Smart Electrolyte Level Monitoring System for Uninterrupted Power Supply (UPS) Batteries

Abstract

The Uninterrupted Power Supply (UPS) plays a crucial role in maintaining a green, taintless environment by providing continuous power to various critical systems, including communication, network, memory devices, and medical support systems. This invention focuses on maintaining a sustained uninterrupted power supply by implementing an alert mechanism to have a constant refilling of electrolyte solutions. The current invention employs an ESP32 board and a mobile alert system via Wi-Fi to notify users instantly to alert the low electrolyte levels. In the current invention, a pair of leads are connected to the top of the existing gauge, with the needle head covered in aluminium foil. When the needle reaches a certain level, as the electrolyte levels decreases below the threshold, the circuit closes, triggering the ESP32 board, which sends an alert to a mobile device via through the software application over Wi-Fi. Once the electrolyte is refilled, the float rises, breaking contact between the aluminium sheet and the metallic conductors, thus reopening the circuit. Immediately, the ESP32 detects the reopened circuit, effectuating the system, and the notifications to the handheld devices are halted.

Specification

Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION:
Smart Electrolyte Level Monitoring System for Uninterrupted Power Supply (UPS) Batteries
2. APPLICANT(S)
Name Nationality Address
Mr. Kheshore JR Indian 20/21, Ganesh Nagar, Veeriampalayam Road, Kalapatti Post, Coimbatore - 641048, Tamil Nadu, India

Dr. J. Grace Jency Gnanammal
Indian No:32 Annamara's Residence, Paari Nagar, Sungam by pass, Coimbatore - 641045.

Dr. Y. R Annie Beasent Indian 3/175.P.B RAJA BHAVAN, MATHAR, VEEYANOOR POST- 629177, KANYAKUMARI DISTRICT, TAMILNADU

Mr Ragland Royal Indian Metro Taylor chowk, opposite Parvati apartment, aludhbani, parsudih, jamshedpur, JH- 831002.

Dr. D Gracia Indian C1,202,Green park provident apartments, Selvapuram, Ukkadam Perur Byepass road, Coimbatore-641026

Ms. K. Ranjani Indian C2 Aditya Enclave ,Keeranatham, saravanampatti post,Coimbatore 641035

Ramchandar RS
Indian 13/1, Mahalakshmi Garden, Villankurichi Road, Villankurichi Post, Coimbatore - 35.

Dakshita L
Indian No 6,Maruthappa Nagar, Kurumbapalayam, Vedapatti Post,Coimbatore 641 007.

Ranjan Kumar
Indian Vill Pewandi, Po+ps Sasaram, Dis Rohtas, 821104 Bihar

Yalini S
Indian Plot no, 231,Saikrish Home, ARUN HI TECH CITY, SURYA NAGAR, MADURAI-625007


PREAMBLE TO THE DESCRIPTION

PROVISIONAL
The following specification describes the invention.
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.
4. DESCRIPTION (Description shall start from next page.)
5. CLAIMS (not applicable for provisional specification. Claims should start with the preamble- "I/ We claim" on separate page)
6. DATE AND SIGNATURE (to be given at the end of last page of specification)
7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page)

 
FIELD OF THE INVENTION
The present invention pertains to the field of power supply systems, specifically to address the problems concerning to uninterrupted power supply (UPS) systems.

BACKGROUND OF THE INVENTION
Uninterrupted power supply (UPS) systems are crucial for providing continuous power to critical applications such as communication systems, network systems, memory devices, and medical support systems. The effectiveness of a UPS system is determined by its ability to deliver a regulated sinusoidal output with low harmonic distortion, regardless of input voltage fluctuations or load changes. UPS systems offer numerous advantages, including unity power factor, high reliability, and high efficiency.
A common challenge in maintaining UPS systems is ensuring the proper electrolyte levels in the batteries. Traditional methods of monitoring electrolyte levels, such as float-based gauge systems, has few setbacks. In the float-based gauge system, as the needle descends down it acidulates causing short circuit and damage to the battery system. There is a great necessity for a more infallible and effective method to monitor and maintain electrolyte levels in UPS batteries even in the physical absence.

SUMMARY OF THE INVENTION
This invention relates to a smart electrolyte level monitoring system for UPS batteries, which utilizes an alert mechanism to ensure the continuous performance of UPS systems. By addressing the limitations of traditional monitoring methods, this system employs an ESP32 board and a mobile alert system via Wi-Fi to notify users instantly to alert the low electrolyte levels. The system uses aluminium foil for its contact plates due to its lightweight properties, enhancing the life expectancy of the sensing kit. Future improvements include integration with personal voice assistants and the adoption of a Low Power Bluetooth protocol to reduce power consumption.

