Power conversion equipment monitor/controller method and apparatus

• US 5,583,413 A
• Filed: 09/06/1994
• Issued: 12/10/1996
• Est. Priority Date: 09/06/1994
• Status: Expired due to Term

• Current Assignee: Xantrex Technology Incorporated (Mission Critical Electronics LLC)
• Original Assignee: Cruising Equipment, Inc.
• Inventors: Proctor, Richard L., Kahle, Steven H., Stokes, Warren D., Young, Richard H. Jr.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): KRISHNAN, ADITYA
• Application Number:
  US08/300,979
• Time in Patent Office: 826 Days
• Field of Search: 320/6, 320/21, 320/20, 320/39, 320/435, 320/48, 320/455, 324/428-436, 364/550, 364/551.01, 364/481, 364/557, 340/636, 307/9.1, 307/10.1, 307/10.7, 307/38, 307/39, 322/28, 322/78, 322/14, 322/54, 322/69.8, 219/202-203
• US Class Current: 320/134
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/0071 with a programmable schedule
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/1438 in combination with power supplies for loads other than batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Power inverter equipment monitor/controller method and apparatus are described. The invented apparatus provides for the semi-automatic state steering and monitoring of an inverter/charger and alternator system. A flat panel user interface includes an array of switches, displays and indicators for establishing modes of operation of the system, for initializing operating parameters of the system and a connected battery, for establishing rates for the system'"'"'s operation, permit the user to monitor the system'"'"'s operating mode and charging data (including charging efficiency factor or CEF) while it is operating to charge the battery and to supply AC power to connected appliances. By the one of the preferred methods of the invention, ramping-up the alternator'"'"'s output of current, sustaining the output until the voltage of the battery is acceptable, adjusting the output while maintaining the battery voltage at an acceptable level, reducing output until float level voltage is obtained and further adjusting output to maintain float level voltage to preserve the battery charge. By the other of the preferred methods, certain charge data related to the charging of the battery--including a present CEF, maximum amp-hour charge level capacity of the battery (AH CL capacity), and the present status of amp-hour charge level--are given and stored in memory, the battery is discharged, the lowest-recorded (LR) AH CL is recorded with recharge begins, completing the recharge and storing amount of amp-hours used to recharge, determining an intermediate CEF by dividing AH used-to-recharge battery by difference between the AH CL capacity and LR AH CL, averaging the present CEF with the intermediate CEF to produce a result which is stored in memory as the present CEF, and resetting present status to the AH CL capacity.

Claims

1. For use with a system including an alternator that supplies a variable alternator-current-output to a connected battery with a multi-cycle battery charger connected thereto, wherein the battery has a battery voltage and receives a charging current, and wherein the alternator is controlled by a regulator, an alternator current-regulation method comprising:

ramping-up the alternator-current-output until the alternator-current-output reaches an alternator-current-limit, wherein the alternator-current-output is being provided to the battery for charging the battery;

sustaining the alternator-current-output substantially at the alternator-current-limit until the battery voltage is substantially at an acceptance voltage which is indicative of the battery approaching its maximum charge capacity and is greater than a float voltage of the battery;

adjusting the alternator-current-output for maintaining the battery voltage substantially at the acceptance voltage, until the battery'"'"'s charging current is substantially at a fully-charged-indication current;

reducing the alternator-current-output, which lowers the battery voltage, until the battery voltage is substantially at the float voltage; and

further adjusting the alternator-current-output for maintaining the battery voltage substantially at the float voltage to preserve a fully charged condition of the battery.

2. The method of claim 1, wherein the system includes a sensor for measuring and a processor comparing, and wherein the regulator is connected to the sensor and the processor, the method further comprising:

a battery-current measuring of the charging current flowing through the battery;

an alternator-current measuring of the alternator-current-output;

a voltage measuring of the battery voltage across the battery;

an alternator-current comparing of the alternator-current-output to the alternator-current-limit;

a battery-current comparing of the charging current to the fully-charged-indication current;

an acceptance-voltage comparing of the battery voltage to the acceptance voltage; and

a float-voltage comparing of the battery voltage to the float voltage.

3. The method of claim 2, wherein

the ramping-up step includes an alternator-current measuring of the alternator-current-output and an alternator-current comparing of the alternator-current-limit thereto;

the sustaining step includes a battery-current measuring of the charging current, a voltage measuring of the battery voltage and an acceptance-voltage comparing of the acceptance voltage thereto;

the adjusting step includes a battery-current measuring of the charging current and a battery-current comparing of the fully-charged-indication current thereto;

the reducing step includes a battery-current measuring of the charging current, a voltage measuring of the battery voltage and a float-voltage comparing of the float voltage thereto; and

the further adjusting step includes a battery-current measuring of the charging current, a voltage measuring of the battery voltage and a float-voltage comparing of the float voltage thereto.

4. The method of claim 2, wherein the system includes a first battery and a second battery with each having a voltage and receiving a charging current, and wherein the battery-current measuring steps and voltage measuring steps are preceded by:

a measuring of the first battery'"'"'s voltage and the second battery'"'"'s voltage;

a comparing of the first battery'"'"'s voltage to the second battery'"'"'s voltage; and

a using of the first battery for measuring of the battery voltage and of the charging current if the first battery'"'"'s voltage is greater than the second battery'"'"'s voltage, otherwise

a using of the second battery for measuring of the battery voltage and of the charging current.

5. The method of claim 1, which further comprises before the ramping-up step,

a defining of settings for the alternator-current-limit, the acceptance voltage, the fully-charged-indication current and the float voltage, and

a storing of the settings in a memory connected to the regulator.

6. The method of claim 5, wherein the setting defining the fully-charged-indication current is a percentage of battery capacity.

