Published October 24, 2017

10 way Battery Condition Monitor

This is a unit that can monitor 10 single cells or 10 battery packs and print data in graphs on excel

IntermediateFull instructions provided5 hours1,342

Things used in this project

Hardware components

Adafruit adalogger 32u4 feather

Adafruit ina219 Current sensor

Adafruit DS3231 precision RTC

SparkFun Pushbutton switch 12mm

LED (generic)

Resistor 100 ohm

ds18b20 temperature sensor

4k7 resistor

Breadboard (generic)

Software apps and online services

Arduino IDE

Hand tools and fabrication machines

Soldering iron (generic)

Story

The Idea....

I was asked if i could come up with a way to measure and test multiple cells or battery packs for battery manufacturers to be able to test their batteries for research purposes, The unit that they had available could only do one battery at a time and it took 2 to 4 hours to complete the tests and a machine that could do more batteries cost around R 40 000 (South African Rand) So i set out to make life a bit easier and also realized that this unit is very useful for testing different types of batteries for my hobby R/C stuff so i can determine the best batteries to use for my 'toys' ?

How it works....

I made use of 10 INA219 current sensors to do my individual measurements, now if you look on the adafruit web site you will see they tell you that you can only add 4 of this units to one micro-controller's I2C line because of the addressing but its actual more like 20. If you read the INA219 IC Datasheet they explain how to change the Hex addresses just by moving and connecting different wires between GND, VCC, SCL and SDA, luckily i have made it easy for you and i uploaded the connections you have to make on the INA219 breakout board to make it easy for you.

Just follow the connections like above on the jumper pins A0 and A1 of the current sensors.

The current sensors sends all the recorded data to the Adafruit feather 32U4 Adalogger where it then gets displayed in any Serial IDE of your choice like Hyper term or cool term and it also gets saved as raw data to your Micro SD card that is on-board the Adalogger ready to be added to an excel file for later use.

I added in a DS3231 RTC so that i can record the times and dates that the measurements are taken.

Making use of Vera Board i placed all the current sensors in an upright position to save some space as well as the RTC, i Used screw down terminals for the battery connections and Two momentary push buttons, one is the start button and the other the reset or stop button. I connected an LED to pin 13 to indicate when data is being written and saved,

Each battery terminal also has an LED connected via a 100R resistor, this will only come on when a battery is connected in order to indicate a live connection.

Making use of the unit

Connect 10 single cells up to the bottom positive ports and top negative ports irrespective to test each cells discharge efficiency and power consumption, The same applies for battery packs, Connecting a charger and a battery/battery pack in series with the terminals will record and test charge efficiency and time , I also added a Dallas Temperature sensor port with a 4K7 resistor, up to 10 temp sensors can be connected to this port simultaneously and they will automatically address them selves, by doing this you can now measure the battery temperature during charge and discharge.

I then placed everything in a simple black plastic enclosure to tidy everything up.

Download Cool Term as your IDE,

Open > Connections >>> Capture to text file >>> Start..

This will start to record your data after you push start on the unit..

NB Remember to push stop in cool term to save the file otherwise it wont save

The file should automatically save to your documents

Also make sure you have the correct port and Baud rate selected,

After your file has finnished saving open excel, and go to

>> File >>> Open.. in the open box of excel where you select the file type to open select 'all files' then the Cool term file will come up. Select this file...

excel open page

After the file opens just chose your prefered settings for viewing the data in a graph format and hit enter.....

example of graph

And there you go... Neat information in Digital format..

Code

Single cell data logger for 10 units

/*************************************************************************** LIBRIARY FUNCTIONS *****************************************************************************/

#include <Wire.h>
#include <DS3231.h>
#include <Adafruit_INA219.h>
#include <OneWire.h>
#include <DallasTemperature.h>

/********************************************************************* CONTROL FUNCTION SETUP *******************************************************************************/

DS3231 clock;
RTCDateTime dt;

Adafruit_INA219 ina219_A(0x40);
Adafruit_INA219 ina219_B(0x41);
Adafruit_INA219 ina219_C(0x44);
Adafruit_INA219 ina219_D(0x45);
Adafruit_INA219 ina219_E(0x42);
Adafruit_INA219 ina219_F(0x43);
Adafruit_INA219 ina219_G(0x46);
Adafruit_INA219 ina219_H(0x47);
Adafruit_INA219 ina219_I(0x48);
Adafruit_INA219 ina219_J(0x49);

int ledState = LOW;

const int ledPin = 13;

void myLoop(void);

int wasItPressed1 = 0;
int buttonPin1 = 6;
int buttonState1 = 0; 

#define ONE_WIRE_BUS A0
OneWire oneWire(ONE_WIRE_BUS);
DallasTemperature sensors(&oneWire);

