Method and apparatus for charging a battery in high amp and automatic charging modes

• US 5,168,205 A
• Filed: 04/04/1990
• Issued: 12/01/1992
• Est. Priority Date: 04/04/1990
• Status: Expired due to Term

• Current Assignee: Clore Automotive, LLC (C3 Holdings LLC)
• Original Assignee: Hein-Werner Corporation
• Inventors: Kan, John F., Kan, John T. C., Habermann, Joseph P.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Dougherty, Thomas M.
• Application Number:
  US07/508,345
• Time in Patent Office: 972 Days
• Field of Search: 320/22-24, 320/31, 320/37, 320/38, 320/39, 320/40
• US Class Current: 320/160
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

A battery charger adapted to be electrically connected to the terminals of a battery for providing a charge to the battery, the battery charger comprising a device for supplying charging current to the battery, the current supplying device being operable to alternatively and selectively supply current at a first and second rate, the first rate providing for high rate charging of the battery, circuitry for sensing the voltage of the battery while the charger is connected to the battery, the sensing circuitry being adapted to be coupled to the battery, circuitry for alternatively selecting the first rate and the second rate, the selecting circuitry being coupled to the supplying circuitry and to the severing circuitry, circuitry for severing the supply of charging current to the battery when the second rate is selected, and when the sensing circuitry senses battery voltage in excess of a first predetermined threshold voltage, and for resuming the supply of current to the battery at the second rate when the sensing circuitry senses battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing circuitry being coupled to the current supplying device and to the sensing circuitry.

Claims

1. A battery charger adapted to be electrically connected to the terminals of a battery for providing a charge to the battery, the battery charger comprising:

means for supplying charging current to the battery, the current supplying means being operable to alternatively and selectively supply current at a first and second rate, the first rate providing for high rate charging of the battery;

means for sensing the voltage of the battery while the charger is connected to the battery, the sensing means being adapted to be coupled to the battery;

means for alternatively selecting the first rate and the second rate, the selecting means being coupled to the supplying means;

means for severing the supply of charging current to the battery when the second rate is selected and when the sensing means senses battery voltage in excess of a first predetermined threshold voltage, and for resuming the supply of current to the battery at the second rate when the sensing means senses battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing means being coupled to the current supplying means, to the sensing means, and to the selecting means;

means for adjusting the first predetermined threshold voltage, and adjusting means comprising a continuously variable selector; and

means for adjusting the second predetermined threshold voltage.

2. A battery charger as set forth in claim 1 wherein the second current rate is at least 14 amps.

3. A battery charger as set forth in claim 1 wherein the first current rate is at least 30 amps.

4. A battery charger as set forth in claim 1 wherein the first current rate is approximately 40 amps.

5. A battery charger as set forth in claim 1 wherein the means for adjusting the second predetermined threshold voltage comprises a continuously variable selector.

6. A battery charger as set forth in claim 1 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is less than 13.6 volts.

7. A battery charger as set forth in claim 1 wherein the first predetermined threshold voltage is approximately 14.4 volts and the second predetermined threshold voltage is approximately 12.8 volts.

8. A battery charger as set forth in claim 1, further adapted to be connected to a source of household alternating current and further including first, second, and third discrete visual indicators, means for illuminating the first indicator in response to the battery charger being connected to the source of alternating current, means for illuminating the second indicator while the current supplying means supplies charging current to the battery at the second current rate, and means for illuminating the third indicator in response to the severing means severing the supply of charging current to the battery while the second charging rate has been selected.

9. A battery charger adapted to be electrically connected to the terminals of a battery for providing a charge to the battery, the battery charger comprising:

means for supplying charging current to the battery, the current supplying means being operable to alternatively and selectively supply current at a first and second rate, the first rate providing for high rate charging of the battery;

means for sensing the voltage of the battery while the charger is connected to the battery, the sensing means being adapted to be coupled to the battery;

means for alternatively selecting the first rate and the second rate, the selecting means including mechanically operable switch means including means for selecting the first current rate and the second current rate, and the selecting means being coupled to the supplying means;

means for severing the supply of charging current of the battery when the second rate is selected and when the sensing means senses battery voltage in excess of a first predetermined threshold voltage, and for resuming the supply of current to the battery at the second rate when the sensing means senses battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing means being coupled to the current supplying means, to the sensing means, and to the selecting means.