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1. Existing float indicator system
Figure 2. Sensor model covered with Aluminium foil
Figure 3. Sensor connected to the ESP board
Figure 4. Implementation flow chart

 
DETAILED DESCRIPTION OF THE INVENTION
The serviceability of uninterrupted power supply (UPS) systems is in high demand due to global warming and greenhouse gas emissions, leading to an increased use of renewable resources. Photovoltaic power has been widely adopted for utilizing solar energy within UPS systems. The global energy demand is growing at an annual rate of 1.4%, necessitating the integration of storage devices or multiple renewable sources to ensure power quality and dependability. Backup systems are essential in preventing undesirable effects caused by power interruptions, particularly in critical areas such as hospitals. The primary reasons for installing backup systems ensures safety, surveillance, financial considerations, and data protection.
Various strategies have been proposed to measure the electrolyte solution levels in batteries. A method using infrared sensors combined with treated float foam is used for sensitive measurement of water surface levels. However, these sensors can be damaged due to acidification during the chemical process, leading to short circuits.
Traditional float-based gauge indicator systems as shown in the Figure 1 employs a needle that moves according to the electrolyte level in the battery. Yet, these systems conjointly suffer from acidification during chemical processes, leading to battery damage and short circuits. The proposed prototype overcomes these issues by utilizing appropriate materials to prevent battery acidification.
The suggested layout features a pair of leads (103,104) connected to the top of the existing gauge (108, 205), with the float stem (101,102) covered in aluminium foil (Figure 2). When the float stem (101,102) reaches a certain level (112,114), the circuit closes (110,204,207), triggering the ESP32 board (105,106,207) (Figure 3), which sends an alert to a mobile device (201) via through the software application over Wi-Fi (201). A typical UPS battery (203) has 6 to 8 electrolyte refill ports. Aluminium foil is chosen for its lower weight compared to copper, despite copper's higher conductivity.
The suggested design uses two leads connected to the top of the current gauge (103,104), with aluminium foil covering the float stem's head (101). When the float stem reaches the posterior level, the circuit closes ((110, 204, 207), and triggering the ESP32 board (204,207), which then uses WiFi to inform a mobile device (201) via through a software application.
The system initializes serial communication portal by setting the baud rate and uses the switch pin for setup. The Blynk connection is authenticated with a token, and the main loop runs continuously to check conditions and send notifications. When the switch pin is activated, the serial monitor receives a message, and a notification is sent to the user's mobile device via Wi-Fi, prompting the user to manually refill the electrolyte.
The proposed smart battery life monitoring system (Figure 4) specifies an indication level for the electrolyte. The system, with proper material selection and IoT integration, aims to enhance battery life and prevent system failures. Future enhancements may include integration with personal voice assistants (e.g., Google Assistant, Alexa, Siri) for user alerts and the development of a standalone interface to reduce dependencies. Additionally, a Low Power Bluetooth protocol could replace the Wi-Fi protocol to decrease electricity consumption.

FLOW

Entities:
• User (receiving notifications on handheld devices)
• ESP32 (connected to sensor, controls API calls)
• Sensor (monitors electrolyte level)
• Blynk (sends notifications to handheld devices)

Process Summary:
• Initial state: Electrolyte level is above the minimum threshold (112,114), the sensor is in an open state, and ESP32 (204, 207) is waiting for a signal.
• As the electrolyte level decreases below the threshold level, the sensor closes (110, 206) establishing connection.
• The closed sensor triggers the ESP32 (106, 107, 204, 207) to initiate an API call to Blynk every 30 minutes.
• Blynk sends notifications to handheld devices.
• Upon refilling the electrolyte (111,113), the sensor connection reopens and signalling to ESP32 (204) stops API calls.
ESP32
The ESP32 (204, 207) is a versatile, low-cost microcontroller with built-in Wi-Fi and Bluetooth capabilities, widely used in IoT, sensor networks, and embedded systems. It features a dual-core processor, multiple GPIO pins, and extensive peripheral support, making the device a popular choice for various applications requiring wireless connectivity and processing power.
• It has higher processing power and hence ensures efficient handling of complex tasks in real-time, making it ideal for advanced sensing applications (Dual-core 240 MHz).
• It has ample memory supports sophisticated programs and data handling, critical for processing sensor data and running multiple tasks (520 KB SRAM, up to 16 MB flash).
• It has built-in Wi-Fi and Bluetooth module thereupon make it well-suited for IoT and remote monitoring, providing seamless communication without additional components.
• It has low-power modes offering flexibility in reducing energy usage, which is useful for battery-powered systems.

