Electronic battery charger device and method

• US 5,055,763 A
• Filed: 09/26/1988
• Issued: 10/08/1991
• Est. Priority Date: 09/26/1988
• Status: Expired due to Term

• Current Assignee: Congress Financial Corporation (Wells Fargo & Company)
• Original Assignee: Eveready Battery Company Incorporated (Energizer Holdings, Inc.)
• Inventors: Doan, Chi-Thien, Smilanich, Nicholas J., Johnson, William A., Budzyna, W. James
• Primary Examiner(s): HICKEY, ROBERT
• Application Number:
  US07/248,962
• Time in Patent Office: 1,107 Days
• Field of Search: 320/15, 320/21, 320/31, 320/37, 320/38, 320/39
• US Class Current: 320/125
• CPC Class Codes: H02J 7/00038 using passive battery identification means, e.g. resistors or capacitors identification by mechanical connections H02J7/0045
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/007192 in response to temperature

Abstract

A battery charger device and method including a charging circuit having a source of charging energy and connections for installing one or more batteries to be charged, the device having a controllable switch associated with each battery to be charged and a microprocessor for controlling the switches to establish a charging sequence of distinct repeated charging periods for each battery, a display device associated with each battery under control of a microprocessor for individually indicating the charging status of each battery, the microprocessor having inputs at which various parameters with respect to the batteries being charged are applied such as battery voltages, ambient temperatures and charging currents, the microprocessor being programmed to terminate a voltage charging operation with respect to any one or more of the batteries if the measured difference between the charging and non charging voltage of any one or more of the batteries during succeeding charging periods exceeds some predetermined value, or if the charging current, or the ambient temperature of the battery being charged is outside of a predetermined range. The present device and method may also include a back up termination means which responds to measurements of the battery voltage during succeeding charging periods and determines therefrom that on a predetermined number of succeeding cycles the condition of the battery voltage has changed by at least some predetermined amount.

Claims

1. A device for charging one or more batteries comprising a circuit having terminal means for connecting to the terminal means on one or more batteries to be charged, said circuit including a source of electric energy, controllable switching means connected respectively between the energy source and each battery to be charged, a microprocessor having a control connection to each of the controllable switching means for controlling communication between the energy source and the respective batteries to be charged, said microprocessor including means to sequentially control the switch means to supply charging current to the batteries one at a time in repeating periods, means responsive to the voltage across the terminals of each battery prior to and during each charging period thereof operatively connected to the microprocessor, said microprocessor being programmed to calculate the difference between the battery terminal voltage of each battery prior to and when it is being charged, means to store for each battery the minimum value of said voltage difference during each charging period, and means to terminate a charging operation for a battery when the battery terminal voltage difference being calculated exceeds the minimum stored value of the battery terminal voltage difference by a predetermined amount.

2. The device of claim 1 including means to compare the value of the terminal voltage of each battery during succeeding charging intervals, and means to terminate a charging operation for a battery when the terminal voltage of a battery decreases during a predetermined number of succeeding charging periods.

3. The device of claim 1 wherein the microprocessor includes timer means for controlling the switching means to individually apply battery charging energy from the energy source respectively to each of the batteries to be charged in a repeatable sequence of charging and non charging periods.

4. The device of claim 1 including first and second sources of charging current one of which is substantially greater than the other, the microprocessor including means for selecting between the first and second sources of charging currents for applying to the respective batteries to be charged depending on at least one parameter of each battery.

5. The device of claim 1 wherein the source of electric energy includes means for producing a fast charge rate, a fast trickle charge rate and a slow maintenance trickle charge rate, the microprocessor including means to select between these rates for applying charging current to the respective batteries.

6. The device of claim 1 wherein the microprocessor includes means responsive to battery terminal voltage to terminate the application of a charging current to a battery if the terminal voltage of the battery during a charging operation exceeds some predetermined voltage.

