High frequency multiphase flyback power supply

• US 10,008,873 B2
• Filed: 03/10/2016
• Issued: 06/26/2018
• Est. Priority Date: 11/12/2008
• Status: Active Grant

• Current Assignee: Bravo Zulu International Ltd.
• Original Assignee: Bravo Zulu International Ltd.
• Inventors: Zeier, Bruce Eric, Hankins, Steve M., Mettler, James A.
• Primary Examiner(s): Nikmanesh, Seahvosh
• Application Number:
  US15/066,996
• Publication Number:
  US 20160268841A1
• Time in Patent Office: 838 Days
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y02E 60/16 Mechanical energy storage, e.g. flywheels or pressurised fluids

Abstract

Improvements in a high frequency multiphase flyback power supply for battery charging and power supplies used in devices that provide de-sulfation capability to the batteries. The system utilizes a high efficiency, multiphase array flyback battery charger or power supply, with a localized or Internet based bi-directional communication means to monitor and optimize battery charging. The de-sulfating current can be a variable, or harmonic, repeating patterns of ON and OFF pulses which may be applied to the battery at an operator-adjustable peak amperage of about 0-350 amps. The de-sulfation process before, during or after the normal battery charging cycle, or any combination thereof. The temperature of the battery and the specific gravity of the fluid within the battery is measure during the de-sulfating process. The connection to the internet allows the processes to be monitored at a distance from where the charging is taking place.

Claims

1. A battery optimization control using a high frequency multiphase flyback power supply with a Localized or Internet Based Bi-Directional Communication comprising:

a multiphase flyback power supply current source;

output conductors that is connectable to a battery;

at least one switching power supply power pack electrically interposing the multiphase flyback power supply current source and the output conductors, each phase including a rectifier electrically connected to the multiphase flyback power supply current source, a capacitor electrically connected to an output of the rectifier, at least one switching device electrically connected to the capacitor, and a diode electrically connected to the output of the switching module;

a controller that controls a conduction state of the at least one switching device;

wherein the control is configured to control the conduction states of the at least one switching power supply power pack to provide a current output to the battery;

wherein the switching device outputs a repeating pattern including an about 0.75 millisecond output followed by an about 9.75 millisecond OFF period.

2. The battery optimization control according to claim 1 wherein said output is a square pulse or a sine wave pulse or a saw tooth pulse or a triangular wave pulse.

3. The battery optimization control according to claim 1 further comprising;

a peak amperage indicator providing an indication of a peak amperage provided to the battery;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an external charging means, which is passed internally through the battery optimization control device from the external device to the battery;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an internal charging means;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an internal battery optimization means;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy flowing from the battery to a power consuming means or devices;

an average amperage indicator providing an indication of a root-mean-square amperage provided to the battery;

an electrolyte temperature indicator providing a real time indication of the battery electrolyte temperature during charging, the application of internal battery optimization means or discharge testing of the battery;

a battery qualitative scoring indicator providing a real time indication of the calculated battery quality value derived from the comparison of currently measured battery metrics, to that same battery'"'"'s historically measured and stored battery metrics, to a database of battery industry qualitative value metrics, or any combination thereof,

and an impedance indicator providing an indication of the real time impedance of the battery during charging, during a battery optimization means, or during discharge of the battery;

a specific gravity indicator providing a real time indication of the optically measured battery electrolyte acidity during charging, the application of internal battery optimization means or discharge testing of the battery, and

wherein the impedance is determined at least in part by ascertaining a difference between the peak amperage provided to the battery and the root-mean-square amperage provided to the battery.

4. The battery optimization control according to claim 1 wherein said battery optimization control device is located between the battery charger and the battery connective means, providing the automated interruption of said means to apply an internal battery de-sulfation process before, during or after the normal battery charging cycle, or any combination thereof.

5. The battery optimization control according to claim 1 that provides at least one of a group consisting of, providing the automated interruption of said means to control the Charge Return Factor of a charger, providing the automated interruption of said means to apply an external device battery de-sulfation process before, during or after the normal battery charging cycle, or any combination thereof and providing the automated interruption of said means to reduce or eliminate a charger Equalization Charge being applied to the battery.

6. The battery optimization control according to claim 1 that is capable of scanning the battery or battery cell metrics of a group consisting of developing device commands based in whole or in part by scanned battery or battery cell metrics, and control internal, devices in the process of optimization of the battery in an automated manner, developing device commands based in whole or in part by scanned battery or battery cell metrics, and control external, devices in the process of optimization of the battery in an automated manner, developing device commands based in whole or in part by scanned battery or battery cell metrics, and control said devices in the process of optimization of the battery in an automated manner for the purpose of controlling a connected battery charger'"'"'s charge return factor, developing and storing qualitative scoring data to determine the battery'"'"'s life expectancy and performance characteristics and including optically digitized specific gravity, impedance, volts per cell and electrolyte temperature, battery electrical energy efficiency rations, then developing and storing qualitative scoring data to determine the battery'"'"'s life expectancy and performance characteristics from such data.