SENSING METHOD / TECHNIQUE
The circuit connectivity-based level sensing technique monitors the electrolyte level by using the conductive properties of the aluminium sheet attached to the head of the float (101) to detect changes in circuit connectivity.
• Metallic Conductors:
Two metallic conductors (wires or metal sheets) are positioned at the head of the float (101,102). These conductors normally make an open circuit state when the float is in its normal, elevated position indicating a safe electrolyte level (111,113).
• Electrolyte Level:
As the electrolyte level decreases (114), the float descends (112) ; as the electrolyte level reaches the threshold level indicating low electrolyte levels; the float moves downward, causing the aluminium sheet (attached to the head of the float) to make contact with the metallic conductors (103,104).
This contact between the aluminium sheet and the conductors closes the circuit, allowing a small current to pass through. The closed circuit signifies that the electrolyte level has fallen below the specified range.
• Material Choice:
The aluminium sheet is attached to the head of the float due to its excellent conductivity and resistance to corrosion in electrolytic environments. It ensures reliable circuit closure when the electrolyte level is low, helping to improve sensing accuracy.

Material Electrical Conductivity Corrosion Resistance Weight Fabrication Ease Oxidation Impact Durability in Electrolyte Environmental Impact
Aluminium Moderate (61% of copper's conductivity) Good (forms oxide layer for protection) Very Light (Density = 2.7 g/cm³) Easy to fabricate and shape Forms a protective oxide layer, maintaining function Good (can resist common electrolytes, especially with oxide layer) Low (recyclable, abundant)
Copper Excellent (Very high conductivity) Poor (Prone to corrosion in electrolytes) Heavier (Density = 8.96 g/cm³) Moderate (more difficult to shape and weld than aluminium) Forms oxide that can impact performance Poor (susceptible to damage from electrolytes) Moderate (high energy consumption in production)
Stainless Steel Good (Less conductive than copper) Excellent (Highly corrosion-resistant) Heavier (Density = 8.0 g/cm³) Difficult (tougher to machine and weld) Minimal impact due to chromium oxide layer Excellent (high resistance to acids, alkalis, and chlorides) High (energy-intensive production)
Carbon Poor (Relatively low conductivity) Very Good (Non-corrosive in most environments) Light (Varies by form; typically low density) Easy (but brittle depending on the form used) Non-oxidizing Moderate (depends on specific electrolyte) Low (sustainable in many forms)

Table 1. Properties of heterogenous materials for sensing the electrolyte level
REAL-TIME USAGE OUTCOME:
● Normal Operation:
At normal operation the electrolyte level is above the threshold (111, 113) and the float is elevated because the electrolyte level is sufficient to operate the UPS system (203) via inverter (202). At this instant, the circuit remains open as the aluminium sheet on the float head is not in contact with the metallic conductors.
No signal is sent as the system remains in a waiting state, and no further actions are taken because the electrolyte level is adequate.
● Detection of Low Electrolyte Level:
As the electrolyte solution decreases and when the electrolyte level (109) falls below the threshold (112, 114); the float descends, causing the aluminium sheet on the float head (102) to contact the metallic conductors (103,104) , closing the circuit (110). This triggers the ESP32 (204, 207), detecting the circuit is closed and initiates the real-time process.
● Trigger Action:
As the trigger action is initiated three stages are eventuated,
 Signal Processing & API Call:
Once the ESP32 (204,207) detects the low electrolyte level (112, 114), it sends an API call to Blynk every 30 minutes.
Blynk sends real-time notifications to the designated handheld devices (201) (e.g., smartphones, tablets) of the responsible personnel, alerting them to refill the electrolyte.
 Real-Time Alerts to User:
The user receives a real-time notification on their handheld device (201), informing them that the electrolyte level is low (112,114) and action is required. This could take the form of a message or an alert sound to the handheld device (201).
 Refill and Reset:
Once the the electrolyte is refilled, the float stem rises (107, 108), breaking contact between the aluminium sheet and the metallic conductors (103,104), thus reopening the circuit. Immediately, the ESP32 detects the reopened circuit (105,106), effectuating the system to intimidate sending the API calls to Blynk, and the notifications to the handheld devices (201) are halted.
Key Real-Time Outcomes:
• Continuous Monitoring: The system constantly monitors the electrolyte level and automatically triggers notifications when a low level is detected.
• Automated Alerts: Real-time alerts ensure timely action is taken, preventing any operational issues due to low electrolyte levels.
• Energy Efficiency: Since the API calls to Blynk only occur when the electrolyte is low, it reduces unnecessary data transmissions.
• System Reset: Once the electrolyte is refilled, the system automatically resets, returning to the monitoring state without manual intervention.
This setup ensures a responsive, real-time solution that maintains the operational efficiency of the system by detecting low electrolyte levels and alerting the relevant personnel immediately.

