculate the frequency & duty cycle of 555 timer used in circuit 2

Curtis 2/03/2003 2/03/2003

11. Build Prototype circuit 1 Harry 2/10/2003 2/17/2003 12. Build Prototype circuit 1 Johnny 2/10/2003 2/24/2003 13. Test the commercial circuit to

the car battery Harry & Johnny 2/17/2003 2/17/2003

14. Test and troubleshoot prototype circuit 1

Harry 2/24/2003 2/24/2003

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15. Test and troubleshoot prototype

circuit 1 Johnny 2/24/2003 3/24/2003

16. Charge up the battery Harry 3/03/2003 3/03/2003 17. Draw the circuit 1 in multisim Curtis 3/03/2003 3/03/20033 18. Current Probe measurement on commercial product & circuit 1 to the new car battery

Curtis & Harry 3/03/2003 3/03/2003

Note: Prototype circuit 1 & commercial circuit are damaged due to the wrong connection setup of scope probes on 3/03/2003

19. Fix the commercial circuit Harry 3/03/2003 3/03/2003 20. Fix the prototype circuit 1 Harry 3/10/2003 3/10/2003 21. Draw the current probe testing circuit by multisim Curtis 3/24/2003 3/24/2003

22. Searching "car battery charge level wrt. Voltage" on the net Curtis 3/24/2003 3/24/2003

23. Test the prototype circuit 2 with car battery Johnny 3/31/2003 04/14/2003

24. Presentation All group Member 4/07/2003 4/07/2003

25. Wire the new core to improve the amplitude of current for circuit 1

Curtis 04/14/2003 04/14/2003

26. Build prototype circuit 1 as real product

Curtis 04/14/2003 04/14/2003

27. PIC programming for 7-segment display, pulse improvement with cold winding connection

Harry 04/14/2003 04/14/2003

28. Web search for modifying circuit 2

Johnny 04/14/2003 04/14/2003

29. Switching Power supply part 1 Harry 04/14/2003 04/14/2003 30. Real product circuit 1

troubleshooting Johnny 04/28/2003 Not finish

31. Troubleshooting Switching Power supply

Harry 04/28/2003 04/28/2003

32. Prepare for presentation (power point)

Curtis 04/28/2003 04/28/2003

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33. Current Probe measurement

with working prototype circuit 1 (the current can be adjust by a resistor, R7)

Curtis & Harry 5/05/2003 5/05/2003

34. Finish the final report and prepare for presentation Curtis & Harry 5/05/2003 5/12/2003

35. Real product circuit 1 troubleshooting Harry 5/12/2003 5/12/2003

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Appendix B: Reference: Magnacharge (Black) Battery: http://www.magnacharge.com/mchg_mcg.htm Magnacharge voltages vs. depth of discharge: http://www.magnacharge.com/mchg_all.htm#Battery%20Charging United States Patent And Trade Mark Office: http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PALL&p=1&u=/netahtml/srchnum.htm&r=1&f=G&l=50&s1=6,184,650.WKU.&OS=PN/6,184,650&RS=PN/6,184,65 http://www.allegromicro.com/techpub2/cadex/index3311.htm http://uuhome.de/william.darden/carfaq9.htm yuasa-battery http://www.yuasa-battery.co.uk/Chargers.html Metals and Electrochemistry http://www.absolit.com/mc/emc7.htm Batterystuff.com http://www.4unique.com/battery/pulsetech/pulsetech.htm