Automatic battery charge apparatus and method

• US 4,270,080 A
• Filed: 12/14/1978
• Issued: 05/26/1981
• Est. Priority Date: 12/14/1978
• Status: Expired due to Term

• Current Assignee: Snap-On Tools Company LLC (Snap-On Incorporated)
• Original Assignee: Sun Electric Corp (Snap-On Incorporated)
• Inventors: Kostecki, Raymond T.
• Primary Examiner(s): HICKEY, ROBERT
• Application Number:
  US05/969,299
• Time in Patent Office: 894 Days
• Field of Search: 320/22-24, 320/39, 320/40, 320/31, 320/32, 320/19
• US Class Current: 320/160
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• CPC Class Codes: Y10S 320/18 Indicator or display

Abstract

An automatic apparatus and method for charging a storage battery from a source of electrical current. The charger includes a current control circuit for conducting regulated charging current through the battery in steps. A voltage monitoring circuit determines when the steps occur by monitoring battery voltage conditions. The steps are sequenced by a ring counter that varies the bias conditions on the current control circuit and voltage monitoring circuit as the steps occur.

Claims

1. An automatic battery charger for charging a storage battery capable of conducting a battery charging current and generating a battery voltage, said charger comprising:

battery cable means for connecting the battery to the charger;

current control means operable in a first mode for conducting through the cable means a charging current regulated at a first predetermined level, and operable in a second mode for conducting through the cable means a charging current regulated at a second predetermined level less than the first predetermined level;

voltage monitor means operable in a first mode for generating a first monitor signal in response to a first battery voltage condition, and operable in a second mode for generating a second monitor signal in response to a second battery voltage condition less than the first battery voltage condition; and

sequencing means for operating the current control means and voltage monitor means in their first modes, for operating the current control means and voltage monitor means in their second modes in response to the first monitor signal, and for enabling the current control means to reduce the charging current in response to the second monitor signal, whereby the battery is automatically charged at a rapid yet safe rate.

2. A charger, as claimed in claim 1, wherein the current control means is operable in an initial mode for conducting through the cable means a charging current regulated at an initial predetermined level greater than the first predetermined level, wherein the voltage monitor means is operable in an initial mode for generating an initial monitor signal in response to an initial battery voltage condition greater than the first battery voltage condition, and wherein the sequencing means comprises means for initially operating the current control means and voltage monitor means in their initial modes, and for operating the current control means and voltage monitor means in their first modes in response to the initial monitor signal.

3. A charger, as claimed in claim 1 or 2, wherein the sequencing means comprises means for enabling the current control means to reduce the charging current to substantially zero in response to the second monitor signal.

4. A charger, as claimed in claim 1 or 2, wherein the sequencing means comprises means for enabling the current control means to reduce the charging current to a trickle current in response to the second monitor signal.

5. A charger, as claimed in claim 4, wherein the voltage monitor means is operable in a third mode for generating a third monitor signal in response to a third battery voltage condition lower than the second battery voltage condition and further comprising indicator means for indicating the existence of the third monitor signal to an operator, whereby the charged state of the battery is detectable.

6. A charger, as claimed in claim 1, and further comprising protection means for disabling the current control means if the battery is connected to the cable means with predetermined polarity or is disconnected from the cable means.

7. A charger, as claimed in claim 6, wherein the protection means comprises a gated power supply.

8. A charger, as claimed in claim 2, and further comprising boost means for operating the current control means in the initial mode so that the initial level of charging current is unregulated.

9. A charger, as claimed in claim 1, and further comprising compensator means for varying the ratio of the first and second levels of charging current, so that the charging of batteries of different voltage ratings and capacities can be optimized.

10. A charger, as claimed in claim 2 and further comprising timing means for continuing the operation of the current control means in the initial mode for a predetermined time period irrespective of battery voltage, whereby a battery can be checked for a sulphated condition.

11. A charger, as claimed in claim 10, wherein the timing means comprises means for inhibiting the sequencing means.

12. A charger, as claimed in claim 10, wherein the predetermined time period is less than four minutes.

13. A charger, as claimed in claim 10, wherein the timing means activates an indicator means for indicating the operation of the timing means.

14. A charger, as claimed in claim 2, wherein the current control means comprises:

a source of fluctuating dc current, occurring in cycles;

an electronic switch including a control gate capable of enabling the conduction of current during an adjustable portion of said cycles in response to firing pulses;

gating means for supplying firing pulses from current supplied by the battery in response to phasing pulses;

pulse generator means for supplying phasing pulses to the gating means;

current comparator means for altering the phase of the phasing pulses relative to the dc fluctuating current depending on the amount of charging current, whereby the charging current is regulated.

15. A charger, as claimed in claim 14, wherein the electronic switch is a controlled rectifier.

16. A charger, as claimed in claim 14, and further comprising starting means for furnishing current to the pulse generator means from the source in the event that the battery is incapable of supplying sufficient current.

17. A charger, as claimed in claim 16, wherein the starting means further comprises timing means for continuing the operation of the current control means in the initial mode for a predetermined time period irrespective of battery voltage, whereby initial fluctuations in battery voltage do not inhibit continued charging.

18. A charger, as claimed in claims 1 or 14, wherein the voltage monitor means comprises a first voltage comparator including a first input, a second input and an output for generating the monitor signals.

19. A charger, as claimed in claim 18, wherein the current control means comprises:

a second voltage comparator including a first input, a second input, and an output for enabling the control of the charging current level.

20. A charger, as claimed in claim 19, wherein the sequencing means comprises a ring counter including an input responsive to the monitor signals and counter output means for establishing a plurality of voltages dependent on the state of the ring counter, wherein the second inputs of the first and second voltage comparators are responsive to the counter output means, wherein the first input of the first voltage regulator is responsive to the battery voltage and wherein the first input of the second voltage comparator is responsive to a voltage proportional to the battery charging current.

21. A charger, as claimed in claims 1 or 2 wherein the battery voltage conditions are battery voltage amplitudes.

28. A charger, as claimed in claim 5, wherein the battery voltage conditions are battery voltage amplitude.

22. A method of automatically charging a storage battery of the type in which a voltage condition of the battery increases as the charge increases, said method comprising the steps of:

a. regulating the charging of the battery at a first predetermined level of charging current so that the battery voltage condition increases;

b. automatically decreasing the regulated charging current supplied to the battery to a second predetermined level less than the first predetermined level in response to the increase of the battery voltage condition to a first predetermined value, whereby the battery voltage condition is decreased;

c. continuing the charging of the battery at the second predetermined level of regulated charging current, so that the battery voltage condition increases; and

d. automatically decreasing the regulated charging current supplied to the battery to a third predetermined level less than the second predetermined level in response to the increase of the battery voltage condition to a second predetermined value less than the first predetermined value, whereby the battery is rapidly and safely charged.

23. A method, as claimed in claim 22, wherein the third predetermined level is substantially zero.

24. A method as claimed in claim 22, wherein the third predetermined level enables the trickle charging of said battery.

25. A method as claimed in claim 22, and further comprising the steps of:

initially charging the battery at an initial level of charging current greater than the first predetermined level;

automatically decreasing the charging current supplied to the battery to the first predetermined level in response to an increase in the battery voltage condition to an initial value greater than the first predetermined value, whereby the battery voltage condition is decreased; and

continuing the charging of the battery at the first predetermined level.

26. A method as claimed in claim 22, wherein the step of automatically decreasing the charging current is inhibited for a predetermined time interval, so that the battery can be checked for a sulphated condition.

27. A method, as claimed in claims 22, 23, 24 or 25 wherein the battery voltage conditions are battery voltage amplitude.