Bar coding car batteries

A German luxury car manufacturer has introduced a system that embeds vital battery information in a bar code label. The label also contains the battery serial number and manufacturing date. When checking batteries with a tester that supports a bar code scanner, the technician only needs to scan the bar code label and the instrument is automatically configured to the correct battery. Battery testing is thus simplified to scanning the label, attaching the leads to the battery and reading the test results.
Figure 2 illustrates such a test in process.

Figure 2: Bar coding car batteries to simplify testing. The technician reads the bar code label and the CA-12 automatically configures to the correct battery type. The test results and battery serial number can be downloaded into a PC running Cadex Companion software.

Bar coding car batteries simplifies battery testing, eliminates configuration errors and allows less trained technicians to perform the service. The accuracy is also improved because the system selects the most suitable matrix. Batteries, which have no bar code can be upgraded by adding a permanent label. The battery data and serial number are entered into the PC, the Companion software translates the information into the bar code format and a label printer generates the adhesive label. Once labeled, subsequent testing on this battery will be simplified.

To eliminate unauthorized warranty claims, a process can be introduced in which both the battery serial number and the car chassis number are required. A battery replacement is only offered if the information is correct. Another system to keep honesty is generating warranty numbers that accompany the battery and paperwork of a faulty battery back to the manufacturer for replacement.

Acid stratification, a problem with luxury cars

A common cause of battery failure is acid stratification. The electrolyte on a stratified battery concentrates on the bottom, causing the upper half of the cell to be acid poor. This effect is similar to a cup of coffee in which the sugar collects on the bottom when the waitress forgets to bring the stirring spoon. Batteries tend to stratify if kept at low charge (below 80%) and never have the opportunity to receive a full charge. Short distance driving while running windshield wiper and electric heaters contributes to this. Acid stratification reduces the overall performance of the battery.