Digitally controlled switch mode power supply for charging rechargeable batteries

• US 6,031,359 A
• Filed: 10/28/1997
• Issued: 02/29/2000
• Est. Priority Date: 10/10/1996
• Status: Expired due to Fees

• Current Assignee: Star Werks Inc.
• Original Assignee: Chartec Laboratories A/S
• Inventors: Michelsen, Jesper, Andersen, Kim A., Andersen, Lars M, Rasmussen, Kim
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US08/860,610
• Time in Patent Office: 854 Days
• Field of Search: 320/106, 320/110, 320/124, 320/125, 320/132, 320/137, 320/139, 320/140, 320/141, 320/145, 320/FOR 118, 320/FOR 120, 320/FOR 121, 320/FOR 131 , 320/FOR 138, 323/282-285, 363/20, 363/21
• US Class Current: 320/141
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

A method of charging rechargeable batteries with a switch mode power supply, the method comprising determining one or more battery charging parameters, and controlling the power output of the switch mode power supply by digitally generating a gate signal for controlling opening periods and closing periods of a switching means of the switch mode power supply, each of the durations of the opening periods and the closing periods of the switching means, respectively, being determined in response to the determined one or more battery charging parameters and one or more charging process reference values. In particular, a method is proposed of controlling the duty cycle of a switch in the switch mode power supply during charging of the battery based on determinations of one or more characteristic charging parameters of the charging process and comparisons of determined parameter values with desired parameter values.

Claims

1. A charging circuit for charging a battery, the circuit comprising:

a. a measurement circuit that determines a parametric battery value while the battery is coupled to the charging circuit; and

b. a control circuit that provides a control signal, the control signal comprising a sequence of consecutive pulses, each pulse comprising a respective duty cycle selected from a set of predetermined duty cycles, the set having a duty cycle resolution, wherein the control circuit selects a plurality of duty cycles for the sequence from the set in response to the battery value; and

c. a supply circuit that receives the control signal and provides a power signal for charging the battery, the power signal having a magnitude and a resolution, the magnitude being responsive to an average of the respective duty cycles, thereby power provided for battery charging is controlled with a power signal resolution of greater precision than the duty cycle resolution.

2. The charging circuit of claim 1 wherein the sequence has a pulse repetition rate within a predetermined frequency range, thereby reducing a ripple voltage of the power signal.

3. The charging circuit of claim 1 wherein the supply circuit comprises a converter from the set consisting of a buck converter, a boost converter, a buck boost converter, a forward converter, a fly back converter, a push pull converter, a half bridge converter, a full bridge converter, and a Cuk converter.

4. The charging circuit of claim 1 wherein:

a. the power signal comprises a charging current; and

b. the measurement circuit provides the battery value in response to the charging current.

5. The charging circuit of claim 1 wherein:

a. the measurement circuit comprises a temperature sensor located for sensing a temperature of the battery; and

b. the measurement circuit provides the battery value in response to the temperature.

6. The charging circuit of claim 1 wherein:

a. the battery provides a terminal voltage; and

b. the measurement circuit provides the battery value in response to the terminal voltage.

7. The charging circuit of claim 1 wherein:

a. the power signal comprises a charging current;

b. the battery provides a terminal voltage; and

c. the measurement circuit provides the battery value in response to the terminal voltage in the absence of the charging current.

8. The charging circuit of claim 1 wherein the control circuit comprises:

a. a processor that operates according to a stored program;

b. a counter that is preset to an initial count in response to the stored program and that provides a terminal signal when a terminal count is reached; and

c. a bi-stable circuit that provides the control signal by toggling between a first state and a second state in response to the terminal signal.

9. The charging circuit of claim 8 wherein the initial count is non-zero.

10. The charging circuit of claim 1 wherein the control circuit comprises:

a. a processor that operates according to a stored program;

b. a counter that provides a count signal that is updated while counting;

c. a register that is preset in response to the stored program and that provides a limit signal; and

d. a comparator, coupled to the counter and to the register, for providing the control signal in response to comparing the count signal and the limit signal.

11. The charging circuit of claim 10 wherein:

a. the control circuit further comprises a second register that is preset in response to the stored program, the second register providing an initial count signal; and

b. the counter, having a counting range with an end count, limits the counting range in response to the initial count signal when the counter reaches the end count.

12. The charging circuit of claim 1, further comprising:

a. a memory that retains a reference course;

b. a timer that provides a signal for identifying a duration of battery charging; and

c. a comparator that provides a difference value in response to comparing the battery value and a reference value, the reference value being recalled from the memory in response to the duration, wherein the control circuit selects the plurality of duty cycles from the set in further response to the difference value.

