Method and apparatus for charging batteries

• US 20060033473A1
• Filed: 08/10/2004
• Published: 02/16/2006
• Est. Priority Date: 08/10/2004
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Stanzel, David A., Reynolds, Jon O.
• Granted Patent: US 7,446,503 B2
• Time in Patent Office: Days
• US Class Current: 320/128
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/0018 using separate charge circuits
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators

Abstract

A method and apparatus for charging batteries includes using an input rectifier to receive an ac input and provide a dc signal. A converter receives the dc signal and provides a converter output. An output circuit receives the converter output and provides a battery charging signal. A controller preferably controls the converter to power factor correct. The system can include multiple output circuits, used either singly or at the same time, and designed for one or more voltages. They can be user removable. Preferably, the converter output has a magnitude independent of a range of frequencies and a range of magnitudes of the ac input, and the range can be, for example, at least a factor of two or at least two utility voltages. The controller includes a charging schedule module that receives feedback, such as voltage and/or current feedback and/or temperature feedback. The output circuit, such as a dc-dc converter, is controlled in response to the feedback in other embodiments. The battery type may be sensed or input by a user, and the charging done in response to the battery type. A defective battery sensor is preferably included, with a user-noticeable indicator.

Claims

1. A battery charger, comprising:

an input rectifier configured to receive an ac input and to provide a first dc signal;

a converter configured to receive the first dc signal and to provide a converter output, and configured to receive at least one control input;

an output circuit configured to receive the converter output and to provide a battery charging signal; and

a controller, including a power factor correction circuit, configured to provide at least one control signal to the converter.

2. The battery charger of claim 1, wherein the converter output has a magnitude independent of a range of frequencies and a range of magnitudes of the ac input.

3. The battery charger of claim 2, wherein the converter output has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

4. The battery charger of claim 3, wherein the range of magnitudes spans a range of at least two utility voltages.

5. The battery charger of claim 1, wherein:

the controller includes a charging schedule module and receives at least one of a voltage feedback signal indicative of the voltage magnitude of the battery charging signal and a current feedback signal indicative of the current magnitude of the battery charging signal;

the output circuit is a dc-dc converter; and

the controller provides at least one load control signal to the dc-dc converter in response to the at least one of the voltage feedback signal and the current feedback signal and a temperature feedback signal.

6. The battery charger of claim 5, wherein the charging schedule module includes a voltage module and a current module.

7. The battery charger of claim 5, wherein the controller includes a battery selection input, and wherein the charging schedule module is responsive to the battery selection input.

8. The battery charger of claim 7, wherein the battery selection input is connected to a user-selectable input.

9. The battery charger of claim 7, wherein the battery selection input is connected to a battery sensor.

10. The battery charger of claim 9, wherein the battery sensor is disposed to be wired to a battery being charged.

11. The battery charger of claim 9, wherein the battery sensor is disposed to be wirelessly connected to a battery being charged.

12. The battery charger of claim 9, wherein the battery sensor includes an RFID sense circuit disposed to be sense an RFID tag on a battery being charged.

13. The battery charger of claim 5, wherein the output circuit is designed for a first battery voltage and further wherein the output circuit is user-removable.

14. The battery charger of claim 13, further comprising a second user-removable output circuit designed for a second battery voltage, wherein only one of the output circuit and second output circuit is connected at any given time.

15. The battery charger of claim 13, further comprising a second user-removable output circuit designed for a second battery voltage, wherein both of the output circuit and second output circuit are connected at any given time.

16. The battery charger of claim 15, wherein the first battery voltage and the second battery voltage are the same.

17. The battery charger of claim 1, wherein the converter is one of a boost converter, a buck-boost converter, and a combined rectifier boost converter.

18. The battery charger of claim 5, wherein the output circuit includes a switched converter.

19. The battery charger of claim 18, wherein the switched converter is one of a pulse width modulated inverter, a pulse width modulated forward converter, and a frequency modulated converter.

20. The battery charger of claim 1, further comprising of least a second output circuit in parallel with the output circuit.

21. The battery charger of claim 5, wherein the controller includes a defective battery sensor module that receives as an input a second at least one of the voltage feedback signal, the current feedback signal and a temperature feedback signal.

22. The battery charger of claim 21, further comprising a user-noticeable output indicative of a defective battery, responsive to the defective battery sensor module.

23. The battery charger of claim 1, further including a controller power source capable of providing a control power signal at a preselected control signal voltage, regardless of the magnitude of the ac input.

24. A method of providing a battery charging current, comprising:

boost or buck-boost converting and power factor correcting an input signal to a dc signal; and

changing the dc signal into a second dc signal having a current suitable for charging a first battery.