7. The device of claim 1 wherein the microprocessor includes means to prevent the application of charging current to selected batteries if the terminal voltage of said selected batteries is equal to or less than a predetermined voltage.

8. The device of claim 1 wherein the microprocessor includes means to prevent the application of charging current to a battery if the voltage of said battery exceeds a predetermined voltage.

9. The device of claim 4 wherein the microprocessor includes means for selecting between the first and second battery charging currents for each battery to be charged depending on the magnitude of the battery terminal voltage.

10. The device of claim 1 wherein the microprocessor includes means for reducing the charging current applied to a selected battery when the battery terminal voltage of said selected battery is within a predetermined voltage range.

11. The device of claim 1 including indicator means associated with each battery being charged to indicate the status thereof, each of said indicator means being connected to the microprocessor and energizable thereby to indicate the charging status of the associate battery.

12. The device of claim 11 wherein the indicator means include a light producing device associated with each battery to be charged.

13. The device of claim 11 wherein the microprocessor includes means to energize each indicator means to indicate that the associated battery is being fast charged, trickle charged, fully charged or is not being charged.

14. The device of claim 1 wherein the switching means associated with each battery includes a Darlington circuit.

15. The device of claim 1 wherein the switching means associated with each battery includes a silicon controlled rectifier.

16. The device of claim 1 wherein the switching means associated with each battery includes a mosfet.

17. The device of claim 1 wherein the switching means associated with each battery includes a gate turn-off SCR (GTO).

18. The device of claim 1 wherein the switching means associated with each battery includes a relay.

19. The device of claim 1 wherein the switching means associated with each battery includes a bipolar power transistor.

20. A battery charger device comprising

a circuit having terminal means for connecting to terminals of batteries to be charged, said circuit including a source of charging energy and separate switch means for connecting said energy source to each battery to be charged,

means including microprocessor means connected to said switch means to control electrical communication between the energy source and the respective batteries,

means in the microprocessor for producing a sequence of distinct charging intervals for the batteries when the respective switch means are closed and the associated batteries are charging separated by non charging intervals when the switch means are open,

means for reading the battery terminal voltage of each battery prior to and during each of its charging intervals,

means for computing the difference between the battery terminal voltage prior to and during each succeeding charging interval for each battery to be charged,

means for storing a value representing the minimum value of the difference between the terminal voltage prior to and during each charging interval, including means for comparing the stored minimum value of the voltage difference with each computed value thereof for each battery during each battery charging operation and replacing the stored minimum value with each subsequent computed value that is less than the stored minimum value, and

means to terminate a battery charging operation for a battery when the ratio of the computed voltage difference to the stored minimum value of the difference exceeds some predetermined amount.

21. The battery charger of claim 20 wherein the circuit terminal means include means for connecting a plurality of batteries to be charged, switch means associated with each battery to be charged, the microprocessor means including means to establish a time ordered sequence of charging and non charging intervals such that the charging intervals for each battery of said plurality occur at distinctly different times so that only one battery at a time receives a charge.

22. The battery charger of claim 20 including means responsive to the ambient temperature of each battery to be charged, and means to terminate a charging operation if the ambient temperature equals or is less than a predetermined temperature.

23. The battery charger of claim 20 including means responsive to the ambient temperature of each battery to be charged, and means to terminate a charging operation if the ambient temperature equals or is greater than a predetermined temperature.

24. The battery charger of claim 20 including means to terminate a battery charging operation for a battery if the battery terminal voltage equals or exceeds a predetermined voltage.

25. The battery charger of claim 20 including means to terminate a battery charging operation for a battery if the battery terminal voltage equals or is less than a predetermined voltage.

26. The battery charger of claim 20 including means responsive to battery charging current for each battery during a battery charging interval, and means to terminate a charging operation if the battery charging current equals or exceeds a predetermined charging current.