13. The charging circuit of claim 1 wherein:

a. the supply circuit comprises a switching element that cooperates with a power storage element to provide the power signal, the switching element operative in response to the control signal; and

b. the control circuit comprises;

(1) a first register that stores a first binary value determining a duration of the opening period of the switching element;

(2) a second register that stores a second binary value determining the duration of the closing period of the switching element;

(3) a counter comprising a first input port, coupled to the first register, and a second input port, coupled to the second register, the first and second binary values, respectively, alternatingly being loaded into the counter when the counter reaches a third binary value; and

(4) a latch that modulates the control signal when the counter reaches the third binary value.

14. The charging circuit of claim 1 wherein:

a. the supply circuit comprises a switching element that cooperates with a power storage element to provide the power signal, the switching element operative in response to the control signal; and

b. the control circuit comprises;

(1) a first register that stores a first binary value determining a switch frequency of the switching element;

(2) a second register that stores a second binary value determining a duty cycle of the switching element;

(3) a counter comprising an input port coupled to the first register, the first binary value being loaded into the counter when the counter reaches a third binary value; and

(4) a comparator that compares the counter binary value with the second binary value, the comparator comprising;

(a) a first input port coupled to the second register;

(b) a second input port coupled to the counter; and

(c) an output, that modulates the control signal, when a sign of the difference between the counter binary value and the second binary value changes.

15. A method for charging a battery, the method comprising:

providing a switch mode power supply comprising a switching element for developing an output signal for charging the battery, the switching element operative in response to a control signal;

comparing a reference course and a measured parameter of the battery;

determining a desired pulse width in response to the comparison; and

providing the control signal to comprise a plurality of pulses, each pulse having a pulse width generated with fixed resolution, the plurality having a moving average pulse width responsive to the desired pulse width, thereby charging the battery in response to the reference course.

16. The method of claim 15 wherein the plurality is four.

17. The method of claim 15 wherein each pulse further has a duty cycle generated with the fixed resolution.

18. The method of claim 17 further comprising limiting variation of a pulse repetition rate of the control signal by limiting variation of each respective duty cycle.

19. The method of claim 18 wherein the pulse repetition rate is in the range from about 10 KHz to about 100 KHz.

20. The method of claim 19 wherein the pulse repetition rate is in the range from about 20 KHz to about 35 KHz.

21. A method for charging a battery, the method comprising:

providing a switch mode power supply comprising a switching element for developing an output signal for charging the battery, the switching element operative in response to a control signal;

comparing a reference course and a measured parameter of the battery;

determining a desired duty cycle in response to the comparison; and

providing the control signal to comprise a plurality of pulses, each pulse having a duty cycle generated with fixed resolution, the plurality having a moving average duty cycle responsive to the desired duty cycle, thereby charging the battery in response to the reference course.

22. The method of claim 21 wherein the plurality is four.

23. The method of claim 21 wherein the plurality has an integer quantity of pulses, and the step of generating further comprises:

providing a target duty cycle by dividing the desired duty cycle by the integer;

determining a remainder by subtracting, from the desired duty cycle, a product of the target duty cycle and the integer; and

providing the respective duty cycle for each pulse in the plurality in response to identifying a selected duty cycle from the set consisting of the target duty cycle and the target duty cycle with an increment, wherein selecting is responsive to the remainder.

24. The method of claim 23 wherein each respective duty cycle comprises a respective pulse width and a respective pulse-to-pulse separation;

and the step of providing the respective duty cycle further comprises;

determining the respective pulse width in response to dividing the target duty cycle by half the integer; and

determining the respective separation in response to subtracting the respective pulse width from a constant.

25. The method of claim 24 further comprising determining the respective pulse width in further response to determining whether the target duty cycle is even.

26. The method of claim 25 wherein twice the constant defines a range comprising a multiplicity of subranges, and the method further comprises determining the respective pulse width in response to determining which subrange includes the target duty cycle.

27. The method of claim 25 wherein a multiple of the constant defines a range comprising a multiplicity of subranges, and the method further comprises determining the respective separation in response to determining which subrange includes the target duty cycle.

28. A method for controlling charging of a battery, the method comprising:

providing a memory having a plurality of stored reference courses;

measuring a parameter of the battery at each of a plurality of times during charging;

developing a parameter course from the plurality of measurements;

selecting a reference course from the plurality of reference courses by comparing the parameter course to at least one stored reference course;

governing further charging in response to the selected reference course; and

repeating the steps of measuring, developing, selecting, and governing.

29. A method for controlling charging of a battery, the method comprising:

providing a memory having a plurality of stored reference courses, each course comprising a multiplicity of values, each value being a rate of change;

measuring a rate of change of a parameter of the battery at each of a plurality of times during charging;

developing a parameter course from the plurality of measurements;

selecting a reference course from the plurality of reference courses by comparing the parameter course to at least one stored reference course;

governing further charging in response to the selected reference course; and

repeating the steps of measuring, developing, selecting, and governing.