/************************************************************************ VOID FUNCTION SETUP *******************************************************************************/

void setup()
{
  uint32_t currentFrequency;
  Serial.begin(9600);
  while(!Serial)
  {;}
  clock.begin();
  clock.setDateTime(__DATE__, __TIME__);
  clock.forceConversion();
  {
  Serial.print("Battery/Cell data logging & Management"); 
  Serial.println("");
  Serial.print("Ambient Temperature: ");Serial.print(clock.readTemperature()); Serial.print(" C");
  Serial.println("");
  dt = clock.getDateTime();
  Serial.print("Date & Time: ");
  Serial.print(dt.year);   Serial.print("-");
  Serial.print(dt.month);  Serial.print("-");
  Serial.print(dt.day);    Serial.print(" ");
  Serial.print(dt.hour);   Serial.print(":");
  Serial.print(dt.minute); Serial.print(":");
  Serial.print(dt.second); Serial.println("");
  Serial.println("");
  delay(100);
  {
  digitalWrite(LED_BUILTIN, HIGH); 
  delay(1000);   
  digitalWrite(LED_BUILTIN, LOW);  
  delay(1000); 
  {
  pinMode(LED_BUILTIN, OUTPUT);
  pinMode(buttonPin1, INPUT);
  {
  sensors.begin();
  ina219_A.begin();
  ina219_B.begin();
  ina219_C.begin();
  ina219_D.begin();
  ina219_E.begin();
  ina219_F.begin();
  ina219_G.begin();
  ina219_H.begin();
  ina219_I.begin();
  ina219_J.begin();
  // Serial.print("Bus Voltage");Serial.print("                                           ");Serial.print("Load Voltage");Serial.print("                                          ");Serial.print("Current");Serial.println("");
  }}}}}
  
void loop()
  {
   if(wasItPressed1 == 0) { 
      buttonState1 = digitalRead(buttonPin1);
   if (buttonState1 == HIGH) {
        wasItPressed1 = 1;
               myLoop();
               }
        } else { 
        myLoop();
          }
          }
          
/********************************************************************** VOID LOOP SETUP *************************************************************************************/
  
  void myLoop()
  {
 // Serial.print("************************** STARTING SESSION *****************************");
 // Serial.println("");
  clock.forceConversion();
 // Serial.print("Ambient Temperature: ");Serial.print(clock.readTemperature()); Serial.print(" C");
  //Serial.println("");
  delay(100);
  {
  dt = clock.getDateTime();
 // Serial.print("Time: ");
//  Serial.print(dt.hour);   Serial.print(":");
//  Serial.print(dt.minute); Serial.print(":");
 // Serial.print(dt.second); Serial.println("");
  delay(100);
  sensors.requestTemperatures();
//  Serial.print("Test Temperature :  ");
 // Serial.print(sensors.getTempCByIndex(0));Serial.print(" C");}
 // Serial.println("");
 // Serial.print("****************************************************************************");
 // Serial.println("");
  {
  digitalWrite(LED_BUILTIN, HIGH); 
  delay(1000);   
  digitalWrite(LED_BUILTIN, LOW);  
  delay(1000); 
  {

/**************************************************************** CURRENT SENSOR CH1 0X40 ************************************************************************************/    
  float shuntvoltage_A = 0;
  float busvoltage_A = 0;
  float current_mA_A = 0;
  float loadvoltage_A = 0;

  shuntvoltage_A = ina219_A.getShuntVoltage_mV();
  busvoltage_A = ina219_A.getBusVoltage_V();
  current_mA_A = ina219_A.getCurrent_mA();
  loadvoltage_A = busvoltage_A + (shuntvoltage_A / 1000);

/*
 Serial.print("Ch1");
 Serial.println("");
 Serial.print("BV:   "); Serial.print(busvoltage_A); Serial.println(" V");
 
 Serial.print("SV: "); Serial.print(shuntvoltage_A); Serial.println(" mV");
 Serial.print("LV:  "); Serial.print(loadvoltage_A); Serial.println(" V");
 Serial.print("Cr:       "); Serial.print(current_mA_A); Serial.println(" mA");
 Serial.println("");
 Serial.print("****************************************************************************");
 Serial.println("");
 delay(500);
 digitalWrite(LED_BUILTIN, HIGH);
 delay(500);
 digitalWrite(LED_BUILTIN, LOW);
 delay(500); 
*/
/**************************************************************** CURRENT SENSOR CH2 0X41 **********************************************************************************/
  float shuntvoltage_B = 0;
  float busvoltage_B = 0;
  float current_mA_B = 0;
  float loadvoltage_B = 0;

  shuntvoltage_B = ina219_B.getShuntVoltage_mV();
  busvoltage_B = ina219_B.getBusVoltage_V();
  current_mA_B = ina219_B.getCurrent_mA();
  loadvoltage_B = busvoltage_B + (shuntvoltage_B / 1000);
/*
  Serial.print("Channel 2");
  Serial.println("");
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_B); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_B); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_B); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_B); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500); 
*/
  