27. The battery charger of claim 20 including means to establish a battery trickle current charge rate, means responsive to battery charging current during a battery charging interval, and means to apply the trickle current charge rate to a battery if the battery charging current equals or is less than a predetermined charging current.

28. The battery charger of claim 20 wherein the battery is a nickel cadium battery.

29. The battery charger of claim 20 wherein the microprocessor includes means for establishing a charging period of predetermined duration during which it is expected that all of the batteries connected thereto will be fully charged.

30. The battery charger of claim 20 including means to establish at least two different second battery charging rates, one of said rates being substantially greater than another of said charging rates, and means to select between the charging rates depending on a predetermined parameter of a battery to be charged.

31. A battery charger device having means for charging a plurality of the same or of different type batteries such that all batteries of the same type are charged at substantially the same fast charging rate during predetermined equal length repeating time periods comprising

a circuit having a plurality of connection means for connecting to the terminals of batteries to be charged,

a source of charging energy,

separate switch means connected between the energy source and each battery and operable between an open non charging condition and a closed charging condition permitting substantially the same fast charging current from the energy source to pass through the associated battery during each equal length repeating charging period thereof,

microprocessor means including means for controlling the condition of the switch means, means to establish predetermined equal length repeating charging periods for each battery, means to establish a charging sequence whereby each of said plurality of batteries in order has distinctive spaced equal length time subperiods when it is being charged followed by a non charge interval,

separate means associated with each battery responsive to battery terminal voltage, battery current, and battery ambient temperature connected to the microprocessor, and

means in the microprocessor for terminating a battery charging operation with respect to any one or more of the plurality of batteries if any one or more of the following occur, the battery voltage of the battery whose charge is to be terminated equals or exceeds for that battery a first predetermined voltage, equals or is less than a second predetermined voltage, if the battery charging current for that battery equals or exceeds a predetermined current, or if the ambient temperature of the battery equals or exceeds a first predetermined temperature or equals or is less than a second predetermined temperature.

32. The battery charger of claim 31 wherein the microprocessor includes means for establishing first and second battery charging rates, the first charging rate substantially exceeding the second charging rate.

33. The battery charger of claim 31 including means to compare the battery terminal voltage during succeeding charging subperiods for each battery, and means to terminate a charging operation with respect to a battery when the battery voltage decreases during a predetermined number of succeeding charging subperiods.

34. The battery charger of claim 31 including a display device associated with each battery to be charged, said microprocessor including means to energize each of said display devices to indicate the charging status of the associated battery.

35. Apparatus for fast charging a battery comprising a circuit having a power supply including a portion for supplying charging current to a battery being charged, said power supply portion including means to select between supplying a fast charge current or a trickle charge current to the battery, controllable switch means connected between the power supply portion and the battery, control circuit means operatively connected to the switch means to close and open the switch means to establish a charging and a non charging condition, program means for establishing a series of time spaced charging and non charging conditions, means to establish a predetermined overall time period for charging the battery when applying a fast charge current, means to read the battery terminal voltage for each battery prior to and during each fast charging condition, means to calculate the absolute value of the difference between these battery terminal voltages for each charging condition, means during each overall time period for storing the minimum value of the calculated difference including means to replace a previously stored value with each newly read and calculated value that is less than the previously stored minimum value, means to compute the ratio of each newly calculated value of the voltage difference to the minimum stored value thereof including means to terminate a fast charge condition when the ratio is greater than some predetermined value.

36. The apparatus of claim 35 including means to change from producing fast charge conditions to producing slow trickle charge conditions when the fast charge condition is terminated.

37. The apparatus of claim 35 wherein the overall time period established is about 60 minutes.

38. The apparatus of claim 35 wherein the battery is a nickel cadium battery.

39. The apparatus of claim 35 wherein batteries capable of being fast charged have a recognizable marking, means to read said markings, and means to select between a fast charge, a trickle charge or no charge based on-the reading of said markings.

