Method and apparatus for controlling battery charging current

• US 5,635,816 A
• Filed: 08/01/1995
• Issued: 06/03/1997
• Est. Priority Date: 08/01/1995
• Status: Expired due to Term

• Current Assignee: Morningstar Incorporated
• Original Assignee: Morningstar Incorporated
• Inventors: Gerken, Kenneth F., Welsh, Daniel
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US08/509,743
• Time in Patent Office: 672 Days
• Field of Search: 320/61, 320/1, 320/2, 320/5, 320/21, 320/31, 320/39, 320/48, 323/906, 136/243, 136/291, 136/293
• US Class Current: 320/102
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers
• CPC Class Codes: Y10S 136/293 Circuits

Abstract

An automatic photovoltaic controller provides a fixed frequency, pulse width modulated charging current to charge and regulate a battery, the duty cycle of the charging current being controlled by the difference between the sensed battery voltage and a desired regulated voltage. Modulation is achieved by controlling the on and off states of plural parallel-connected FET switches placed in series between the photovoltaic array and the battery. The duty cycle is adjustable in discrete steps over the entire range of 0% to 100% and is updated numerous times per second with new battery voltage measurements to provide highly accurate regulation. The charge current pulse rise time is selected to match the response time of the photovoltaic array. The fixed frequency of the charge current is within the preferred range of 100 Hz to 600 Hz to provide sufficient time for the chemical reaction within the battery cells to be substantially completed between charge pulses during the regulation mode. Automatic protection of the controller and the load is achieved by rapidly disconnecting the battery and/or load in response to specified conditions. The photovoltaic array is disconnected from the battery at night to prevent battery discharge into the array. Equalization of the battery is performed automatically, at a voltage level slightly higher than the regulated voltage, after a predetermined number of days or if the battery voltage falls below a predetermined level.

Claims

1. A photovoltaic controller for controlling delivery of charging current from a photovoltaic array to charge and regulate a battery to a voltage V_r while the battery is driving a load, said controller comprising:

switching means connected in series in a charging current path between said array and said battery for alternatively passing and interrupting charging current through said path;

battery voltage sensing means for sensing the voltage across said battery;

means for comparing the sensed battery voltage to V_r ; and

control means for cyclically actuating and deactuating said switching means in a fixed frequency, pulse width modulated mode, said control means comprising pulse width adjustment means responsive to said means for comparing for varying the duty cycle of said pulse width modulation such that the time for passing a charging current pulse during each cycle increases in response to a battery voltage less than V_r, and decreases in response to a battery voltage greater than V_r.

2. The controller of claim 1 wherein said fixed frequency is in the range between 100 Hz and 600 Hz.

3. The controller of claim 1 wherein said pulse width adjustment means includes means for adjusting the pulse width modulation duty cycle over a range extending from 0% to 100%.

4. The controller of claim 3 wherein said adjustment means includes means for selecting predetermined discrete duty cycles located at spaced percentage intervals between 0% and 100% .

5. The controller of claim 4 wherein said discrete duty cycles are uniformly separated by approximately six or seven percent.

6. The controller of claim 4 wherein said switching means includes means for passing said charging current pulse with a rise time selected to substantially match the inherent transition time for said array in switching from open circuit to battery voltage.

7. The controller of claim 1 further comprising means responsive to said battery voltage being at or below a predetermined low voltage for automatically disconnecting said battery from said load.

8. The controller of claim 1 further comprising means responsive to the voltage across said photovoltaic array being at or below a predetermined low voltage for interrupting said charging current path.

9. The controller of claim 1 further comprising equalization means for automatically equalizing the battery charge by charging the battery to an equalization voltage higher than V_r in response to either:

(a) elapse of a predetermined number of days between equalizations;

or (b) the battery voltage being at or below a predetermined voltage.

10. The controller of claim 9 wherein said equalization means comprises means for establishing said equalization voltage between 1.5% and 2.5% higher than V_r.

11. The controller of claim 1 further comprising processor means for establishing multiple operating states of said controller, each operating state being characterized by a respective unique combination of photovoltaic array output voltage and battery voltage.

12. The controller of claim 1 wherein said switching means comprising a plurality of parallel-connected field effect transistors connected in series between the array and battery.