7. The battery optimization control according to claim 1 that includes a Kelvin Connection device that accommodates at least one of a group consisting of the size and shape of an industrial battery cell-to-cell interconnection means, a device that easily penetrates the natural corrosive boundary layer of the interconnection means, a device that is constructed of sharpened contact pointed electrodes manufactured from corrosion resistant material, a device comprised of sharpened contact pointed electrodes that may allow the exposed pointed area to be extended or retracted in a manner to affect the calibration of the measured raw data, a device that is constructed of sharpened contact pointed electrodes spring pressure forced into the subsurface layer of the cell-to-cell interconnection means that may allow the increase or decrease of pressure to affect the calibration of the measured raw data, a connection constructed of sharpened contact pointed electrodes using an outer spring to apply pressure to an inner electrode, were the inner electrode is electrically isolated from the outer spring, a connection device comprised of sharpened contact pointed electrodes that may allow the measured length between the contact tip of the electrode and the attached connective flexible means to be increased or decreased to affect the calibration of the measured raw data, a connection device that easily accommodates the size and shape of certain industrial battery cell terminal posts, a connection device that is immersed within the battery electrolyte using corrosion resistant contact points contacting the electrolyte, a connection device that easily accommodates the size and shape of certain automotive, marine, telecomm or other battery terminal posts, a connection device that easily accommodates the size and shape of certain automotive, marine, telecomm or other battery interconnection means, a connection device that easily penetrates the applied corrosive preventive boundary layer of the interconnection means, a connection device that is constructed of sharpened contact pointed electrodes that are spring pressure forced into the subsurface layer of the cell-to-cell interconnection means of a battery cell array.

8. The battery optimization control according to claim 1 that further includes an electrolyte immersed device that measures at least one of a group consisting of a temperature of the electrolyte by contacting the electrolyte fluid within a battery or battery cell, a device that measures the specific gravity by optical digitization of the physical movement of specific gravity sensitive device, floating past a light bar that provides a light source, a light receiving means and a processing module, comparing that floating specific gravity sensing device light output to the light output of a stationary and identical, non-floating light sensitive device, providing a baseline calibration of the electrolyte turbidity, a device that contains a specific gravity optical digitization processor with an integral temperature sensing device that provides temperature data the processor may use to compensate floatable disk data to temperature compensated disk data, a device that that in conjunction with a terminal or interconnecting means Kelvin connection, measures battery cell impedance between the electrolyte and the negative battery or battery cell terminal, a device that in conjunction with a terminal or interconnecting means Kelvin connection, measures battery cell impedance between the electrolyte and the positive battery or battery cell terminal, a device that the measures battery cell impedance between the electrolytes of adjacent batteries or adjacent battery cells, of a series connected array, a device that measures the voltage of the electrolyte by contacting the electrolyte fluid within a battery or battery cell, a device that in conjunction with a terminal or interconnecting means Kelvin connection, measures battery cell voltage between the electrolyte and the negative battery or battery cell terminal, a device that in conjunction with a terminal or interconnecting means Kelvin connection, measures battery cell voltage between the electrolyte and the positive battery or battery cell terminal and a device that the measures battery cell voltage between the electrolytes of adjacent batteries or adjacent battery cells, of a series connected array.

9. The battery optimization control according to claim 1 that further includes a Control Device that uses an integral processor, memory, computer software algorithms and hardware combinations, to apply specific calibration adjustments, schedules and data tables modifying the raw data output of the device sensors, transducers and probes thereby providing a calibration compensation for the specific combination or permutation of the different arrangement possibilities of the stationary and non-stationary transducer elements, and a transducer support means.

10. The battery optimization control according to claim 1 that operates with a group consisting of taking a single battery or battery cell metric reading, or multiple cell metric reading of multiple cells, the quantity of individual readings approaching infinity if desirous, a calibration modification subroutines for cell electrolyte temperature and turbidity, processor temperature, applied probe pressure, ambient temperature, cell metric data averaging or smoothing, or other data calibration requirements, and a collect cell data that includes;

1) individual cell (battery) voltage;

2) individual cell (battery) temperature;

3) individual cell (battery) electrolyte temperature;

4) individual cell electrolyte level;

5) individual or comparative cell (battery) impedance as measured from cell post to cell post;

6) individual or comparative cell (battery) impedance as measured from cell electrolyte to the positive battery post;

7) cumulative battery or cell array impedance;

8) individual or comparative cell specific gravity;

9) individual or comparative battery or cell charging rate;

10) individual or comparative battery or cell discharging rate;

11) the individual or comparative peak-to-peak values of applied pulse width modulated signals to the battery or battery cells, either individually or collectively;