7. The method of claim 1, which further comprises before the ramping-up

a starting of the alternator by the regulator, and

a providing of a delay before the ramping-up.

8. The method of claim 1, which further comprises after adjusting, a step of periodically adjusting the alternator-current-output to maintain the battery voltage for a hold-time.

9. The method of claim 8, wherein the periodically adjusting step includes a repeating of the ramping-up, sustaining and adjusting steps if the battery voltage falls below the acceptance voltage.

10. The method of claim 1, wherein the ramping-up step includes a raising of the alternator-current-output to the alternator-current-limit within a defined ramp-up time period.

11. The method of claim 1, wherein the system further includes the regulator connected to the battery charger and after the further adjusting step,

a directing of the battery charger into a battery electrolyte equalization mode, and

a varying of the alternator-current-output to maintain the charging current substantially at the fully-charged-indication current, and

a continuing of the varying of the alternator-current-output, which raises the battery voltage, until the battery voltage is substantially at an equalization voltage.

12. For use with a system including a battery charger, a battery, and a controller having a processor for storing data into a memory connected thereto, wherein the battery has a present charge efficiency, an adaptive charge efficiency factor determination method comprising:

a providing of a present charge efficiency factor, a maximum amp-hour charge level capacity of the battery, and a present status of amp-hour charge level;

a storing of the present charge efficiency factor, the maximum amp-hour charge level capacity of the battery, and the present status of amp-hour charge level in the memory;

a discharging of the battery and while discharging, decrementing the present status of amp-hour charge level;

a recharging of the battery and a storing of the present status of amp-hour immediately before recharging in the memory as the lowest-recorded amp-hour charge level;

a measuring of amp-hours used to recharge battery and a storing in memory the amp-hours used as amp-hours used-to-recharge the battery;

a completing of the recharging of the battery;

a determining of an intermediate charge efficiency factor by dividing amp-hours used-to-recharge battery by difference between the maximum amp-hour charge level capacity and the lowest-recorded amp-hour charge level;

an averaging of the present charging efficiency factor with the intermediate charge efficiency factor to produce a result, whereby the result more accurately represents the present charge efficiency of the battery than does the present charge efficiency factor; and

a storing of the result in memory as the present charge efficiency factor so that the present factor more accurately represents the present charge efficiency of the battery.

13. The method of claim 12, which further comprises, following the storing of the result, a step of setting the present status of amp-hour charge level to the maximum amp-hour charge level capacity.

14. The method of claim 12, for use with a display connected to the controller, which further comprises a displaying of the present charge efficiency factor and the present status of amp-hour charge level.

15. A battery charge monitoring apparatus for use with a battery charging system which includes a battery charger for storing AC-to-DC converted electric power and a battery connected thereto, wherein the battery has an amp-hour charge level and a present charge efficiency, the apparatus comprising:

an ammeter connected to the battery, the ammeter for measuring current flow through the battery;

a processor for calculating a present charge efficiency factor, wherein during a charging of the battery, the processor calculates a present status of the amp-hour charge level based on the present charge efficiency factor, the processor being connected to the ammeter and the battery charger;

a display that indicates the present charge efficiency factor and the present status of the amp-hour charge level of the battery, wherein the display is connected to the processor; and

a memory connected to the processor, wherein the memory is for storing the present charge efficiency factor, a lowest-recorded amp-hour charge level and a maximum amp-hour charge level capacity of the battery, and

wherein after the battery charger fully charges the battery, the processor calculates an intermediate charge efficiency factor by dividing amp-hours used to charge battery by a difference between the maximum amp-hour charge level capacity and the lowest-recorded amp-hour charge level and averaging the present charging efficiency factor with the intermediate charge efficiency factor to produce a result, whereby the result more accurately represents the present charge efficiency of the battery than does the present charge efficiency factor, and the processor stores the result into the memory as the present charge efficiency factor.

16. The apparatus of claim 15, which further comprises:

a voltmeter connected to the battery, the voltmeter for measuring voltage across the battery, and

wherein the display further indicates a voltage across the battery and the current flow through the battery, wherein the voltage is measured by the voltmeter and the current flow is measured by the ammeter.

17. The apparatus of claim 16, further comprising a console including:

a processor-scanned keypad with keys, wherein the keypad is connected to and scanned by the processor, and

the display, wherein the display further indicates a present status of charging data when a user selects a key on the keypad, wherein each key is associated one or more of the charging data and wherein the charging data include the voltage across the battery, the current flow through the battery, the present charge efficiency factor, and the present status of the amp-hour charge level of the battery.

18. The apparatus of claim 15, further comprising a regulator for regulating an alternator'"'"'s current output, wherein the regulator is connected to the processor and to an alternator, and wherein the regulator includes an enablement indicator for indicating the enablement of the regulator and a drive indicator for indicating an intensity of a drive current that the regulator sends to the alternator for controlling operation of the alternator.

19. The apparatus of claim 15, further comprising a remote controller connected to the battery charging system, wherein the system includes an inverter/charger that includes the battery charger and an inverter, the controller including:

a processor-scanned keypad for receiving a user-input, wherein the keypad is connected to the processor, and

the processor, wherein the processor is for scanning the keypad, storing setup parameters in a memory connected thereto, and controlling the inverter/charger based on the user-input and the setup parameters of the inverter/charger.

20. The apparatus of claim 19, wherein the setup parameters include an idle mode sensitivity of the inverter/charger and a load-limit AC power share of the inverter/charger.

21. The apparatus of claim 19, wherein the controller activates a battery equalization mode of the inverter/charger.

22. The apparatus of claim 19, wherein the setup parameters include an acceptance voltage, a fully-charged-indication current, and a maximum amp-hour charge level capacity.