REAL-TIME USE APPLICATIONS:
• Solar Energy Storage Systems (Electrolyte Batteries)
Use Case: Electrolyte batteries, such as lead-acid and flow batteries, are widely used for solar energy storage. These systems store excess solar energy during peak hours for use during nighttime or low-light conditions.
Real-Time Outcome: The level sensing system can monitor electrolyte levels in real-time and trigger API notifications when refilling is necessary, ensuring optimal battery health and continuous power availability.
Value Proposition: Ensures sustainable energy storage for solar installations, preventing system failures, increasing battery life, and improving energy reliability.
• Telecommunications and Remote Infrastructure (Backup Power Systems)
Use Case: Telecom towers, remote communication stations, and critical infrastructure often rely on backup power from electrolyte-based batteries, such as lead-acid, to ensure uninterrupted services during outages.
Real-Time Outcome: The real-time electrolyte level sensor can automatically monitor and alert operators to low electrolyte levels, ensuring that batteries are maintained properly and that backup power is always available when needed.
Value Proposition: Improves reliability of backup power for critical systems, reduces maintenance costs by preventing premature battery failure, and ensures uninterrupted services for remote locations.
• Electric Vehicle (EV) Charging Stations
Use Case: Many EV charging stations utilize battery energy storage systems (BESS) to store power and manage load demands, especially during peak times. Electrolyte-based batteries play a key role in maintaining the availability of stored energy.
Real-Time Outcome: The sensing system monitors the electrolyte levels in these batteries in real time. When levels drop, station operators are notified to refill the batteries before they become inoperable. This ensures the station's continuous operation, meeting the charging demands of EV users.
Value Proposition: Maximizes uptime and reduces the risk of outages at EV charging stations, supporting the growing demand for sustainable transportation infrastructure.
• Uninterruptible Power Supply (UPS) Systems for Data Centers
Use Case: Data centers and critical IT infrastructure rely on UPS systems (often with electrolyte-based batteries) to provide backup power during outages. Any failure in these systems can result in massive data loss and service interruptions.
Real-Time Outcome: Real-time monitoring of the electrolyte levels within the UPS batteries ensures the system remains operational when power disruptions occur. Immediate notifications are sent to maintenance teams if the electrolyte levels drop, ensuring timely refills.
Value Proposition: Ensures uptime and data integrity for mission-critical applications, minimizes risks of power outages, and supports smooth operations of data centers and IT facilities.
• Marine and Off-Grid Applications (Remote Energy Systems)
Use Case: Marine vessels, off-grid cabins, and remote research stations often rely on off-grid battery systems to store power from renewable sources (solar, wind) or generators. Electrolyte-based batteries are commonly used due to their robustness.
Real-Time Outcome: The electrolyte level sensor can monitor battery health remotely. When the electrolyte level falls below a certain threshold, the system sends real-time alerts to maintenance teams or operators, enabling timely refilling, especially in difficult-to-access locations.
Value Proposition: Provides remote maintenance capabilities, ensures continuous energy supply in isolated or off-grid locations, and improves the efficiency and reliability of power systems for marine or remote operations.
, Claims:We claim:

1. A smart electrolyte level monitoring system for UPS batteries (203), characterized in that the system sends a mobile alert (201) when the electrolyte level (109) reaches below a threshold (111, 113), the system comprising of;

comprising a pair of leads (103,104) connected to the top of the existing gauge, a float stem head (101) covered with aluminum foil, an ESP32 board (204,207), and a mobile alert system (201) using a software application via Wi-Fi.

2. The system as claimed in claim 1, wherein the aluminum foil serves as contact plates (103,104) due to its lower weight and higher durability compared to copper.

3. The system as claimed in claim 1, wherein the ESP32 board (204,207) is triggered to send an alert to the user's mobile device (201) when the float stem (101,102) in the gauge descends to a predetermined level.

4. The system as claimed in claim 1, wherein the smart electrolyte sensing kit is installed in only one port of the UPS battery (203) connected to the inverter (202) to monitor the entire battery.

5. The system as claimed in claim 1, wherein a Low Power Bluetooth protocol can be employed instead of a Wi-Fi protocol.

Dated this 13th Nov' 2024

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