12) the individual or comparative peak-to-peak frequency values of applied pulse width modulated signals to the battery or battery cells, either individually or collectively;

13) the comparison of peak amperage amplitude vs., average amperage applied to the battery or battery cells, either individually or collectively;

14) the collection of individual or comparative raw data related to the calculation of a Charge Return Factor;

15) the individual or comparative raw data relating to the collection of the battery or battery cell electrical efficiency index;

16) the individual or comparative cell (battery) lifetime cumulative re-charging energy consumed, and

17) ambient operational temperature, a flexible conductive means from the stationary means to the probes, sensors and transducers utilizing a special wire twist, braided pattern, or shielding process to minimize electrical noise, RMI or RFI interference, a non-flexible conductive means from the probes, sensors and transducers of the device, to the processing unit, to reduce electrical noise, RMI or RFI interference, automatically determine the battery or cell array voltage, capacity or type by the physical configuration, the measured voltage and an RFID identifying chip located on the battery, a device that measures and collects raw individual cell data with a reference to a common ground, within a multi-cell battery array, a device capable of exporting raw or calibrated data in numerous electronic formats, allowing many different types and brands of external instruments or computer based operating systems to access the data, a device incorporating special software algorithms that create a “

Virtual Cell Identification Number”

for the purpose of applying unique calibration modifications to the raw data of every monitored cell or battery, a device that can calculate the cumulative cell metrics of the entire battery or cell array, a device provides for the electrical isolation of discrete battery or battery cell channels during the data collection process, measuring batteries or battery cells in a random, sequential, or a combined random and sequential monitoring algorithm, during the raw data collection process, a device provides the means to control external ancillary devices such as a charger or load-testing device.

11. The battery optimization control according to claim 1 that creates an applied pulse width modulated signal that can be operated using an integral High Frequency, Isolated, Power Factor Corrected power supply, which can store and release current to the IBO device at least one switching power supply power pack to allow numerous combinations of symmetrical and asymmetrical frequencies, synchronous or asynchronous pulse amplitudes, which in totality may provide for a harmonic affect upon the internal lead plates of the lead-acid battery, wherein the harmonic affect may provide for increased sulfation and an increase in battery performance.

12. The battery optimization control according to claim 1 that creates an applied pulse width modulated signal which can be operated by switching the flow of current from the positively orientated Charging and Industrial Battery Optimization pathways, to a negatively oriented Discharge pathway, through a variable or constant resistive load bank providing a means to discharge a battery for the purpose of testing the battery'"'"'s discharge capacity and to de-sulfate the battery, the polarity of the current flow through the pulse width modulated device would be reversed from a charging current flow directional pathway, to a discharging current flow directional pathway;

the controlled device'"'"'s variance of the pulse width modulated ON STATE frequency would correspondingly vary the current average discharged from the battery;

a lengthening of the applied pulse width modulated signal ON STATE frequency results in a higher discharge current flow measured in Amps root mean squared;

a shortening of the applied pulse width modulated signal ON STATE frequency results in a lower discharge current flow measured in Amps root mean squared;

an ON STATE frequency can be varied between 0 and a 100% duty cycle resulting in an average root mean square measured discharge rate between 0 amps RMS and the total capacity of the attached resistive load bank calculated using Ohms'"'"' Law;

a discharge rate between 0 and 1000 amps RMS;

the ON and OFF switching of a high current flow through a resistive load bank results in high inductive voltage peak applied to the battery plates, which are limited within the device'"'"'s hardware and software design to harness the useful applied voltage peak range to de-sulfate the battery, that voltage peak range may vary between types of batteries, an exemplary embodiment would measure and control the applied inductive voltage peaks between 0 and 1000 volts per pulse;

wherein the control means is configured to control the conduction states of the at least one switching power supply power pack module, or an alternating pattern between two or more channels to create an average discharge current output from the battery through a resistive load bank;

wherein the control means is configured to control the conduction states of the at least one switching power supply power pack module, or an alternating pattern between two or more channels to create a discharge OFF State inductive voltage peaks within the battery;

wherein the measurement and control means is configured to control the amplitude of the inductive voltage peaks created during the discharge switching means OFF State, to provide a limited inductive voltage peak within the battery ranging from 0 to 1000 volts, to de-sulfate the battery;

wherein at least one channel of the least one switching power supply power pack module outputs a repeating pattern ranging from an about 0.0 millisecond output followed by an about 100% OFF period, to an about 100% millisecond output followed by an about 0.0 millisecond OFF period, together, or any combination in-between;

wherein the combination of one or more channels of the at least one switching power supply power pack modules outputs a repeating pattern, for the purpose of creating applied voltage and amperage discharge peaks within the battery, de-sulfating the battery as a means to improve the battery'"'"'s performance, the variance of the pulse width modulated ON STATE current duration would correspondingly create variable peak voltage and amperage currents though the battery;