/**************************************************************** CURRENT SENSOR CH3 0X44 **********************************************************************************/
  float shuntvoltage_C = 0;
  float busvoltage_C = 0;
  float current_mA_C = 0;
  float loadvoltage_C = 0;

  shuntvoltage_C = ina219_C.getShuntVoltage_mV();
  busvoltage_C = ina219_C.getBusVoltage_V();
  current_mA_C = ina219_C.getCurrent_mA();
  loadvoltage_C = busvoltage_C + (shuntvoltage_C / 1000);
/*
  Serial.print("Channel 3");
  Serial.println("");
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_C); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_C); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_C); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_C); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);

  */
/**************************************************************** CURRENT SENSOR CH4 0X45 ***********************************************************************************/
  float shuntvoltage_D = 0;
  float busvoltage_D = 0;
  float current_mA_D = 0;
  float loadvoltage_D = 0;

  shuntvoltage_D = ina219_D.getShuntVoltage_mV();
  busvoltage_D = ina219_D.getBusVoltage_V();
  current_mA_D = ina219_D.getCurrent_mA();
  loadvoltage_D = busvoltage_D + (shuntvoltage_D / 1000);
/*
  Serial.print("Channel 4");
  Serial.println("");
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_D); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_D); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_D); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_D); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println(""); 
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500); 

  */
/**************************************************************** CURRENT SENSOR CH5 0X42 ***********************************************************************************/
  float shuntvoltage_E = 0;
  float busvoltage_E = 0;
  float current_mA_E = 0;
  float loadvoltage_E = 0;

  shuntvoltage_E = ina219_E.getShuntVoltage_mV();
  busvoltage_E = ina219_E.getBusVoltage_V();
  current_mA_E = ina219_E.getCurrent_mA();
  loadvoltage_E = busvoltage_E + (shuntvoltage_E / 1000);
/*
  Serial.print("Channel 5");
  Serial.println("");  
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_E); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_E); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_E); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_E); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");  
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);

  */
/**************************************************************** CURRENT SENSOR CH6 0X43 ***********************************************************************************/
  float shuntvoltage_F = 0;
  float busvoltage_F = 0;
  float current_mA_F = 0;
  float loadvoltage_F = 0;

  shuntvoltage_F = ina219_F.getShuntVoltage_mV();
  busvoltage_F = ina219_F.getBusVoltage_V();
  current_mA_F = ina219_F.getCurrent_mA();
  loadvoltage_F = busvoltage_F + (shuntvoltage_F / 1000);
/*
  Serial.print("Channel 6");
  Serial.println("");  
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_F); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_F); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_F); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_F); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");  
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);

  */
/**************************************************************** CURRENT SENSOR CH7 0X46 ***********************************************************************************/
  float shuntvoltage_G = 0;
  float busvoltage_G = 0;
  float current_mA_G = 0;
  float loadvoltage_G = 0;

  shuntvoltage_G = ina219_G.getShuntVoltage_mV();
  busvoltage_G = ina219_G.getBusVoltage_V();
  current_mA_G = ina219_G.getCurrent_mA();
  loadvoltage_G = busvoltage_G + (shuntvoltage_G / 1000);
/*
  Serial.print("Channel 7");
  Serial.println("");  
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_G); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_G); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_G); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_G); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);

  */
/**************************************************************** CURRENT SENSOR CH8 0X47 ***********************************************************************************/
  float shuntvoltage_H = 0;
  float busvoltage_H = 0;
  float current_mA_H = 0;
  float loadvoltage_H = 0;

  shuntvoltage_H = ina219_H.getShuntVoltage_mV();
  busvoltage_H = ina219_H.getBusVoltage_V();
  current_mA_H = ina219_H.getCurrent_mA();
  loadvoltage_H = busvoltage_H + (shuntvoltage_H / 1000);
/*
  Serial.print("Channel 8");
  Serial.println("");  
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_H); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_H); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_H); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_H); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");  
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);
*/
  
