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BQ40Z80: Pack cycling/capacity learning - necessary for volume production?

Part Number: BQ40Z80

Tool/software:

Hi,

We are preparing to enter production using BQ40Z80 on a pack of our design.  We are wondering if it is necessary to perform the time consuming learning cycle on all packs we produce?

The TRM describes a process involving

  1. Discharge at -C/5, until CUV.
  2. Rest until REST bit = 1
  3. Charge at C/2, until Charge Termination
  4. Rest until REST bit = 1
  5. Discharge at -C/5, until CUV.
  6. Rest until REST bit = 1

This equates to 12 hours, plus roughly the same again depending on how long it takes for the pack to set the REST flag after each step.

This seems impractical and labor intensive for volume pack production.  Is there a way to override the full charge capacity, so that the pack reports a realistic capacity based on the design capacity, without having to cycle?

Note, we require accurate gauging for the end user out of the box, as the remaining Wh is reported to the device, which uses it to provide the user with an estimate of run time and amount of work the device can perform with the available charge.  
Without cycling, I've found  our packs typically report about 20% less full charge capacity when first assembled, compared to after cycling.

regards,
Daniel