Method and apparatus for providing battery charging in a backup power system

• US 5,302,858 A
• Filed: 12/11/1991
• Issued: 04/12/1994
• Est. Priority Date: 12/11/1991
• Status: Expired due to Term

• Current Assignee: General Signal Power Systems, Inc. (Schneider Electric SE)
• Original Assignee: Best Power Technology, Inc. (SPX Corporation)
• Inventors: Folts, Douglas C.
• Primary Examiner(s): Gaffin, Jeffrey A.
• Assistant Examiner(s): FLEMING, FRITZ M
• Application Number:
  US07/805,496
• Time in Patent Office: 853 Days
• Field of Search: 307/48, 307/66, 307/100, 307/104, 307/106, 320/14, 320/21, 363/132, 363/126, 363/127
• US Class Current: 307/66
• 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
• CPC Class Codes: H02J 9/062 for AC powered loads
• CPC Class Codes: H02M 7/219 in a bridge configuration

Abstract

A battery in a back-up power system is charged during the time that power is available from the main AC power system by utilizing the main power transformer and the main inverter. When power is available from the main AC power source, an AC voltage appears across the primary of the transformer, which is connected to the inverter. Switches in the bridge inverter are turned on for a relatively brief period of time to short the primary of the transformer causing current through the leakage inductances of the transformer to rapidly build up. When the switching devices are turned off, the inductances induce a current to continue to flow from the primary into the inverter through anti-parallel diodes, normally back biased by the voltage from the battery, into the battery thereby charging the battery with the energy stored in the transformer inductances. The inverter current reaches zero when the energy stored in the inductance is fully discharged. The cycle may be repeated by turning on the switching devices in the inverter bridge at periodic points in time, allowing the current in the inverter to dwell periodically at zero, or by immediately turning on the switching devices again when the current into the inverter reaches zero.

Claims

1. A backup power system having battery charging capability comprising:

(a) input lines for receiving AC power input and output lines for providing AC power output to a load;

(b) a power transformer having its secondary connected across the output lines and a primary coupled to the secondary;

(c) a battery providing a DC output voltage;

(d) an inverter having an output connected to the primary of the power transformer and switching devices connected in a bridge configuration which are controllable to convert DC voltage power from the battery connected to an input of the inverter to AC voltage power at the primary of the power transformer, the switching devices being responsive to control signals to switch between one and off states;

(e) control means, connected to the switching devices in the inverter to control the same, for controlling the inverter during normal supply of AC power on the input lines to the output lines to provide a charging cycle to the battery, the charging cycle including a first energy build-up state in which switching devices in the inverter bridge conduct to provide a conduction path which shorts the primary of the transformer for a selected period of time to build up a current through the effective leakage inductances of the primary and secondary of the transformer, and a second energy discharge state in which a conduction path is provided from the primary through the switching devices of the bridge to the battery and back to the primary of the transformer, the total period of the charging cycle being short in comparison to the period of the AC input power waveform, wherein the current induced by the inductances of the transformer flows into the battery during the second state to discharge the energy stored in the inductances.

2. The system of claim 1 wherein the control means controls the switching devices of the inverter to repeat the first and second states continuously to charge up the battery.

3. The system of claim 1 wherein the control means controls the switching of the switching devices in the inverter so that the first state begins at regularly spaced periodic points in time and the second state terminates when the energy stored in the transformer inductances is completely discharged and the current flowing to the battery reaches zero, and wherein the current in the inverter remains at zero until the initiation of the next first state.

4. The system of claim 1 wherein the switching devices of the inverter are gate controlled switching devices which allow current flow therethrough with antiparallel diodes connected thereto, wherein there are four switching devices connected in an H-bridge configuration, and wherein the battery voltage is selected to be greater than the peak AC voltage applied across the output of the inverter by the primary of the transformer so that the antiparallel diodes of the switching devices are back-biased except when current is flowing from the transformer inductances to discharge the energy stored in the inductances.

5. The system of claim 4 wherein the gate controlled switching devices are power MOSFETs and the anti-parallel diodes are intrinsic anti-parallel diodes.

6. The system of claim 1 further including a static switch connected between the input and output lines which is responsive to a control signal to disconnect or reconnect power from the input lines to the output lines.

7. A backup power system having battery charging capability comprising:

(a) input lines for receiving AC power input and output lines for providing AC power output to a load;

(b) a power transformer having a secondary connected across the output lines and a primary coupled to the secondary;

(c) a battery providing a DC output voltage;

(d) an inverter having an output connected to the primary of the power transformer and having four gate controlled switching devices which allow current flow therethrough with anti-parallel diodes connected thereto which are connected in an H-bridge configuration, the switching devices controllable to convert DC voltage power from the battery connected to an input of the inverter to AC voltage power at the primary of the power transformer, the switching devices being responsive to control signals to switch between on and off states, wherein the battery voltage is selected to be greater than the peak AC voltage applied across the output of the inverter by the primary of the transformer so that the antiparallel diodes of the switching devices are normally back-biased by the voltage from the battery;

(e) control means, connected to the switching devices in the inverter to control the same, for controlling the inverter during normal supply of AC power on the input lines to the output lines to provide a charging cycle to the battery, the charging cycle including a first energy build-up state in which during the positive half cycle and the negative half cycle of the voltage waveform across the primary, at least one of the switching devices in the inverter bridge is turned on for a selected period of time to provide a conduction path which shorts the primary of the transformer through the switching device and through one of the anti-parallel diodes to build up a current through the effective leakage inductances of the primary and secondary of the transformer, and a second energy discharge state in which the switching device is turned off and a conduction path is provided from the primary through two of the anti-parallel diodes to the battery and back to the primary of the transformer, the total period of the charging cycle being short in comparison to the period of the AC input power waveform, wherein the current induced in the inductances of the transformer flows into the battery during the second state to discharge the energy stored in the inductances.

