Method and apparatus for varying the sample rate of a fast battery charger

• US 5,268,630 A
• Filed: 05/04/1992
• Issued: 12/07/1993
• Est. Priority Date: 05/04/1992
• Status: Expired due to Term

• Current Assignee: BioControl Systems, Inc. (Merck & Co., Inc.), Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Walter, Richard T., Brotto, Daniele C., Bhagwat, Pradeep M.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Dougherty, Thomas M.
• Application Number:
  US07/878,103
• Time in Patent Office: 582 Days
• Field of Search: 320/20, 320/27, 320/30, 320/37, 320/39, 320/40
• US Class Current: 320/151
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient

Abstract

This invention discloses a method and apparatus for rapidly charging a battery by monitoring the voltage of the battery and changing the effective sampling rate of the battery voltage during the charging sequence. More particularly, a first disclosed embodiment of the battery charging system takes voltage readings of the battery as it is being charged at a predetermined rate and stores the voltage values in a first-in, first-out stack in the order in which they are taken. Therefore, a stack of consecutive data samples spaced in time is created. During an interval in the charging sequence where the rate of increase in battery voltage is relatively low, the charging system retrieves voltage values from the stack which are widely separated in time to calculate a slope of the charging profile to determine the status of the charging sequence. During a second interval of the charging sequence when the rate of increase in battery voltage is relatively high, the effective sampling rate is reduced by taking sample points from the stack which are closer together in time. In this manner, the effective sampling rate of the charging system is changed to improve the effective signal-to-noise ratio of the system during the first interval while maintaining an appropriately fast response time during the second interval. An alternative embodiment is disclosed which changes the rate at which the battery voltage is sampled from the first to the second interval in the charging sequence.

Claims

1. A method of charging a battery, said method comprising the steps of:

periodically sampling a measured voltage value of the battery during a charging sequence that includes a first predetermined interval characterized by a relatively low rate of increase in battery voltage and a second predetermined interval characterized by a relatively high rate of increase in battery voltage;

storing a predetermined number of consecutive voltage samples;

calculating an average voltage value from the stored voltage samples in order to determine the status of the charging sequence; and

changing the effective period over which said average voltage value is calculated as the charging sequence proceeds from said first predetermined interval to said second predetermined interval in the charging sequence.

2. The method according to claim 1 wherein the step of calculating said average voltage value includes the steps of selecting a plurality of stored voltage samples and calculating said average voltage value from said selected plurality of stored voltage samples.

3. The method according to claim 1 wherein the step of changing the effective period includes sampling and storing the battery voltage value at a first sample rate when the charging sequence is in said first predetermined interval, and sampling and storing the battery voltage value at a second shorter sampling rate when the charging sequence is in said second predetermined interval.

4. The method according to claim 1 wherein the step of changing the effective period includes sampling the battery voltage at a constant rate and calculating said average voltage value from selected stored voltage samples which were sampled over a first time period during the first predetermined interval and from selected stored voltage samples which were sampled over a second time period during the second predetermined interval, and further wherein said second time period is shorter than said first time period.

5. The method according to claim 1 wherein the step of storing a predetermined number of battery voltage samples includes the step of storing the battery voltage samples in a first-in, first-out computer stack, wherein the most recent voltage sample is pushed onto the stack and the oldest voltage sample is pushed off of the stack at each sample period.

6. The method of claim 1 wherein the resulting battery voltage versus time charging curve from the charging sequence defines an inflection point that comprises the boundary between said first and second predetermined intervals, and further wherein said calculating step includes calculating first and second average voltage values from first and second selected pluralities of stored voltage samples and calculating from said first and second average voltage values the slope of the battery voltage versus time charge curve to determine the status of the charging sequence.

7. An apparatus for charging a battery by applying a charging current to the battery and monitoring the battery voltage during a charging sequence that includes a first predetermined interval characterized by a relatively low rate of increase in battery voltage and a second predetermined interval characterized by a relatively high rate of increase in battery voltage said apparatus comprising:

sampling for periodically sampling measured voltage values of the battery;

a memory for storing a predetermined number of consecutive voltage samples; and

controller means connected to said sampling means and said memory for calculating an average voltage value from the stored voltage samples and determining from said average voltage value the status of the battery charging sequence;

said controller means further changing the effective period over which said average voltage value is calculated as the charging sequence proceeds from said first predetermined interval to said second predetermined interval in the charging sequence.

8. The apparatus according to claim 7 wherein a controller means selects a plurality of stored voltage samples and calculates said average voltage value from said selected plurality of stored voltage samples.

9. The apparatus according to claim 7 wherein said controller means causes said sampling means to sample the battery voltage value at a first sample rate when the charging sequence is in said first predetermined interval and at a second shorter sampling rate when the charging sequence is in said second predetermined interval.

10. The apparatus according to claim 7 wherein said sampling means samples the battery voltage at a constant rate and said controller means calculates said average voltage value from selected stored voltage samples which were sampled over a first time period during said first predetermined interval and from selected stored voltage samples which were sampled over a second time period during said second predetermined interval, and further wherein said second time period is shorter than said first time period.

11. The apparatus according to claim 7 wherein said memory stores a predetermined number of battery voltage samples in a first-in, first-out computer stack such that the most recent battery voltage sample is pushed onto the stack and the oldest battery voltage sample is pushed off of the stack at each sample period.

12. The apparatus of claim 7 wherein the resulting battery voltage versus time charging curve from the charging sequence defines an inflection point that comprises the boundary between said first and second predetermined intervals.

13. The apparatus of claim 12 wherein said controller means comprises a microprocessor that is programed for calculating first and second average voltage values from first and second selected pluralities of stored voltage samples, and for calculating the slope of the battery voltage versus time curve from said first and second average voltage values.

14. A method of controlling the charging of a rechargeable battery by monitoring the battery voltage during the charging sequence, the resulting battery voltage versus time charging curve from the charging sequence being characterized by a first region where the rate of increase in the battery voltage is relatively low and a second region wherein the rate of increase in the battery voltage is relatively high, said method comprising the steps of:

periodically sampling at a substantially constant rate of voltage of the battery during the charging sequence;

storing a predetermined number of consecutively sampled battery voltage values; and

determining the status of the charging sequence from said stored voltage samples using stored voltage samples which were sampled over a first time period during said first region and using stored voltage samples which were sampled over a second time period shorter than said first time period during said second region.

15. The method of claim 14 wherein said step of determining the status of the charging sequence includes calculating the slope of the battery voltage versus time charging curve.

16. The method of claim 15 wherein said step of calculating the slope includes the steps of calculating a first voltage value from the average of a first selected plurality of said stored battery voltage samples, calculating a second voltage value from the average of a second selected plurality of said stored battery voltage samples, and calculating the difference between said first and second voltage values.

17. The method of claim 16 wherein said first and second voltage values are calculated from stored battery voltage samples that are sampled over said first time period when the charging sequence is in said first region, and from stored battery voltage samples that are sampled over said second shorter time period when the charging sequence is in said second region.

18. The method of claim 17 wherein said first and second voltage values are calculated from the average of twice the number of consecutive stored battery voltage samples in said first region than used in said second region.

19. The method of claim 17 wherein the boundary between said first region and said second region is defined by an inflection point in the battery voltage versus time charging curve.