10. A battery charger adapted to be electrically connected to the terminals of a battery for providing a charge to the battery, the battery charger comprising:

means for supplying charging current to the battery, the current supplying means being operable to alternatively and selectively supply current at a first and second rate, the first rate providing for high rate charging of the battery, the current supplying means including a transformer having a primary winding adapted to be electrically connected to household alternating current, and a secondary winding adapted to be electrically connected to the battery;

means for sensing the voltage of the battery while the charger is connected to the battery, the sensing means being adapted to be coupled to the battery;

means for alternatively selecting the first rate and the second rate, the selecting means being coupled to the supplying means;

means for severing the supply of charging current of the battery when the second rate is selected and when the sensing means senses battery voltage in excess of a first predetermined threshold voltage, and for resuming the supply of current to the battery at the second rate when the sensing means senses battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing means being coupled to the current supplying means, to the sensing means, and to the selecting means, the severing means including relay contacts operative to open to sever current flow through the primary winding of the transformer to sever the supply of charging current to the battery when the sensing means senses battery voltage in excess of the upper predetermined threshold voltage.

11. A battery charger adapted to be electrically connected to the terminals of a battery for providing a charge to the battery, the battery charger comprising:

means for supplying a charging current to the battery, the current supplying means being operable to alternatively and selectively supply current at a first and second rate, the first current rate being at least 30 amps and providing for high rate charging of the battery;

means for sensing the voltage of the battery when the charger is connected to the battery, the sensing means being adapted to be coupled to the battery;

timer means for selecting the first rate for a selected period of time, and for selecting the second rate after the selected period of time expires, the timer means being coupled to the supplying means; and

means for severing the supply of charging current to the battery when the second rate is selected and when the sensing means senses battery voltage in excess of a first predetermined threshold voltage, and for resuming the supply of charging current to the battery at the second rate when the sensing means senses battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing means being coupled to the current supplying means, to the sensing means, and to the timer means.

12. A battery charger as set forth in claim 13 wherein the second current rate is at least 14 amps.

13. A battery charger as set forth in claim 11 wherein the first current rate is at least 30 amps.

14. A battery charger as set forth in claim 11 wherein the first current rate is approximately 40 amps.

15. A battery charger as set forth in claim 11 and further comprising means for adjusting the first predetermined threshold voltage, the adjusting means comprising a continuously variable selector.

16. A battery charger as set forth in claim 11 and further comprising means for adjusting the second predetermined threshold voltage.

17. A battery charger as set forth in claim 16 wherein the means for adjusting the second predetermined threshold voltage comprises a continuously variable selector.

18. A battery charger as set forth in claim 11 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is less than 13.6 volts.

19. A battery charger as set forth in claim 11 wherein the first predetermined threshold voltage is approximately 14.4 volts and the second predetermined threshold voltage is approximately 12.8 volts.

20. A battery charger as set forth in claim 11, further adapted to be connected to a source of household alternating current, and further including first, second, and third discrete visual indicators, means for illuminating the first indicator in response to the battery charger being connected to the source of alternating current, means for illuminating the second indicator while the supplying means supplies charging current to the battery at the second current rate, and means for illuminating the third indicator in response to the severing means severing the supply of charging current to the battery while the second charging rate has been selected.

21. A battery charger as set forth in claim 11 wherein the current supplying means comprises a transformer having a primary winding adapted to be electrically connected to household alternating current, and a secondary winding adapted to be electrically connected to the battery, wherein the severing means includes relay contacts operative to open to sever current flow through the primary winding of the transformer to sever the supply of charging current to the battery when the sensing means senses battery voltage in excess of the upper predetermined threshold voltage.

22. A battery charger comprising:

means for sensing the voltage of a battery when a battery is electrically connected to the charger;

means for supplying at least 14 amps of charging current to the battery;

means for severing the supply of charging current to the battery when the sensing means senses battery voltage in excess of a first predetermined threshold voltage and for resuming the supply of at least 14 amps of charging current to the battery when the sensing means sense battery voltage below a second predetermined threshold voltage lower than the first predetermined threshold voltage, the severing means being coupled to the current supplying means and to the sensing means.

23. A battery charger as set forth in claim 22, said sensing means further comprising means for adjusting the first threshold voltage, the adjusting means comprising a continuously variable selector.

24. A battery charger as set forth in claim 22, said sensing means further comprising means for adjusting the second predetermined threshold voltage.

25. A battery charger as set forth in claim 24 wherein the means for adjusting the second predetermined threshold voltage comprises a continuously variable selector.

26. A battery charger as set forth in claim 22 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is lower than 13.6 volts.