wherein the combination of one or more channel of the at least one switching power supply power pack modules outputs a repeating pattern, creating symmetrical or asymmetrical with respect to ON and OFF state duration, and synchronous or asynchronous with respect to ON state frequency when using a dual channel PWM discharging system;

wherein the combination of one or more channel of the at least one switching power supply power pack modules, and control means, outputs a repeating discharging pattern, discharging the battery at a rate which would then be measured in terms of minutes of discharge runtime, Amps RMS and KWH of discharge energy removed from the battery, and the volts per cell of an individual battery cell, or multiple individual cells sequentially or comparatively, or the volts per cell average of the combined individual cells constituting a battery; and

the specific gravity of the battery cells electrolyte measured individually, sequentially or comparatively, or the average specific gravity of the combined individual cells constituting a battery, or any ratio analysis or qualitative factor resulting from the comparative combination of any of the aforementioned measurements;

wherein the combination of one or more channel of the at least one switching power supply power pack modules, and control means, outputs a repeating discharging pattern, automatically controlling or terminating this discharge pattern once the desirous level of runtime minutes has been attained or exceeded, the desirous level of Amps RMS has been attained or exceeded, the desirous level of KWH has been attained or exceeded, the desirous level of volts per cell of an individual cell, multiple cells sequentially or comparatively measured, or the average cell values of a battery, has been attained or exceeded;

the desirous level of the electrolyte specific gravity of the battery cells electrolyte measured individually, sequentially or comparatively, or the average specific gravity of the combined individual cells constituting a battery, has been attained or exceeded, or any ratio analysis or qualitative factor resulting from the comparative combination of any of the aforementioned measurements has been attained or exceeded.

13. The battery optimization control according to claim 12 wherein said bi-directional external communication control means utilizes a processor that adjusts an operational output of the multiphase flyback power supply based upon computer processed metrics provided by probes or sensors, a software algorithm that operates the multiphase flyback power supply at an optimum power factor, and a software algorithm that predicts battery, or device, life expectancy or serviceability.

14. A high frequency multiphase flyback power supply comprising:

a multiphase flyback power supply current source;

at least one switching power supply power pack electrically interposing the multiphase flyback power supply current source and the output conductors, each phase including a rectifier electrically connected to the multiphase flyback power supply current source, a capacitor electrically connected to an output of the rectifier, at least one switching device electrically connected to the capacitor, and a diode electrically connected to the output of the switching module;

a controller that controls a conduction state of the at least one switching device;

wherein the control is configured to control the conduction states of the at least one switching power supply power pack to provide a current output.

15. The high frequency multiphase flyback power supply according to claim 14 wherein said multiphase flyback power supply current source includes interleaving of multiple channels.

16. The high frequency multiphase flyback power supply according to claim 14 further comprising;

a peak amperage indicator providing an indication of a peak amperage provided to the battery;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an external charging means, which is passed internally through the battery optimization control device from the external device to the battery;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an internal charging means;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy restored to the battery from an internal battery optimization means;

a Kilo-watt hour indicator providing an indication of the consumed electrical energy flowing from the battery to a power consuming means or devices;

an average amperage indicator providing an indication of a root-mean-square amperage provided to the battery;

an electrolyte temperature indicator providing a real time indication of the battery electrolyte temperature during charging, the application of internal battery optimization means or discharge testing of the battery;

a battery qualitative scoring indicator providing a real time indication of the calculated battery quality value derived from the comparison of currently measured battery metrics, to that same battery'"'"'s historically measured and stored battery metrics, to a database of battery industry qualitative value metrics, or any combination thereof,

and an impedance indicator providing an indication of the real time impedance of the battery during charging, during a battery optimization means, or during discharge of the battery;

a specific gravity indicator providing a real time indication of the optically measured battery electrolyte acidity during charging, the application of internal battery optimization means or discharge testing of the battery, and

wherein the impedance is determined at least in part by ascertaining a difference between the peak amperage provided to the battery and the root-mean-square amperage provided to the battery.

17. The high frequency multiphase flyback power supply according to claim 14 wherein said multiphase flyback power supply current source is scalable by staggering a timing of primitive elements in a sliding timeline.

18. The high frequency multiphase flyback power supply according to claim 14 wherein a period, or duration, of each cycle of a switching frequency is divided by the number of primitive flyback elements.

19. The high frequency multiphase flyback power supply according to claim 14 wherein if a circuit failure is detected within any given primitive element, said faulty element is taken offline, thereby yielding a degradation in power output as said faulty element is individual taken offline.

20. The high frequency multiphase flyback power supply according to claim 14 wherein said power supply is a transformer with an “

I”

plate and a plurality of consecutive “

E”

plates, wherein each “

E”

plate has a separate coil assembly.