Fractional depletion estimation for battery condition metrics

1. A computer-implemented process of evaluating a battery state comprising:

collecting, by a battery monitor that is coupled to an industrial vehicle battery, samples that represent a measure of a magnitude of a current discharged from the industrial vehicle battery during use of a corresponding industrial vehicle, wherein the battery monitor has at least one sensor to sample battery current;

sorting, by a processor, collected samples into corresponding bins based upon the magnitude of the collected current samples, wherein the corresponding bins are stored in memory that is accessible by the processor;

creating, by the processor, a battery use estimate based upon a number of samples sorted into the corresponding bins;

determining, by the processor, for each of the corresponding bins, a fractional depletion contribution of the industrial vehicle battery by computing a quotient where the quotient is computed by dividing a lifetime expected estimate for that bin by the battery use estimate for that bin;

generating, by the processor, a depletion estimate associated with the battery state based upon an accumulation of the fractional depletion contributions; and

outputting a measure of the battery state based upon the generated depletion estimate.

2. The method of claim 1 , wherein:

outputting a measure of the battery state based upon the generated depletion estimate comprises outputting a prediction of how much of a battery capacity has been depleted based upon the evaluation of the depletion estimate.

3. The method of claim 1 , wherein:

outputting a measure of the battery state based upon the generated depletion estimate comprises outputting a prediction of how much of a battery capacity is remaining based upon the evaluation of the depletion estimate.

4. The method of claim 1 , wherein:

outputting a measure of the battery state based upon the generated depletion estimate comprises outputting a prediction of an interval until an occurrence of an event of interest related to the battery state, based upon the evaluation of the depletion estimate.

5. The method of claim 1 , wherein:

collecting, by a battery monitor that is coupled to an industrial vehicle battery, samples, comprises collecting the samples over a load history; and

sorting, by a processor, collected samples comprises accumulating each sample of the load history that represent a measure of a magnitude of a current discharged from the industrial vehicle battery into a corresponding bin based upon the value of the current sample, where each bin stores only samples accumulated during the load history.

6. The method of claim 5 , wherein:

outputting a measure of the battery state based upon the generated depletion estimate comprises outputting a prediction of an accumulated depletion in a capacity related to the battery state, based upon the depletion estimate for the load history.

7. The method of claim 6 , wherein:

outputting a prediction of an accumulated depletion in a capacity related to the battery state further comprises:

outputting a prediction of the accumulated depletion in the capacity based upon the depletion estimate for the load history and fractional depletion estimates of previously collected and aggregated load histories.

8. The method of claim 1 , wherein:

determining, by the processor, for each of the corresponding bins, a fractional depletion contribution of the industrial vehicle battery comprises:

identifying a curve that represents a battery characteristic as a function of current; and

comparing each battery use estimate with an associated point on the curve, and computing therefrom, a fractional depletion estimate that estimates a fraction of the expected characteristic of the battery depleted by the current samples in the corresponding bin.

9. The method of claim 8 , wherein:

creating, by the processor, a battery use estimate further comprises:

integrating across each bin to determine discharged amp-hours represented by the bin.

10. The method of claim 9 , wherein:

identifying a curve that represents a battery characteristic comprises:

identifying a curve that characterizes battery lifetime amp-hours as a function of current; and

comparing each battery use estimate with an associated point on the curve comprises:

comparing the computed discharged amp-hours for each bin to an associated point on the curve identifying lifetime amp-hours for that bin.

11. The method of claim 10 , wherein:

comparing the computed discharged amp-hours for each bin comprises:

computing a quotient for each bin based upon the computed discharged amp-hours for that bin and a magnitude associated with a point on the curve identifying lifetime amp-hours for that bin.

12. The method of claim 11 , wherein:

generating, by the processor, a depletion estimate comprises:

accumulating each computed quotient to predict an amount of life of the battery used up by the load history.

13. The method of claim 1 further comprising:

predicting an accumulated depletion in a capacity related to the battery state, by performing the prediction off-line after the samples have been collected on an industrial vehicle and wirelessly transmitted to a remote server.