13. The controller of claim 12 further comprising gate drive means for limiting drive signals actuating said field effect transistors in order to minimize transients in the charging current path upon actuation of said switching means.

14. The controller of claim 1 wherein said pulse width adjustment means includes means for adjusting the pulse width modulation duty cycle over a range extending from 0% to 100%, and further means for selecting predetermined discrete duty cycles in response to the magnitude of said voltage difference.

21. The controller of claim 4 wherein said array exhibits an inherent transition time in switching between an interrupted charging current mode to a passage of charging current mode under the control of said switching means, and wherein said switching means comprises means for transitioning between interrupting and passing said charging current with a rise time selected to substantially match said inherent transition time of said array.

22. The controller of claim 9 wherein V_r is approximately 14.1 volts, and wherein said equalization means comprises means for establishing said equalization voltage at less than 15 volts.

23. The controller of claim 22 wherein said equalization voltage is established at approximately 14.35 volts.

24. The controller of claim 8 wherein said means for interrupting includes at least two field effect transistors connected to each other in back-to-back relation for interrupting said charging current path in response to the voltage across said array being at or below said predetermined low voltage.

25. The controller of claim 1 further comprising protection means for automatically protecting the controller and load against damage from abnormal operation.

26. The controller of claim 25 wherein said protection means comprises means responsive to detection of a short circuit across said load for automatically disconnecting said load from said battery.

27. The controller of claim 25 wherein said protection means comprises means responsive to an open circuit condition across said battery for disconnecting said load from said array.

28. The controller of claim 25 wherein said protection means comprises:

means for sensing temperature at said controller;

means for automatically opening said switching means to interrupt said charging current in response to the sensed temperature reaching a first high temperature; and

means for automatically disconnecting said load from said controller in response to the second temperature reaching a second high temperature above said first high temperature.

29. The controller of claim 28 further comprising means for automatically reconnecting said load to said controller, and for restoring said charging current, in response to the sensed temperature falling to a normal temperature below said first and second high temperatures.

15. A method of controlling the charging current applied to a battery from a photovoltaic array while said battery is driving a load, said method comprising the steps of:

(a) applying said charging current to said battery continuously when the battery voltage is below a first predetermined voltage;

(b) applying said charging current to said battery in pulses of a fixed frequency pulse train when the battery voltage is in a narrow range surrounding a desired regulation voltage; and

(c) controlling the duration of said charging current pulses as a function of said battery voltage over a duty cycle range extending from 0% to 100%.

16. The method of claim 15 wherein step (b) includes applying said pulses at a fixed frequency in the range extending from 100 Hz to 600 Hz.

17. The method of claim 15 wherein step (b) includes providing said pulses of charging current having a rise time selected to substantially match the inherent transition time for said array when switching from open circuit to battery voltage.

18. The method of claim 17 wherein step (b) comprises alternatively opening and closing a switch connected in series between said photovoltaic array and said battery.

19. The method of claim 15 wherein step (b) includes changing said duty cycle in discrete duty cycle steps in response to corresponding changes in the battery voltage, wherein battery voltage is measured multiple times per second and the duty cycle step is updated in response to the battery voltage measurement.

20. The method of claim 15 further comprising the step of inhibiting said charging current from flowing to said battery when the battery voltage is at or above a second predetermined voltage above said regulating voltage.

30. The method of claim 15 further comprising the step of sensing the battery voltage to control steps (a), (b) and (c), wherein:

in response to said duty cycle being at or above a predetermined duty cycle, battery voltage is sensed during said charging current pulses; and

in response to said duty cycle being below said predetermined duty cycle, battery voltage is sensed between said charging current pulses.

31. The method of claim 15 further comprising the steps of:

sensing the temperature at said battery; and

automatically changing said regulation voltage as a function of the sensed temperature.

32. The method of claim 15 further comprising the steps of:

sensing the ambient temperature; and

automatically changing said regulation voltage as a function of the sensed temperature.

33. The method of claim 15 further comprising the steps of:

indicating whether said battery is a sealed battery or a flooded battery; and

adjusting said regulation voltage as a function of whether the battery is sealed or flooded.