Methods and apparatus for providing protection to batteries in an uninterruptible power supply

• US 5,994,794 A
• Filed: 05/09/1997
• Issued: 11/30/1999
• Est. Priority Date: 05/09/1997
• Status: Expired due to Term

• Current Assignee: Piller USA, Inc. (Langley Holdings PLC)
• Original Assignee: Active Power Incorporated
• Inventors: Wehrlen, David J.
• Primary Examiner(s): Paladini, Albert W.
• Application Number:
  US08/853,751
• Time in Patent Office: 935 Days
• Field of Search: 307/66, 307/64, 307/67, 307/68, 322/4
• US Class Current: 307/66
• CPC Class Codes: H02J 9/066 characterised by the use of dynamo-electric machines H02J9/08 takes precedence

Abstract

An uninterruptible power supply (UPS) provides improved reliability by extending the useful life of a bank of batteries that provide backup power to the UPS in the event of an extended power outage. In the preferred embodiment, battery life is extended by switchably isolating the bank of batteries from the DC buss that is coupled to the critical load. Backup power for short duration outages, on the order of about ten seconds or less, is provided by a flywheel energy storage unit. Once the outage becomes extended, the isolation circuit is triggered to electrically connect the bank of batteries directly to the DC buss. In this manner, the bank of batteries does not experience AC ripple or the common, short duration outages that would otherwise cause the batteries to experience a discharge/recharge cycle.

Claims

1. An uninterruptible power supply for providing continuous power to a critical load, said uninterruptible power supply comprising:

an AC-to-DC converter circuit having an input coupled to a source of primary power, and an output;

a DC-to-AC converter circuit having an input coupled to said output of said AC-to-DC converter circuit to form a DC buss, and an output;

a battery bank;

a first monitoring circuit that monitors for an extended outage of primary power;

a flywheel energy storage unit electrically coupled to said DC buss, said flywheel unit providing power in the event of short duration outages of primary power; and

a first isolation circuit coupled to receive information from said first monitoring circuit regarding status of primary power, said first isolation circuit being coupled between said battery bank and said DC buss, said first isolation circuit being triggered to switch out of isolation when said extended outage of primary power is detected so that said battery bank is then directly coupled to said DC buss to provide power to said buss.

2. The uninterruptible power supply of claim 1 further comprising a battery charger coupled to said battery bank and to said source of primary power.

3. The uninterruptible power supply of claim 1, wherein said first monitoring circuit monitors said DC buss.

4. The uninterruptible power supply of claim 1, wherein said first monitoring circuit monitors said input of said AC-to-DC converter.

5. The uninterruptible power supply of claim 1, wherein said first monitoring circuit monitors said output of said DC-to-AC converter.

6. The uninterruptible power supply of claim 1 further comprising:

a transfer switch coupled to said source of primary power, said transfer switch having an output;

a GENSET electrically coupled to said transfer switch and to said first monitoring circuit, said GENSET being capable of providing replacement power to said critical load in the event of an extended outage.

7. The uninterruptible power supply of claim 6, wherein said GENSET is activated by a GENSET trigger signal from said first monitoring circuit.

8. The uninterruptible power supply of claim 6, wherein said GENSET is activated by a GENSET trigger signal from said flywheel unit.

9. The uninterruptible power supply of claim 1 further comprising:

a first gating circuit coupled to said first isolation circuit, said first gating circuit triggering said first isolation circuit to switch out of isolation upon the receipt of a first trigger signal.

10. The uninterruptible power supply of claim 9, wherein said first trigger signal is provided to said first gating circuit by said flywheel unit.

11. The uninterruptible power supply of claim 9, wherein said first trigger signal is provided to said first gating circuit by said first monitoring circuit.

12. The uninterruptible power supply of claim 9, wherein said first monitoring circuit monitors the voltage of said DC buss and determines that said extended outage has occurred when said voltage falls below a predetermined level.

13. The uninterruptible power supply of claim 12, wherein said flywheel unit maintains the voltage on said DC buss at least equal to said predetermined level during said short duration outage.

14. The uninterruptible power supply of claim 9 further comprising:

a second monitoring circuit coupled to said DC buss that monitors said DC buss for an extended outage of primary power;

a second isolation circuit coupled between said battery bank and said DC buss, said second isolation circuit being triggered to switch out of isolation when said extended outage of primary power is detected so that said battery bank is then directly coupled to said DC buss to provide power to said buss; and

a second gating circuit coupled to said second isolation circuit, said second gating circuit triggering said second isolation circuit to switch out of isolation upon the receipt of a second trigger signal.

15. The uninterruptible power supply of claim 14, wherein said second trigger signal is provided to said second gating circuit by said flywheel unit.

16. The uninterruptible power supply of claim 14, wherein said second trigger signal is provided to said second gating circuit by said second monitoring circuit.

17. The uninterruptible power supply of claim 14 further comprising:

a transfer switch coupled to said source of primary power, said transfer switch having an output;

a GENSET electrically coupled to said transfer switch and to said second monitoring circuit, said GENSET being capable of providing replacement power to said critical load in the event of an extended outage.

18. A method of extending useful life of a bank of batteries in an uninterruptible power supply, said method comprising the steps of:

converting AC power from a primary source to DC power;

outputting said DC power to a DC buss;

monitoring the voltage level of power in said uninterruptible power supply with a first monitoring circuit;

providing backup power to said DC buss from a flywheel storage unit in the event of a short duration loss of power from said primary source;

coupling a first switchable isolation circuit between said bank of batteries and said DC buss; and

triggering said first isolation circuit to couple said bank of batteries to said DC buss in the event of an extended loss of power from said primary source.

19. The method of claim 18, wherein said step of triggering is performed by a first trigger signal produced by said flywheel unit.

20. The method of claim 18, wherein said step of triggering is performed by a first trigger signal produced by said first monitoring circuit.

21. The method of claim 18 further comprising the step of:

recharging said bank of batteries by coupling a low ripple battery charger between said primary power source and said bank of batteries.

22. The method of claim 18, wherein said step of monitoring monitors power on said DC buss.

23. The method of claim 18, wherein said step of monitoring monitors power from said power source.

24. The method of claim 18, wherein said step of triggering comprises the steps of:

providing a first trigger signal to a first gating circuit;

producing a first switch signal in response to said first trigger signal; and

switching said first isolation circuit in response to said produced first switch signal.

25. The method of claim 24, further comprising the steps of:

monitoring the voltage level of said DC buss with a second monitoring circuit;

coupling a second switchable isolation circuit between said bank of batteries and said DC buss; and

triggering said second isolation circuit to couple said bank of batteries to said DC buss in the event of an extended loss of power from said primary source, such that, in the event of an extended loss of power, one of said first and second isolation circuits couple said bank of batteries to said DC buss.

26. The method of claim 18 further comprising the steps of:

providing an alternate source of AC power in said step of converting, said alternate AC power being provided by a GENSET, said GENSET being capable of providing replacement power to said critical load in the event of an extended outage; and

electrically coupling said GENSET to at least one of said flywheel unit and said first monitoring circuit to provide an activation signal to said GENSET.

27. The method of claim 26, wherein said step of coupling said GENSET comprises the steps of:

coupling said GENSET to said flywheel unit; and

tapping power from said flywheel unit to provide startup power to said GENSET.