14. The method of claim 1 further comprising:

predicting an accumulated depletion in a capacity related to the battery state by performing the prediction on an industrial vehicle on the fly as samples are recorded by a processor of the materials handling vehicle.

15. The method of claim 1 further comprising:

clearing current samples from bins after being wirelessly transmitted to a remote server.

16. A system for evaluating a battery state comprising:

a battery monitor that couples to an industrial vehicle battery to collect samples during use of an industrial vehicle, wherein the battery monitor has at least one sensor to sample battery current that represents a measure of a magnitude of a current discharged from a battery powering the industrial vehicle; and

a processor that couples to the industrial vehicle and the battery monitor, the processor further coupled to memory that includes program code that when executed, causes the processor to:

sort collected samples into corresponding bins based upon the magnitude of the collected current samples;

create a battery use estimate based upon a number of samples sorted into the corresponding bins;

determine for each of the corresponding bins, a fractional depletion contribution of the industrial vehicle battery by computing a quotient where the quotient is computed by dividing a lifetime expected estimate for that bin by the battery use estimate for that bin;

generate a depletion estimate associated with the battery state based upon an accumulation of the fractional depletion contributions; and

output a measure of the battery state based upon the generated depletion estimate.

17. The system of claim 16 , wherein the processor is programmed to:

output a measure of the battery state by executing code to output at least one of:

a prediction of how much of a battery capacity has been depleted based upon the evaluation of the depletion estimate;

a prediction of how much of a battery capacity is remaining based upon the evaluation of the depletion estimate; and

a prediction of an interval until an occurrence of an event of interest related to the battery state, based upon the evaluation of the depletion estimate.

18. The system of claim 16 , wherein the processor is programmed to:

collect the samples over a load history;

sort, by a processor, collected samples by accumulating each sample of the load history that represent a measure of a magnitude of a current discharged from the industrial vehicle battery into a corresponding bin based upon the value of the current sample, where each bin stores only samples accumulated during the load history; and

output a prediction of an accumulated depletion in a capacity related to the battery state, based upon the depletion estimate for the load history.

19. The system of claim 18 , wherein:

the processor outputs a prediction of the accumulated depletion in the capacity based upon the depletion estimate for the load history and fractional depletion estimates of previously collected and aggregated load histories.

20. The system of claim 16 , wherein:

the processor determines, for each of the corresponding bins, a fractional depletion contribution of the industrial vehicle battery by executing code that:

identifies a curve that represents a battery characteristic as a function of current; and

compares each battery use estimate with an associated point on the curve, and computing therefrom, a fractional depletion estimate that estimates a fraction of the expected characteristic of the battery depleted by the current samples in the corresponding bin;

the processor creates a battery use estimate by executing code that:

integrates across each bin to determine discharged amp-hours represented by the bin.

21. The system of claim 20 , wherein:

the processor executes code that identifies a curve by executing code that:

identifies a curve that characterizes battery lifetime amp-hours as a function of current; and

the processor executes code that compares each battery use estimate by executing code that:

compares the computed discharged amp-hours for each bin to an associated point on the curve identifying lifetime amp-hours for that bin by computing a quotient for each bin based upon the computed discharged amp-hours for that bin and a magnitude associated with a point on the curve identifying lifetime amp-hours for that bin.

22. The system of claim 21 , wherein:

the processor generates a depletion estimate by executing code that:

accumulates each computed quotient to predict an amount of life of the battery used up by the load history.

23. The system of claim 16 , wherein the processor is further programmed to:

predict an accumulated depletion in a capacity related to the battery state, by performing the prediction off-line after the samples have been collected on an industrial vehicle and wirelessly transmitted to a remote server.

24. The system of claim 16 , wherein the processor is further programmed to:

predict an accumulated depletion in a capacity related to the battery state by performing the prediction on an industrial vehicle on the fly as samples are recorded by a processor of the materials handling vehicle.

25. The system of claim 16 , wherein the processor is further programmed to:

clear current samples from bins after being wirelessly transmitted to a remote server.