8. The system of claim 7 wherein the control means controls the switching devices of the inverter bridge to repeat the first and second state continuously to charge up the battery.

9. The system of claim 7 wherein the control means controls the switching of the switching devices in the inverter so that the first state begins at regularly spaced periodic points in time and the second state terminates when the energy stored in the transformer inductances is completely discharged and the current flowing to the battery reaches zero, and wherein the current in the inverter remains at zero until the initiation of the next first state.

10. The system of claim 7 wherein the gate control switching devices are power MOSFETs and the anti-parallel diodes are intrinsic anti-parallel diodes.

11. The system of claim 7 further including a static switch connected between the input and output lines which is responsive to a control signal to disconnect or reconnect power from the input lines to the output lines.

12. The system of claim 7 wherein during the first state the controls means turns on two of the switching devices to short out the primary of the transformer and turns off both switching devices during the second state.

13. A method of charging the battery in a power system of the type having power lines for receiving AC input power having a waveform with positive and negative half cycles, a power transformer having its secondary connected across the power lines and a primary coupled to the secondary, a battery providing a DC output voltage, and an inverter connected to the battery and having an output connected to the primary of the power transformer and switching devices connected in a bridge configuration with anti-parallel diodes associated with each of the switching devices which are normally back-biased off by the battery voltage, comprising the steps of:

(a) turning on at least one of the switching devices in the bridge to provide a current path from the primary of the transformer through the switching device and through one of the anti-parallel diodes back to the primary to effectively short the primary during a positive or negative half cycle of the input power waveform for a selected period of time which is short compared to the period of the power waveform to build up a current through the effective leakage inductances of the primary and secondary of the transformer;

(b) then, turning off the switching device and allowing current induced by the inductances of the transformer to flow through one of the anti-parallel diodes into the battery and through another of the anti-parallel diodes back to the primary to discharge the energy stored in the transformer inductances.

14. The method of claim 13 including the further step of leaving off all switching devices in the bridge after the current into the battery from the inductances has dropped to zero, and then again turning on the switching device to provide a conduction path which shorts the primary of the transformer at a selected time after the switching device had previously been turned on, and repeating the steps to charge the battery.

15. The method of claim 13 wherein the switching device which has been switched off is left off until the current in the inductances reaches zero, and thereafter turning on the switching device to again provide a conduction path which shorts the primary of the transformer and repeating the cycles to charge the battery.

16. The method of claim 13 wherein the switching devices in the inverter are power MOSFETs having intrinsic anti-parallel diodes and wherein the step of turning the switching device on and off comprises applying a signal to the gate of the selected MOSFET to provide a conduction path which shorts out the primary of the transformer and the step of turning off the switching device comprises removing the gate signal from the MOSFET to turn it off to allow current to flow through the intrinsic anti-parallel diodes of the MOSFETs into the battery.

17. The method of claim 13 wherein in step (a) two switching devices are turned on to short the primary and in step (b) the two switching devices are turned off.

18. A battery charger for a battery, which is adapted to receive AC input power, having alternating positive and negative peak voltages, across power lines, comprising:

(a) a power transformer having a secondary connected across the power lines and a primary coupled to the secondary;

(b) four diodes connected in a bridge configuration having an output connected to the primary of the power transformer and having an input connected to the battery, wherein the battery voltage is selected to be greater than the peak AC voltage applied across the output of the bridge by the primary of the transformer when the AC input power is applied from the power lines to the secondary of the transformer so that the diodes are normally back-biased by the voltage from the battery, and switching devices connected across at least two of the diodes in the bridge so that when the switching devices are turned on the primary is shorted by the switching devices, the switching devices being responsive to control signals to switch between on and off states;

(c) control means, connected to the switching devices to control the same, for controlling the switching devices during normal supply of AC power on the power lines to provide a charging cycle to the battery, the charging cycle including a first energy build-up state in which the switching devices are turned on for a selected period of time to provide a conduction path which shorts the primary of the transformer to build up a current through the effective leakage inductances of the primary and secondary of the transformer, and a second energy discharge state in which the switching devices are turned off and a conduction path is provided from the primary through two of the diodes to the battery and back to the primary of the transformer, the total period of the charging cycle being short in comparison to the period of the AC input power waveform, wherein the current induced in the inductances of the transformer flows into the battery during the second state to discharge the energy stored in the inductances.

19. The battery charger of claim 18 wherein the control means controls the switching devices to repeat the first and second states continuously to charge up the battery.

20. The battery charger of claim 18 wherein the control means controls the switching of the switching devices so that the first state begins at regularly spaced periodic points in time and the second state terminates when the energy stored in the transformer inductances is completely discharged and the current flowing to the battery reaches zero, and wherein the current remains at zero until the initiation of the next first state.

21. The battery charger of claim 18 wherein the switching devices are power MOSFETs and the diodes across which the switching devices are connected are intrinsic anti-parallel diodes in the MOSFETs.

22. The battery charger of claim 18 wherein the control means monitors battery voltage during charging, and when the battery voltage reaches a selected level the control means controls the switching devices so that the selected period of time of the first state when the switching devices are turned on thereafter is decreased as battery voltage increases.