Apparatus and method for charging batteries

• US 5,365,160 A
• Filed: 09/06/1991
• Issued: 11/15/1994
• Est. Priority Date: 09/06/1991
• Status: Expired due to Term

• Current Assignee: Symbol Technologies, Inc. (Zebra Technologies Corporation)
• Original Assignee: Telxon Corporation (Zebra Technologies Corporation)
• Inventors: Rinkes, Charles A., Leppo, Lee E.
• Primary Examiner(s): HICKEY, ROBERT
• Application Number:
  US07/755,890
• Time in Patent Office: 1,166 Days
• Field of Search: 320/31, 320/32, 320/39, 320/20, 320/21, 320/22
• US Class Current: 320/160
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient

Abstract

A charging system monitors the rate of change in battery voltage, adjusts the rate of charging, and checks the changes in battery voltage following adjustments in the rate of charging to observe a predetermined sequence of voltage changes that signifies when a battery is fully charged. The charging system determines the slope between consecutive battery voltage measurements. The charging system charges a battery at the full battery capacity in response to positive or zero voltage slope measurements and reduces the charging rate in response to negative voltage slope measurements. A nickel-cadmium battery is fully charged when at least one sequence of a negative slope, followed by a decrease in charging rate, then a positive or flat slope, followed by an increase in charge rate, and finally another negative slope is observed.

Claims

1. An apparatus for charging a rechargeable battery that has a voltage that varies with its state of charge, the apparatus comprising:

charging means for delivering electrical energy to the battery at a controllably-variable charging rate;

measurement means for providing periodic measurements of battery voltage; and

control means for detecting any change in value between successive battery voltage measurements and conditioning the charging means to decrease the charging rate if the detected voltage change is negative, increase the charging rate up to a predetermined maximum rate if the detected voltage change is positive, and decrease to zero the charging rate after initially detecting a negative voltage change and subsequently detecting a positive voltage change.

2. An apparatus as defined in claim 1, wherein the control means determines a slope that corresponds to the change in value between battery voltage measurements and halts charging by the charging means if the control means detects at least one sequence of negative slope, followed by positive slope, followed by negative slope.

3. An apparatus as defined in claim 1, wherein the measurement means includes digital conversion means for periodically obtaining a plurality of battery voltage measurements during a measurement period and selecting one of the values obtained in the period as the measure of battery voltage to be provided.

8. An apparatus as defined in claim 3, wherein the digital conversion means selects the most prevalent battery voltage measurement obtained in the period as the measure of battery voltage to be provided.

4. An apparatus for charging a rechargeable battery that has a voltage that varies with its state of charge, the apparatus comprising:

charging means for delivering a variable amount of electrical energy to the battery and charging it;

measurement means for providing a measure of battery voltage, wherein the measurement means includes digital conversion means for periodically obtaining a plurality of battery voltage measurements during a measurement period and selecting one of the values obtained in the period as the measure of battery voltage to be provided; and

control means for periodically receiving the measured battery voltage and changing the energy delivered to the battery by the charging means and detecting a characteristic sequence of measured-battery voltages that indicates a fully charged battery, wherein the control means decreases the electrical energy provided by the charging means by a predetermined proportion of the maximum allowable charging rate each time a change in the battery voltage indicates that the battery is near full charge.

5. An apparatus as defined in claim 4, wherein:

the charging means includes a constant current source that produces a current; and

the control means reduces and increases the amount of electrical energy provided by the charging means by varying the amount of time the current produced by the constant current source is applied to the battery.

6. An apparatus as defined in claim 5, wherein the digital conversion means periodically obtains battery voltage measurements and disregards the first battery voltage measurements obtained during the first measurement period after the control means has changed the electrical energy provided by the charging means.

7. An apparatus as defined in claim 5, wherein the control means disregards the first measure of battery voltage from the measurement means received after changing the electrical energy provided by the charging means.

9. An apparatus for charging a rechargeable battery that has a voltage that varies with its state of charge, the apparatus comprising:

charging means for delivering a variable amount of electrical energy to the battery and charging it;

measurement means for providing a measure of battery voltage; and

control means for periodically receiving the measured battery voltage and changing the energy delivered to the battery by the charging means and detecting a characteristic sequence of measured battery voltages that indicates a fully charged battery;

wherein the charging means includes

a constant current source that produces a predetermined current, and

regulating means for switching the constant current source between an on state, in which the constant state, in which the constant current source is connected to the battery, and an off state, in which the constant current source is disconnected from the battery;

and wherein the measurement means includes sample means for periodically obtaining a battery voltage reading.

