Charging of batteries

• US 6,154,011 A
• Filed: 05/10/1999
• Issued: 11/28/2000
• Est. Priority Date: 09/15/1997
• Status: Expired due to Term

• Current Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education)
• Original Assignee: Commonwealth Scientific & Industrial Research Organisation (Commonwealth Of Australia As Represented By Department Of Industry, Innovation, Climate Change, Science, Research And Tertiary Education), International Lead Zinc Research Organisation Inc.
• Inventors: Lam, Lan T, Wilson, Nicholas C, Phyland, Christopher G
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): TIBBITS, PIA FLORENCE
• Application Number:
  US09/307,755
• Time in Patent Office: 568 Days
• Field of Search: 320/139, 320/141, 320/147, 320/155, 320/DIG. 17
• US Class Current: 320/139
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

A method and apparatus for fast charging of batteries such as lead acid batteries is provided. A repeatedly pulsed current is applied to the battery to enable a determined resistance free maximum pulsed voltage to be reached where the determined resistance free maximum pulsed voltage is below that at which unacceptable gassing will occur. The determined resistance free maximum pulsed voltage is above that of a known average resistance free pulsed voltage for the battery type. When the determined maximum pulsed voltage is reached the pulsed current is continued to be applied to maintain the resistance free maximum pulsed voltage at approximately the determined resistance free maximum pulsed voltage by at least one of: (I) reducing the amplitude of the pulsed charging current, (II) increasing the OFF-time of pulses of the pulsed charging current, (III) decreasing the ON-time of pulses of the pulsed charging current, (IV) a combination of any two or more of (I), (II) or (III). In addition, the present invention may employ a combination of stages to charge the battery. Alternatively or in combination, the system may use a repeatedly pulsed charging current or a repeatedly pulsed charge voltage to control and adjust the charging of the battery.

Claims

1. A method for charging a battery comprising:

determining a resistance free maximum pulsed voltage as the battery is being charged above that of a known average resistance free pulsed voltage for the battery type, said determined resistance free maximum pulsed voltage being below that at which unacceptable gassing will occur,

providing a repeatedly pulsed charging current to the battery sufficient to cause the determined resistance free maximum pulsed voltage to be reached over time,

monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the determined resistance free maximum pulsed voltage,

continuing charging with the repeatedly pulsed charging current to maintain the resistance free maximum pulsed voltage at approximately the determined resistance free maximum pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

2. A method as claimed in claim 1 and further comprising:

determining the known average resistance free pulsed voltage for the battery type,

monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches the determined known average resistance free pulsed voltage,

continuing charging with the repeatedly pulsed charging current to maintain the average resistance free pulsed voltage at approximately the determined known average resistance free pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the Pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

3. A method as claimed in claim 1 further comprising terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a predetermined level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed second stage charging current of a larger amplitude than in the first stage and of a shorter ON-time than the pulsed charging current ON-time in the first stage of charging,

said second stage comprising:

determining a new average resistance free pulsed voltage above that in the first stage, said new average resistance free pulsed voltage resulting in controlled gassing sufficient to establish balance between cells in the battery,

monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches the determined new average resistance free pulsed voltage,

continuing charging with the repeatedly pulsed second stage charging current to maintain the average resistance free pulsed voltage at approximately the determined new average resistance free pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

4. A method as claimed in claim 2, further comprising terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a predetermined level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed second stage charging current of a larger amplitude than in the first stage and of a shorter ON-time than the pulsed charging current ON-time in the first stage of charging:

determining a new resistance free maximum pulsed voltage above that in the first stage, said new resistance free maximum pulsed voltage resulting in controlled gassing sufficient to establish balance between cells in the battery,

monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the determined new resistance free maximum pulsed voltage,

continuing charging with the repeatedly pulsed second stage charging current to maintain the resistance free maximum pulsed voltage at approximately the determined new resistance free maximum pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

5. A method as claimed in claim 2 further comprising:

terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and then

charging at a second stage of charging by applying a repeatedly pulsed charging voltage to maintain the average pulsed charging current above the level where the time taken to provide further appreciable charge is unacceptable by at least one of;

I) increasing the ON-time of pulses of the repeatedly pulsed charging voltage, and

II) decreasing the OFF-time of pulses of the repeatedly pulsed charging voltage,

said repeatedly pulsed charging voltage in said second stage resulting in controlled gassing sufficient to establish balance between cells in the battery.