25. The method of claim 24, wherein the dc signal has a magnitude independent of a range of magnitudes of the input signal.

26. The method of claim 25, wherein the dc signal has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

27. The method of claim 25, wherein the range of magnitudes spans a range of at least two utility voltages.

28. The method of claim 26, further comprising controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal and a temperature feedback signal.

29. The method of claim 26, wherein the controlling a charging current is further responsive to a user-selectable input.

30. The method of claim 26, wherein the controlling is further responsive to sensing a battery to be charged.

31. The method of claim 30, wherein sensing includes sensing a bar code on the battery.

32. The method of claim 30, wherein sensing includes sensing an RFID tag on the battery.

33. The method of claim 24, further comprising selecting between a plurality of user-removable output circuits, each designed for a battery voltage, and connecting the selected user-removable output circuit to a battery charger.

34. The method of claim 25, further comprising changing the dc signal into a third dc signal having a current suitable for charging a second battery.

35. The battery charger of claim 34 wherein the first battery is charged at the same voltage as the second battery.

36. The method of claim 26, wherein boost or buck-boost converting includes rectifying.

37. The method of claim 26, wherein changing includes one of switching a converter, pulse width modulating an inverter, pulse width modulating a forward converter, and frequency modulating a converter.

38. The method of claim 24, further comprising monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

39. The battery charger of claim 34 wherein the first battery is charged at a different voltage from the second battery

40. A battery charger, comprising:

converter means for receiving an input signal and providing a converter output;

control means for controlling the converter means to provide power factor correction and to provide the converter output at a desired voltage; and

output means for receiving the converter output and providing a battery charging signal.

41. The battery charger of claim 40, wherein the converter output has a magnitude independent of a range of magnitudes of the input signal.

42. The battery charger of claim 41, wherein the converter output has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

43. The battery charger of claim 42, wherein the range of magnitudes spans a range of at least two utility voltages.

44. The battery charger of claim 41, wherein the control means further is for controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal and a temperature signal.

45. The battery charger of claim 41, wherein the control means is responsive to a user-selectable input.

46. The battery charger of claim 41, further comprising means for sensing a battery to be charged and controlling the charging current in response thereto.

47. The battery charger of claim 46, wherein the means for sensing a battery includes means for sensing an RFID tag.

48. The battery charger of claim 44, wherein the output means is user-removable, and the converter means is capable of having one of a plurality of user-removable output means attached thereto, wherein each output means is designed for a battery voltage.

49. The battery charger of claim 48, wherein each output means is designed for a different battery voltage.

50. The battery charger of claim 44, wherein the converter means is capable of having one of a plurality of output means attached thereto, wherein each output means is designed for a battery voltage.

51. The battery charger of claim 44, wherein the converter means includes one of a boost converter, a buck-boost converter, and combined rectifier boost converter.

52. The battery charger of claim 44, wherein the output means includes a dc-dc converter.

53. The battery charger of claim 52, wherein the output means includes a pulse width or frequency modulated inverter.

54. The battery charger of claim 52, wherein the output means includes a pulse width or frequency modulated forward converter.

55. The battery charger of claim 40, further comprising means for monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

82. The battery charging system of claim 41, wherein the output control means further is for controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal.

83. The battery charging system of claim 82, wherein the output control means is responsive to a user-selectable input.

56. A battery charging system, comprising:

an input circuit, configured to receive an input signal and to provide a first dc signal;

a plurality of user-removable output circuits, each configured to receive the first dc signal and each designed to provide a battery charging signal at a desired voltage and a desired current, wherein a chosen one of the plurality is connected at a time; and

a controller, configured to provide at least one control signal to the chosen one output circuit.

57. The battery charging system of claim 56, wherein the input circuit includes a rectifier and a boost converter or a buck-boost converter, and further including an input controller that provides power factor correction.

58. The battery charging system of claim 57, wherein the first dc signal has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

59. The battery charging system of claim 56, wherein the controller includes a charging schedule module and receives at least one of a voltage feedback signal indicative of the voltage magnitude of the battery charging signal and a current feedback signal indicative of the current magnitude of the battery charging signal.

60. The battery charging system of claim 59, wherein the controller includes a battery selection input, and wherein the charging schedule module is responsive to the battery selection input.

61. The battery charging system of claim 60, wherein the battery selection input is connected to a user-selectable input.

62. The battery charging system of claim 60, wherein the battery selection input is connected to a battery sensor.

63. The battery charging system of claim 62, wherein the battery sensor includes an RFID sense circuit disposed to be sense an RFID tag on a battery being charged.