/**************************************************************** CURRENT SENSOR CH9 0X48 ***********************************************************************************/
  float shuntvoltage_I = 0;
  float busvoltage_I = 0;
  float current_mA_I = 0;
  float loadvoltage_I = 0;

  shuntvoltage_I = ina219_I.getShuntVoltage_mV();
  busvoltage_I = ina219_I.getBusVoltage_V();
  current_mA_I = ina219_I.getCurrent_mA();
  loadvoltage_I = busvoltage_I + (shuntvoltage_I / 1000);
/*
  Serial.print("Channel 9");
  Serial.println(""); 
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_I); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_I); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_I); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_I); Serial.println(" mA");
  Serial.println("");
  Serial.print("****************************************************************************");
  Serial.println("");
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500); 
  */
/**************************************************************** CURRENT SENSOR CH10 0X49 **********************************************************************************/
  float shuntvoltage_J = 0;
  float busvoltage_J = 0;
  float current_mA_J = 0;
  float loadvoltage_J = 0;

  shuntvoltage_J = ina219_J.getShuntVoltage_mV();
  busvoltage_J = ina219_J.getBusVoltage_V();
  current_mA_J = ina219_J.getCurrent_mA();
  loadvoltage_J = busvoltage_J + (shuntvoltage_J / 1000);
/*
  Serial.print("Channel 10");
  Serial.println(""); 
  Serial.print("Bus Voltage:   "); Serial.print(busvoltage_J); Serial.println(" V");
  Serial.print("Shunt Voltage: "); Serial.print(shuntvoltage_J); Serial.println(" mV");
  Serial.print("Load Voltage:  "); Serial.print(loadvoltage_J); Serial.println(" V");
  Serial.print("Current:       "); Serial.print(current_mA_J); Serial.println(" mA");
  Serial.println("");
  Serial.print("************************ END OF SESSION **********************************");
  Serial.println("");
  delay(500);
  digitalWrite(LED_BUILTIN, HIGH);
  delay(500);
  digitalWrite(LED_BUILTIN, LOW);
  delay(500);
  {
  */
/**************************************************************** Excel layout graph  ************************************************************************************/ 

 Serial.print(busvoltage_A);
 Serial.print("   ");
 Serial.print(busvoltage_B);
 Serial.print("   ");
 Serial.print(busvoltage_C);
 Serial.print("   ");
 Serial.print(busvoltage_D);
 Serial.print("   ");
 Serial.print(busvoltage_E);
 Serial.print("   ");
 Serial.print(busvoltage_F);
 Serial.print("   ");
 Serial.print(busvoltage_G);
 Serial.print("   ");
 Serial.print(busvoltage_H);
 Serial.print("   ");
 Serial.print(busvoltage_I);
 Serial.print("   ");
 Serial.print(busvoltage_J);
 Serial.print("          ");
 Serial.print(loadvoltage_A);
 Serial.print("   ");
 Serial.print(loadvoltage_B);
 Serial.print("   ");
 Serial.print(loadvoltage_C);
 Serial.print("   ");
 Serial.print(loadvoltage_D);
 Serial.print("   ");
 Serial.print(loadvoltage_E);
 Serial.print("   ");
 Serial.print(loadvoltage_F);
 Serial.print("   ");
 Serial.print(loadvoltage_G);
 Serial.print("   ");
 Serial.print(loadvoltage_H);
 Serial.print("   ");
 Serial.print(loadvoltage_I);
 Serial.print("   ");
 Serial.print(loadvoltage_J);
 Serial.print("          ");
 Serial.print(current_mA_A,2);
 Serial.print("   ");
 Serial.print(current_mA_B,2);
 Serial.print("   ");
 Serial.print(current_mA_C,2);
 Serial.print("   ");
 Serial.print(current_mA_D,2);
 Serial.print("   ");
 Serial.print(current_mA_E,2);
 Serial.print("   ");
 Serial.print(current_mA_F,2);
 Serial.print("   ");
 Serial.print(current_mA_G,2);
 Serial.print("   ");
 Serial.print(current_mA_H,2);
 Serial.print("   ");
 Serial.print(current_mA_I,2);
 Serial.print("     ");
 Serial.print(current_mA_J,2);
 Serial.print("        ");
 Serial.print(sensors.getTempCByIndex(0));
 Serial.print("     ");
 Serial.print(dt.hour);   Serial.print(":");
 Serial.print(dt.minute); Serial.print(":");
 Serial.print(dt.second);
 Serial.println("");

/****************************************************************************************************************************************************************************/
  digitalWrite(ledPin, HIGH);
  delay(1000);
  digitalWrite(ledPin, LOW);
  delay(1000);
}}}}

/****************************************************************************************************************************************************************************/

Credits

Theo Rossouw

0 projects • 21 followers

Hi i am an junior Electronics and Software engineer that works in Benoni South Africa for a company that develop long term battery solutions

10 way Battery Condition Monitor

Things used in this project

Hardware components

Software apps and online services

Hand tools and fabrication machines

Story

Schematics

Schematic diagram for data logger connections

Code

Single cell data logger for 10 units

Credits

Theo Rossouw

Comments

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10 way Battery Condition Monitor

10 way Battery Condition Monitor

Things used in this project

Hardware components

Software apps and online services

Hand tools and fabrication machines

Story

Schematics

Schematic diagram for data logger connections

Code

Single cell data logger for 10 units

Credits

Theo Rossouw

Comments

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