6. A method as claimed in claim 5 further comprising:

at the end of an ON pulse in the repeatedly pulsed charging voltage in the second stage, momentarily drawing current from the battery before commencement of the next ON pulse.

7. A method as claimed in claim 6 wherein the repeatedly pulsed charging current is that of a square wave.

8. A method as claimed in claim 6 wherein the repeatedly pulsed charging voltage is that of a square wave.

9. A method as claimed in claim 2 further comprising terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a predetermined level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed second stage charging current of a larger amplitude than in the first stage and of a shorter ON-time than the pulsed charging current ON-time in the first stage of charging,

said second stage comprising:

determining a new average resistance free pulsed voltage above that in the first stage, said new average resistance free pulsed voltage resulting in controlled gassing sufficient to establish balance between cells in the battery,

monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches the determined new average resistance free pulsed voltage,

continuing charging with the repeatedly pulsed second stage charging current to maintain the average resistance free pulsed voltage at approximately the determined new average resistance free pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

10. A method as claimed in claim 9, further comprising terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a predetermined level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed second stage charging current of a larger amplitude than in the first stage and of a shorter ON-time than the pulsed charging current ON-time in the first stage of charging:

determining a new resistance free maximum pulsed voltage above that in the first stage, said new resistance free maximum pulsed voltage resulting in controlled gassing sufficient to establish balance between cells in the battery,

monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the determined new resistance free maximum pulsed voltage,

continuing charging with the repeatedly pulsed second stage charging current to maintain the resistance free maximum pulsed voltage at approximately the determined new resistance free maximum pulsed voltage by at least one of

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

11. A method as claimed in claim 1, further comprising terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a predetermined level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed second stage charging current of a larger amplitude than in the first stage and of a shorter ON-time than the pulsed charging current ON-time in the first stage of charging:

determining a new resistance free maximum pulsed voltage above that in the first stage, said new resistance free maximum pulsed voltage resulting in controlled gassing sufficient to establish balance between cells in the battery,

monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the determined new resistance free maximum pulsed voltage,

continuing charging with the repeatedly pulsed second stage charging current to maintain the resistance free maximum pulsed voltage at approximately the determined new resistance free maximum pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

12. A method as claimed in claim 1 further comprising:

terminating the repeatedly pulsed charging current when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and then charging at a second stage of charging by applying a repeatedly pulsed charging voltage to maintain the average pulsed charging current above the level where the time taken to provide further appreciable charge is unacceptable by at least one of;

I) increasing the ON-time of pulses of the repeatedly pulsed charging voltage, and

II) decreasing the OFF-time of pulses of the repeatedly pulsed charging voltage,

said repeatedly pulsed charging voltage in said second stage resulting in controlled gassing sufficient to establish balance between cells in the battery.

13. A method as claimed in claim 12 further comprising:

at the end of an ON pulse in the repeatedly pulsed charging voltage in the second stage, momentarily drawing current from the battery before commencement of the next ON pulse.