64. The battery charging system of claim 59, wherein the output circuit includes a switched converter.

65. The battery charging system of claim 59, wherein the switched converter is a pulse width or frequency modulated inverter.

66. The battery charging system of claim 59, wherein the switched converter is a pulse width or frequency modulated forward converter.

67. The battery charging system of claim 59, wherein the controller includes a defective battery sensor module that receives as an input a second at least one of the voltage feedback signal and the current feedback signal, and provides a user-noticeable output indicative of a defective battery.

68. A method of battery charging, comprising:

converting an input signal to a first dc signal; and

selecting one of a plurality of user-removable output circuits, each designed for a battery voltage, and using the selected output circuit, changing the first dc signal into a second dc signal having a current suitable for battery charging.

69. The method of claim 68, wherein converting includes boost converting and power factor correcting such that the first dc signal has a magnitude independent of a range of magnitudes of the input signal.

70. The method of claim 69, wherein the first dc signal has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

71. The method of claim 68, further comprising controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal.

72. The method of claim 71, wherein the controlling a charging current is responsive to a user-selectable input.

73. The method of claim 71, wherein the controlling is responsive to sensing a battery to be charged.

74. The method of claim 73, wherein sensing includes sensing an RFID tag on the battery.

75. The method of claim 73, wherein converting includes one of buck-boost converting and boost converting.

76. The method of claim 75, wherein changing includes switching a converter.

77. The method of claim 76, further comprising monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

78. A battery charging system, comprising:

converter means for receiving an input signal and providing a converter output; and

a plurality of user-removable output means for receiving the converter output and providing a battery charging signal, wherein each output means is further for providing the battery charging at a desired voltage, wherein a selected one of the plurality is connected to the converter means at one time.

79. The battery charging system of claim 78, further comprising an output control means for controlling the selected one output means, connected to the selected one output means.

80. The battery charging system of claim 79, further comprising a converter control means for controlling the converter to provide power factor correction and to provide the converter output at a desired voltage, and connected to the converter.

81. The battery charging system of claim 80, wherein the converter means includes one of a boost and a buck-boost converter, and wherein the converter output has a magnitude independent of a range of magnitudes of the input signal.

84. The battery charging system of claim 78, further comprising means for sensing a battery to be charged, and controlling the charging current in response thereto.

85. The battery charging system of claim 84 wherein the means for sensing a battery includes means for sensing an RFID tag.

86. The battery charging system of claim 84, wherein each output means includes a dc-dc converter.

87. The battery charging system of claim 84, wherein each output means includes a pulse width or frequency modulated inverter.

88. The battery charging system of claim 84, wherein output means includes a pulse width or frequency modulated forward converter.

89. The battery charging system of claim 84, further comprising means for monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

90. A battery charging system, comprising:

an input circuit, configured to receive an input signal and to provide a first dc signal;

a plurality of output circuits, each configured to receive the first dc signal and each designed to provide a battery charging signal at a desired voltage and a desired current, and

a controller, configured to provide at least one control signal to each of the plurality of output circuits.

91. The battery charging system of claim 90, wherein the input circuit includes a rectifier and a boost converter or a buck-boost converter, and further including an input controller that provides power factor correction.

92. The battery charging system of claim 90, wherein the controller includes a battery selection input, and wherein a charging schedule module is responsive to the battery selection input.

93. The battery charging system of claim 92, wherein the battery selection input is connected to a battery sensor.

94. The battery charging system of claim 93, wherein the battery sensor includes an RFID sense circuit disposed to be sense an RFID tag on a battery being charged.

95. A method of battery charging, comprising:

converting an input signal to a first dc signal; and

using a plurality of output circuits, each designed for a battery voltage, to change the first dc signal into a plurality of charging dc signals suitable for battery charging.

96. The method of claim 95, wherein converting includes boost converting and power factor correcting such that the first dc signal has a magnitude independent of a range of magnitudes of the input signal.

97. The method of claim 96, wherein the controlling is responsive to sensing a battery to be charged.

98. The method of claim 97, wherein sensing includes sensing an RFID tag on the battery.

99. A battery charging system, comprising:

converter means for receiving an input signal and providing a converter output; and

a plurality of output means for receiving the converter output and providing a plurality of battery charging signals.

100. The battery charging system of claim 99, further comprising an output control means for controlling the plurality of output means, connected to each of the plurality of the output means.

101. The battery charging system of claim 100, further comprising a converter control means for controlling the converter to provide power factor correction and to provide the converter output at a desired voltage, and connected to the converter means.

102. The battery charging system of claim 99, further comprising means for sensing at least one battery to be charged, and controlling a charging current in response thereto.

103. The battery charging system of claim 102 wherein the means for sensing a battery includes means for sensing an RFID tag.