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The regenerator and core process 

The procedures 

This is an example of a normal procedure with traction batteries: 

1.  Control if the battery could be regenerated, no mechanical failures 

2. Charge the battery 

3. Controlled discharge to document State of health, indicating the present capacity in comparison with full original capacity.  

4. Regeneration process 

5. Controlled discharge to document State of health, indicating the present regenerated capacity in comparison with full original capacity.

6. Normal charge in order to deliver the battery. 


The Regenerator 

The regenerator is designed for the environment of a mechanical workshop. The robust design includes mobility so the Regenerator can be attached to temporary as well permanent sockets.

The controls are only using four bottoms in order to control the Regenerator. This ingenious design is done to simplify for the operator. The regenerator could be regarded as a computer. The four main alternatives, on the first level, are manual settings, preset settings, programmable settings and current operating status. It is possible with just a few pushes to start a pre-set program or start with a complete manual setting. A programmed setting can be named according to the wishes of the operator.

The software can be updated on site from a portable computer if the necessary application from Cobatec is installed. The transfer of new version is done through Internet. The whole updating process is encrypted. 

The Regenerator has an input of 3 phases and requires a fairly stable electric network. The normal voltage is 400 V but it is possible to adapt to other voltages. The Regenerator handles 50 and 60 Hz of net frequency. This Regenerator can regenerate batteries from 2 V to 120 V.

Depending upon in which segments of the market the customer is operating can the capacity of the Regenerator be adapted. Cobatec have tools to evaluate the electrical network on the site of installation. For installation with a new customer it is recommended to have training on site in order to be able to properly operate the Regenerator. The documentation includes both operating and installation manual. Please find here below a picture which is a close up of the control unit. 

 

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Process

 This is a high energy process utilizing only electricity to restore or regenerate the battery. A normal charger has not the power to perform a real desulfation, but has the ability to charge the battery with small energy losses. It also well known that too powerful charging will break down the battery. This process has an effective way to desulfate lead-acid batteries by combining advanced pulse technique with periods of constant charge. Old lead-acid batteries needs to be controlled therefore The Regenerator has safety levels which temporary stops The regenerator. In certain conditions the Regenerator will adapt the settings in order to proceed with the regeneration. If necessary the regenerator will stop the regeneration so that the operator can make necessary changes in the settings.

After several years of research and testing have Cobatec identified a desulfation process where the result is increased capacity of the battery and prolonged battery life.  Observe that only electricity is added, the process has been validated by The Central Laboratory of Electrical Industry (LCIE) of VERITAS.

 Depending of type of battery, condition of the battery and the desired treatment the process could last from half a day to several days.