14. A method as claimed in claim 13 wherein the repeatedly pulsed charging current is that of a square wave.

15. A method as claimed in claim 13 wherein the repeatedly pulsed charging voltage is that of a square wave.

16. Apparatus for charging a battery comprising:

a repeatedly pulsed current providing means for providing a determined resistance free maximum pulsed voltage to the battery that is determined as the battery is being charged and that is above that of a known average resistance free pulsed voltage for the battery type, said resistance free maximum pulsed voltage being below that at which unacceptable gassing will occur,

monitoring means for monitoring the resistance free pulsed voltage to detect when the resistance free pulsed voltage reaches the determined resistance free maximum pulsed voltage,

controlling means connected with the monitoring means for controlling the repeatedly pulsed charging current following the determined maximum pulsed voltage being reached to approximately maintain the resistance free maximum pulsed voltage at the determined resistance free maximum pulsed voltage by at least one of;

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

17. Apparatus as claimed in claim 16 wherein said monitoring means is also for monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches a known average resistance free pulsed voltage for the battery type, and

wherein said controlling means is also for controlling the repeatedly pulsed charging current following the known average resistance free pulsed voltage being reached, to approximately maintain the average resistance free pulsed voltage at the known average resistance free pulsed voltage by at least one of:

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

18. Apparatus as claimed in claim 17 including average pulsed charging current monitoring means for monitoring the average pulsed charging current in a first stage of charging to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging at a second stage of charging by causing the controlling means to then provide a new repeatedly pulsed charging current of a shorter ON-time than the repeatedly pulsed charging current ON-time in the first stage,

said repeatedly pulsed current providing means then providing a new average resistance free pulsed voltage above that in the first stage which will result in controlled gassing to establish balance between cells in the battery,

said monitoring means then monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches the new average resistance free pulsed voltage,

said controlling means then controlling the new repeatedly pulsed charging current to approximately maintain the average resistance free pulsed voltage at the new average resistance free pulsed voltage by at least one of

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

19. Apparatus as claimed in claim 18 including processing means interconnected with said repeatedly pulsed current providing means, said monitoring means and said controlling means, said processing means being under control of a program for charging operation.

20. Apparatus as claimed in claim 17 including average pulsed charging current monitoring means for monitoring the average pulsed charging current in a first stage of charging to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging at a second stage of charging by causing the controlling means to then provide a new repeatedly pulsed charging current of a shorter ON-time than the repeatedly pulsed charging current ON-time in the first stage,

said repeatedly pulsed current providing means then providing a new resistance free maximum pulsed voltage above that in the first stage which will result in controlled gassing to establish balance between cells in the battery,

said monitoring means then monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the new resistance free maximum pulsed voltage,

said controlling means then controlling the new repeatedly pulsed charging current following the new resistance free maximum pulsed voltage being reached to approximately maintain the resistance free maximum pulsed voltage at the new resistance free maximum pulsed voltage by at least one of:

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

21. Apparatus as claimed in claim 17 including charging terminating means controlled by timing means to terminate charging after a predetermined time period after commencement of the second stage of charging.

22. Apparatus as claimed in claim 16 including average pulsed charging current monitoring means for monitoring the average pulsed charging current in a first stage of charging to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging at a second stage of charging by causing the controlling means to then provide a new repeatedly pulsed charging current of a shorter ON-time than the repeatedly pulsed charging current ON-time in the first stage,

said repeatedly pulsed current providing means then providing a new average resistance free pulsed voltage above that in the first stage which will result in controlled gassing to establish balance between cells in the battery,

said monitoring means then monitoring the average resistance free pulsed voltage to detect when the average resistance free pulsed voltage reaches the new average resistance free pulsed voltage,

said controlling means then controlling the new repeatedly pulsed charging current to approximately maintain the average resistance free pulsed voltage at the new average resistance free pulsed voltage by at least one of

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the 5 pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

23. Apparatus as claimed in claim 22 including average pulsed charging current monitoring means for monitoring the average pulsed charging current in a first stage of charging to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging at a second stage of charging by causing the controlling means to then provide a new repeatedly pulsed charging current of a shorter ON-time than the repeatedly pulsed charging current ON-time in the first stage,

said repeatedly pulsed current providing means then providing a new resistance free maximum pulsed voltage above that in the first stage which will result in controlled gassing to establish balance between cells in the battery,

said monitoring means then monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the new resistance free maximum pulsed voltage,

said controlling means then controlling the new repeatedly pulsed charging current following the new resistance free maximum pulsed voltage being reached to approximately maintain the resistance free maximum pulsed voltage at the new resistance free maximum pulsed voltage by at least one of:

