Charging voltage control circuit for battery chargers

• US 5,254,932 A
• Filed: 12/24/1990
• Issued: 10/19/1993
• Est. Priority Date: 12/24/1990
• Status: Expired due to Term

• Current Assignee: Power-One Incorporated (ABB Limited)
• Original Assignee: Magnetek Incorporated (Columbus Mckinnon Corporation)
• Inventors: Bittar, Hussein I., Karlin, Richard A.
• Primary Examiner(s): Peckman, Kristine L.
• Application Number:
  US07/634,093
• Time in Patent Office: 1,030 Days
• Field of Search: 320/17, 320/18, 320/20, 320/21, 320/22, 320/23, 320/24, 320/39, 320/40, 320/31, 320/32
• US Class Current: 320/145
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

Charging voltage and current control circuits for battery chargers provide for a constant output voltage above a first predetermined value of charging current and an increasing output voltage below the first predetermined value of charging current. The charger makes use of a pulse-width modulated control circuit utilizing a variable duty cycle proportional to charging current and couples a signal proportional to charging current via a diode-resistor network to the pulse-width modulator for values below the first predetermined value of charging current. A current limit control circuit provides a current limit function by driving the pulse-width modulator to a minimum duty cycle during overcurrent conditions.

Claims

1. An improved method of operating a lead-acid-battery charger of the pulse-width modulated type having a duty cycle varying in response to charging current to maintain a desired charging voltage comprising the steps of:

a) holding the charging voltage at a constant voltage when the charging current is above a predetermined value; and

b) increasing the charging voltage when the charging current is in a range below the predetermined value by sensing the duty cycle and adjusting the charging voltage in response to changes in the duty cycle.

2. The method of claim 1 wherein the charging voltage increases linearly as the charging current decreases below the predetermined value.

3. The method of claim 2 wherein the charging voltage is held constant when the charging current is below the range of the charging current in which the charging voltage is increased.

4. The method of claim 1 wherein the predetermined value of the charging current is 3 amperes.

5. The method of claim 4 wherein the range is between 3 and 1 ampere.

6. The method of claim 1 wherein the charging voltage is held at 13.6 volts when the charging current is above the predetermined value.

7. The method of claim 6 wherein the charging voltage remains substantially constant at 14.2 volts when the charging current is below the range of the charging current in which the charging voltage is increased.

8. An improved charging voltage trim circuit for use in a variable duty cycle pulse-width modulated battery charger of the type having a charging current proportional to the duty cycle, the trim circuit comprising:

a) a resistor-capacitor averaging network connected to time-average the duty cycle to provide a voltage proportional to the charging current; and

b) means for coupling the averaging network voltage to an error detection and correction means for controlling a charging voltage output of the battery charger while the charging current is below a predetermined value such that the charging voltage increases as the charging current decreases in a range below the predetermined value of the charging current.

9. The improved charging voltage trim circuit of claim 8 further comprising:

c) override biasing means for overriding the averaging network voltage when the charging current is above the predetermined value such that the charging voltage is held constant for values of the charging current above the predetermined value.

10. An output charging voltage trim circuit for use in a variable duty cycle battery charger of the type providing an output charging voltage delivered by a pulse-width modulated inverter driving a DC converter to provide an output charging current proportional to the duty cycle, the trim circuit comprising:

a) a first capacitor connected to an input of the DC converter to provide AC coupling of the inverter output;

b) a first resistor connected in series with the first capacitor to receive the AC coupled inverter output;

c) a second capacitor connected in series with the first resistor and operable with the first resistor to form a duty cycle integrator;

d) a second resistor connected in parallel with the second capacitor to continuously discharge the second capacitor is proportional to the duty cycle of the pulse-width modulated inverter; and

e) coupling means for coupling the voltage across the second capacitor to a pulse modulation input when the output charging current is below a predetermined value such that the output charging voltage increases in proportion to decreases in the output charging current below the predetermined value.

11. The output charging voltage trim circuit of claim 10 wherein the coupling means further comprises a diode-resistor network biased to block the voltage across the second capacitor when the output charging current is at or above the predetermined value to maintain the output charging voltage substantially constant.