10. An apparatus as defined in claim 9, wherein the regulating means switches the constant current source to the charge state for a maximum amount of time equal to the time in the measurement period to provide a charging rate equal to a maximum allowable charging rate capacity for the battery.

11. A battery charging apparatus for charging a first rechargeable battery that has a battery voltage that varies with the state of charge of the battery, the apparatus comprising:

charging means for delivering a variable amount of electrical energy to the battery, at up to a predetermined maximum allowable charging rate capacity of the battery, and charging the battery;

detecting means for periodically providing an indication of the battery voltage;

slope means for providing a slope value that indicates whether the slope of the battery voltage curve corresponding to the previous two battery voltage indicators from the detecting means is positive, negative, or flat; and

control means for receiving the slope value from the slope means, decreasing the amount of electrical energy delivered by the charging means if the slope is negative, increasing the amount of electrical energy delivered by the charging means up to the maximum allowable rate if the slope is positive or flat, and terminating the delivery of electrical energy from the charging means if the battery voltage undergoes three consecutive sequences of change from negative slope to positive or flat slope.

12. An apparatus as defined in claim 11, wherein the detecting means includes digital conversion means for obtaining a plurality of battery voltage values that are within a predetermined range of accuracy corresponding to a resolution unit and for selecting the most prevalent value as the indicator of battery voltage.

13. An apparatus as defined in claim 12, wherein the slope means indicates a negative slope if the current battery voltage value is more than two resolution units less than the previous battery voltage value, indicates a positive slope if the current battery voltage value is more than two resolution units greater than the previous battery voltage value, and indicates a flat slope otherwise.

14. An apparatus as defined in claim 12, wherein the slope means provides a new slope value when the control means changes the amount of electrical energy provided to the battery by the charging means.

15. An apparatus as defined in claim 14, wherein the detecting means disregards at least the first indication of battery voltage after the control means has changed the amount of electrical energy delivered to the first battery by the charging means.

16. An apparatus as defined in claim 15, wherein the slope means indicates a change in slope if the current battery voltage value is one resolution unit different from the previous battery voltage value if the indicated battery voltage has not changed for three consecutive readings from the detecting means.

17. An apparatus as defined in claim 11, wherein the charging means includes:

a constant current source that produces a predetermined current; and

regulating means for switching the constant current source between an on state, in which the constant current source is connected to the battery, and an off state, in which the constant current source is disconnected from the battery, operable each time the detecting means provides an indication of the battery voltage.

18. An apparatus as defined in claim 17, further including:

receiving means for receiving at least one additional rechargeable battery in addition to the first rechargeable battery; and

distribution means for providing electrical energy to the additional rechargeable battery, at a charging rate less than the maximum allowable charging rate, if the regulating means has switched the charging means to provide electrical energy to the first rechargeable battery at less than the maximum allowable rate.

19. An apparatus as defined in claim 18;

wherein the receiving means is adapted to receive more than one additional rechargeable battery; and

wherein the distribution means provides electrical energy to each additional rechargeable battery, at a predetermined rate less than the maximum allowable charging rate, if the regulating means has switched the charging means to provide electrical energy to the first rechargeable battery at less than the maximum allowable rate.

20. A method for charging rechargeable batteries having a battery voltage that varies with their state of charge, comprising the steps of:

delivering electrical energy to a first battery at a rate up to a maximum allowable charging rate capacity of the battery and charging it;

periodically measuring the battery voltage of the first battery and determining a slope that corresponds to the change in battery voltage between measurements;

reducing the rate at which electrical energy is delivered to the first battery if the slope is negative and increasing it up to the maximum allowable rate if the slope is positive; and

indicating that the first battery is at full charge after at least one sequence of determining a negative battery voltage slope, reducing the rate at which electrical energy is delivered to the first battery, determining a positive battery voltage slope, increasing the rate at which electrical energy is delivered to the first battery, and determining a negative battery voltage slope.

21. A method for recharging a rechargeable battery as defined in claim 20, further including the step of halting the delivery of electrical energy to the battery when the battery is indicated as being at full charge.

22. A method for recharging a rechargeable battery as defined in claim 20, wherein the step of periodically measuring the battery voltage includes the steps of:

obtaining a plurality of battery voltage values within a measurement interval; and

selecting the most prevalent value as the battery voltage measurement.

23. A method for recharging a rechargeable battery as defined in claim 20, wherein the step of reducing the rate at which electrical energy is delivered further includes the step of:

delivering electrical energy to a second battery at a predetermined rate lower than the maximum allowable charging rate of the battery.