Method and apparatus for charging batteries

• US 6,037,751 A
• Filed: 07/01/1998
• Issued: 03/14/2000
• Est. Priority Date: 07/01/1998
• Status: Expired due to Term

• Current Assignee: Midtronics Incorporated
• Original Assignee: GNB Technologies Inc.
• Inventors: Klang, James K.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): TOATLEY, GREGORY J
• Application Number:
  US09/108,929
• Time in Patent Office: 622 Days
• Field of Search: 320/127, 320/129, 320/156, 320/160, 320/161
• US Class Current: 320/160
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

A method and apparatus for efficiently charging lead-acid batteries applies small voltage steps to probe the charging efficiency of a battery being charged. The application of a voltage step causes the current to change from a base current to a surge current immediately after the voltage step, and to decay asymptotically to a plateau current after the surge current. A current ratio, defined as the difference between the plateau current and the base current divided by the difference between the surge current and the base current, is used as an indicator of the charging efficiency. The output voltage of the power supply charging the battery is then adjusted according to the measured current ratio. A current-voltage slope, defined as the difference between the plateau current and the base current divided by the magnitude of the voltage step, may also be used as an indicator of the charging efficiency for controlling the charging process. Alternatively, in a current-controlled charging process, small current steps are used to probe the charging efficiency. For a current step, the induced voltage changes are measured, and a transient-plateau voltage ratio is calculated. The charging current is then adjusted according to the calculated voltage ratio.

Claims

1. A method of controllably charging a battery over a charging period, comprising the steps of:

connecting a charging voltage to the battery;

applying a plurality of separate and distinct voltage steps in the charging voltage to the battery, the plurality of voltage steps being distributed over the charging period and each having a step magnitude significantly smaller than the charging voltage applied to the battery, for each of the plurality of voltage steps;

detecting current changes induced by said each voltage step;

calculating a ratio from the detected current changes; and

varying the charging voltage according to the ratio.

2. The method of claim 1, wherein the step of varying comprises the steps of comparing the ratio to a reference level and changing the charging voltage in a voltage change direction in accordance with a result of the comparison.

3. The method of claim 2, wherein the voltage change direction is negative when the current ratio is smaller than the reference level and positive when the current ratio is greater than the reference level.

4. The method of claim 3, wherein the reference level has a fixed value.

5. The method of claim 2, further including the step of dynamically adjusting the reference level in accordance with the calculated ratio.

6. The method of claim 5, wherein the step of dynamically adjusting includes the steps of:

comparing the calculated ratio with a previously stored comparison ratio when the calculated ratio is greater than the reference level by a difference more than a preselected value;

when the calculated ratio is greater than the comparison ratio, reversing the voltage change direction;

storing the calculated ratio as the comparison ratio; and

adjusting the reference level according to the calculated ratio by weighted averaging.

7. The method of claim 2, wherein the step of detecting measures a base current immediately before said each voltage step is applied, a surge current after said each voltage step is applied, and a plateau current after the surge current, and wherein the ratio is calculated as the difference between the plateau current and the base current divided by the difference between the surge current and the base current.

8. The method as in claim 2, wherein the ratio is calculated as a current-to-voltage slope.

9. The method of claim 1, wherein at least one of the plurality of voltage steps is positive.

10. The method of claim 1, wherein at least one of the plurality of voltage steps is negative.

11. The method of claim 1, wherein the plurality of voltage steps are in the range of 0.01-0.3 volt for a 12-volt battery.

12. The method of claim 1, further comprising the step of maintaining the charging voltage below an upper limit to prevent charging the battery at a high gassing rate or damaging devices attached to the battery.

13. An apparatus for charging a battery comprising:

a variable DC power supply for providing adjustable charging voltage and charging current to the battery;

a voltage controller for controlling the charging voltage of the variable DC power supply over a charging period and for applying a plurality of separate and distinct voltage steps distributed over the charging period to the battery for probing charging efficiency, each of the voltage steps having a step magnitude significantly smaller than the charging voltage applied to the battery;

a current detector for detecting current changes in response to said each voltage step; and

an analyzer for determining a ratio from the detected current changes for said each voltage step,

the voltage controller being coupled to the analyzer for varying the charging voltage according to the ratio for said each voltage step.

14. The apparatus of claim 13, wherein the voltage controller adjusts the charging voltage of the variable DC power supply in a voltage change direction according to a comparison of the ratio to a reference level.

15. The apparatus of claim 14, wherein the voltage controller increases the charging voltage when the ratio is greater than the reference level and reduces the charging voltage when the ratio is smaller than the reference level.

16. The apparatus of claim 14, wherein the reference level is a preselected fixed value.

17. The apparatus of claim 14, wherein the analyzer dynamically adjusts the reference level according to the ratio.

18. The apparatus of claim 17, wherein the analyzer reverses the voltage change direction when the calculated ratio is greater than the reference level by more than a preselected value and when the calculated ratio is greater than a previously stored comparison ratio.

19. The apparatus of claim 13, wherein at least one of the plurality of voltage steps is positive.

20. The apparatus of claim 13, wherein at least one of the plurality of voltage steps is negative.

21. The apparatus of claim 13, wherein the plurality of voltage steps are in the range of 0.01-0.3 volt for a 12-volt battery.

22. The apparatus of claim 13, wherein the current detector measures a base current immediately before said each voltage step is applied, a surge current after said each voltage step is applied, and a plateau current after the surge current, and wherein the ratio is calculated as a difference between the plateau current and the base current divided by a difference between the surge current and the base current.

23. The apparatus of claim 13, wherein the ratio is calculated as a current-to-voltage slope.

24. A method of charging a battery, comprising the steps of:

connecting a charging current to the battery;

applying a current step in the charging current to the battery;

detecting voltage changes in response to the current step;

calculating a ratio from the detected voltage changes;

varying the charging current according to the ratio.

25. The method of claim 24, wherein the step of varying comprises the steps of comparing the ratio to a reference level and changing the charging current in a current change direction in accordance with a result of the comparison.

26. The method of claim 25, wherein the reference level has a fixed value.

27. The method of claim 25, further including the step of dynamically adjusting the reference level in accordance with the calculated ratio.

28. The method of claim 24, wherein the current step is positive.

29. The method of claim 24, wherein the direction of the current step is negative.

30. The method of claim 24, wherein the current step is set to be a sum of a predetermined portion of the charging current and a predetermined minimum step magnitude.

31. An apparatus for charging a battery comprising:

a variable DC power supply for providing adjustable charging current to the battery;

a current controller coupled to the variable DC power supply for controlling the charging current and for applying a current step to the battery to probe charging efficiency;

a voltage detector for detecting voltage changes in response to the current step; and

an analyzer for determining a ratio from the detected voltage changes,

the current controller being coupled to the analyzer for varying the charging current according to the ratio.

32. The apparatus of claim 31, wherein the current controller adjusts the charging current of the variable DC power supply in a current change direction according to a comparison of the ratio to a reference level.

33. The apparatus of claim 31, wherein the current controller sets the current step to be a sum of a predetermined portion of the charging current and a predetermined minimum step magnitude.