27. A battery charger as set forth in claim 22 wherein the first predetermined threshold voltage is approximately 14.4 volts and the lower predetermined threshold voltage is approximately 12.8 volts.

28. A battery charger as set forth in claim 22 further adapted to be connected to a source of household alternating current and further including first, second and third discrete visual indicators, means for illuminating the first indicator in response to the battery charger being connected to the source of alternating current, means for illuminating the second indicator while the supplying means supplies charging current to the battery, and means for illuminating the third indicator in response to the severing means severing the supply of charging current to the battery while the second charging rate has been selected.

29. A battery charger as set forth in claim 22 wherein the current supplying means comprises a transformer having a primary winding adapted to be electrically connected to household alternating current, and a secondary winding adapted to be electrically connected to the battery, wherein the severing means includes relay contacts operative to open to sever current flow through the primary winding of the transformer to sever the supply of charging current to the battery when the sensing means senses battery voltage in excess of the first predetermined threshold voltage.

30. A method of charging a battery comprising the steps of:

providing means for supplying charging current to the battery, the current supplying means being operable to alteratively supply current at a first rate and at a second rate;

selecting one of the first rate and the second rate;

electronically severing the supply of charging current to the battery when the second rate is selected and when the battery voltage exceeds a first predetermined threshold voltage;

electronically resuming the supply of current to the battery at the second rate when the battery voltage falls below a second predetermined threshold voltage lower than the first predetermined threshold voltage; and

adjusting the second predetermined threshold voltage after said providing step.

31. A method in accordance with claim 30 wherein the second current rate is at least 14 amps.

32. A method in accordance with claim 30 wherein the first current rate is at least 30 amps.

33. A method in accordance with claim 30 and further including the step of adjusting the first predetermined threshold voltage.

34. A method in accordance with claim 30 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is less than 13.6 volts.

35. A method in accordance with claim 30 wherein the first predetermined threshold voltage is approximately 14.4 volts and the second predetermined threshold voltage is approximately 12.8 volts.

36. A method in accordance with claim 30 and further including the steps of illuminating a visual indicator when current is supplied at the second rate, and illuminating a visual indicator when the supply of charging current has been severed while the second current rate has been selected.

37. A method of charging a battery comprising the steps of:

providing means for supplying charging current to the battery, the current supplying means being operable to selectively supply current at a first rate of at least 30 amps and at a second rate;

selecting the first rate for a selected period of time and thereafter selecting the second rate;

electronically severing the supply of charging current to the battery when the second rate is selected and when the battery voltage exceeds a first predetermined threshold voltage; and

electronically resuming the supply of current to the battery at the second rate when the battery voltage falls below a second predetermined threshold voltage lower than the first predetermined threshold voltage.

38. A method in accordance with claim 37 wherein the second current rate is at least 14 amps.

39. A method in accordance with claim 37 wherein the first current rate is at least 30 amps.

40. A method in accordance with claim 37 and further including the step of adjusting the first predetermined threshold voltage.

41. A method in accordance with claim 37 and further including the step of adjusting the second predetermined threshold voltage.

42. A method in accordance with claim 37 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is less than 13.6 volts.

43. A method in accordance with claim 37 wherein the first predetermined threshold voltage is approximately 14.4 volts and the second predetermined threshold voltage is approximately 12.8 volts.

44. A method in accordance with claim 37 and further including the steps of illuminating a visual indicator when current is supplied at the second rate, and illuminating a visual indicator when the supply of charging current has been severed while the second current rate has been selected.

45. A method of charging a battery comprising the steps of:

providing means for supplying at least 14 amps of charging current to the battery;

electronically severing the supply of charging current to the battery when the battery voltage exceeds a first predetermined threshold voltage; and

electronically resuming the supply of current to the battery when the battery voltage falls below a second predetermined threshold voltage lower than the first predetermined threshold voltage.

46. A method in accordance with claim 45 further including the step of adjusting the first predetermined threshold voltage.

47. A method in accordance with claim 45 and further including the step of adjusting the second predetermined threshold voltage.

48. A method in accordance with claim 45 wherein the first predetermined threshold voltage is greater than 13.6 volts and the second predetermined threshold voltage is less than 13.6 volts.

49. A method in accordance with claim 45 wherein the first predetermined threshold voltage is approximately 14.4 volts and the second predetermined threshold voltage is approximately 12.8 volts.

50. A method in accordance with claim 45 and further including the steps of illuminating a visual indicator when the supply of charging current at the second rate is severed.