MANUFACTURING
Dr. Olson has unique experience in lead-acid battery manufacturing. John worked for Optima Batteries from 1994 to 2001 and was involved in plant operation and troubleshooting. As R&D Manager he oversaw operations of the prototype lab, chemistry lab and the test lab. John can provide manufacturing consulting for lead-acid battery manufacturing.
His capabilities lie in the realm of materials and performance. He understands the chemical side of battery manufacturing. Often lapses in product quality can be found in changes in materials or processes that change the materials chemistry.
CHARGING
Dr. Olson has particular expertise in charging lead-acid batteries. In particular, sealed (aka VRLA, AGM, Gel) batteries are difficult to charge properly. Overcharge leads to dramatic lower lifetimes, but undercharge is worse leading to a rapid loss of capacity. To make things more complex, the optimum charge varies over the life of the battery. Charging large packs adds another layer of complexity to the optimization of charging.
Long Charge Times: Any lead-acid battery requires long charge times of about 16 hours for full charge. Dr. Olson has developed effective charge algorithms that can reduce this time to 3 – 4 hours.
Recovering Aged Batteries: Another important area is recovering aged batteries. Lead-acid batteries will become resistant to standard charging techniques if they have aged due to prolonged storage. These batteries develop ‘sulfation’ which is resistant to charging. Depending on the condition of the battery they may be permanently damaged or can be recovered with aggressive charging techniques.
Thermal Runaway: A related topic for sealed lead-acid batteries is thermal runaway. Overcharging, particularly at higher temperatures, can lead to thermal runaway that can permanently damage the batteries. Dr. Olson understands the mechanisms and can help you avoid the dangers of thermal runaway.