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

24. Apparatus as claimed in claim 22 wherein said average pulsed charging current monitoring means monitors the average pulsed charging current to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging in a second stage of charging to maintain the average pulsed charging current at approximately the level where the time taken to provide further appreciable charge is unacceptable by applying a repeatedly pulsed charging voltage from a voltage providing means by at least one of:

I) increasing the ON-time of the pulses of the 5 repeatedly pulsed charging voltage, and

II) decreasing the OFF-time of the pulses of the repeatedly pulsed charging voltage,

said repeatedly pulsed charging voltage in said second stage resulting in controlling gassing sufficient to establish balance between cells in the battery.

25. Apparatus as claimed in claim 24 wherein said repeatedly pulsed current providing means provides a repeatedly pulsed square wave current.

26. Apparatus as claimed in claim 25 having battery internal resistance calculating means for calculating the internal resistance of the battery and for providing the calculated internal resistance to said monitoring means so the resistance free maximum pulsed voltage can be determined, using the internal resistance derived from said square wave current.

27. Apparatus as claimed in claim 25 having battery internal resistance calculating means for calculating the internal resistance of the battery and for providing the calculated internal resistance to said monitoring means so the average resistance free voltage can be determined from said square wave current.

28. Apparatus as claimed in claim 24 wherein said voltage providing means for providing repeatedly pulsed charging voltage in the second stage of charging is a square wave voltage providing means.

29. Apparatus as claimed in claim 28 having battery internal resistance calculating means for calculating the internal resistance of the battery and for providing the calculated internal resistance to said monitoring means so that the new resistance free maximum pulsed voltage in the second stage of charging can be derived from said square wave voltage.

30. Apparatus as claimed in claim 28 having battery internal resistance calculating means for calculating the internal resistance of the battery and for providing the calculated internal resistance to said monitoring means so that the new average resistance free pulsed voltage in the second stage can be determined from said square wave voltage.

31. Apparatus as claimed in claim 24 wherein current drawing means is provided for momentarily drawing current from the battery during the second stage at the end of an ON pulse and before commencement of the next ON pulse.

32. Apparatus as claimed in claim 22 including charging terminating means controlled by timing means to terminate charging after a predetermined time period after commencement of the second stage of charging.

33. Apparatus as claimed in claim 16 including average pulsed charging current monitoring means for monitoring the average pulsed charging current in a first stage of charging to detect when the average pulsed charging current falls to a level where the time taken to provide further appreciable charge is unacceptable and for then charging at a second stage of charging by causing the controlling means to then provide a new repeatedly pulsed charging current of a shorter ON-time than the repeatedly pulsed charging current ON-time in the first stage,

said repeatedly pulsed current providing means then providing a new resistance free maximum pulsed voltage above that in the first stage which will result in controlled gassing to establish balance between cells in the battery,

said monitoring means then monitoring the resistance free maximum pulsed voltage to detect when the resistance free maximum pulsed voltage reaches the new resistance free maximum pulsed voltage,

said controlling means then controlling the new repeatedly pulsed charging current following the new resistance free maximum pulsed voltage being reached to approximately maintain the resistance free maximum pulsed voltage at the new resistance free maximum pulsed voltage by at least one of:

(I) reducing the amplitude of the pulsed charging current,

(II) increasing the OFF-time of pulses of the pulsed charging current, and

(III) decreasing the ON-time of pulses of the pulsed charging current.

34. Apparatus as claimed in claim 16 including charging terminating means controlled by timing means to terminate charging after a predetermined time period after commencement of the second stage of charging.