40. The apparatus of claim 35 wherein batteries capable of being fast charged have a recognizable dimensional characteristic, means to sense said characteristic, and means to select between a fast charge and a no charge based on a sensing of this characteristic.

41. The apparatus of claim 35 including a back up fast charge condition termination means including means to compare the battery terminal voltage during succeeding charging conditions, and means to terminate a fast charge condition when the battery terminal voltage of a battery decreases during a predetermined number of succeeding charging periods.

42. The apparatus of claim 35 including means to prevent a charging operation if the battery terminal voltage during a non charging condition exceeds some predetermined voltage for the type of battery being charged.

43. The apparatus of claim 35 including means to terminate a charging operation when the overall time period has expired.

44. The apparatus of claim 35 including means to read ambient battery temperature, said means including means to terminate a charging condition if the ambient temperature exceeds some predetermined temperature.

45. The apparatus of claim 35 including means for fast charging a plurality of batteries of differing type and charge condition, said circuit means including means for establishing distinct periods for the charging conditions reserved for each battery of said plurality.

46. The apparatus of claim 45 wherein the means for establishing distinct periods includes means for establishing the charging and non charging periods for each battery.

47. A method of rapidly and efficiently charging one or more than one batteries of a type in which the voltage characteristics thereof varies with the state of charge of the battery comprising the steps of:

connecting one or more batteries to be charged to a battery charger that includes means for supplying electrical energy for charging the batteries,

establishing a time sequence for supplying energy to each of the batteries one at a time in time-spaced intervals so that each battery undergoes periodic charging and non charging intervals,

reading the voltage across each battery being charged prior to and during each charging interval thereof,

computing the difference between the battery voltage read prior to and during each succeeding charging interval for each battery,

storing the value of the said calculated voltage difference between the battery voltage prior to and the battery voltage during each succeeding charging interval including updating the stored difference voltage when the calculated difference voltage is less than the value previously stored, and

terminating a battery charging operation for a battery when the ratio of the present value of the computed voltage difference therefor to the stored minimum value of the voltage difference for said battery exceeds a predetermined ratio.

48. The method of claim 47 including the further step of comparing the terminal voltage of each battery during a portion of each succeeding charging cycle thereof and terminating a battery charging operation for a battery when terminal voltage of a battery decreases during a predetermined number of succeeding charging intervals.

49. The method of claim 48 wherein the terminal voltage being compared is the open circuit battery voltage.

50. A battery charger device having means for charging a plurality of batteries over a predetermined time period comprising

a circuit having a plurality of connection means for connecting to the terminals of batteries to be charged,

a source of charging energy,

a separate switch means connected between the energy source and each battery and operable between an open non charging condition and a closed charging condition permitting charging current from the energy source to pass through the associated battery,

microprocessor means including means for controlling the condition of the switch means, means to establish a predetermined charging period, means to establish a charging sequence whereby each of said plurality of batteries in order has distinctive spaced timed subperiods when it is being charged followed by a non charge interval,

separate means associated with each battery responsive to battery terminal voltage, battery current, and battery ambient temperature connected to the microprocessor,

means in the microprocessor for terminating a battery charging operation with respect to any one or more of the plurality of batteries if any one or more of the following occur, the battery voltage of the battery whose charge is to be terminated equals or exceeds a first predetermined voltage, equals or is less than a second predetermined voltage, if the battery charging current equals or exceeds a predetermined current, or if the ambient temperature of the battery equals or exceeds a first predetermined temperature or equals or is less than a second predetermined temperature, and

means in the microprocessor for computing the difference between the battery terminal voltage for each battery prior to and during each charging subperiod, means to store the computed voltage difference for each battery including means to replace the stored difference for each battery by a succeeding difference that is less than the previously stored difference, and means to terminate a charging operation with respect to a battery when the ratio of the computed voltage difference value to the stored minimum difference exceeds some predetermined amount.