Battery charger capable of evaluating battery charge state

• US 6,160,376 A
• Filed: 12/06/1999
• Issued: 12/12/2000
• Est. Priority Date: 06/22/1998
• Status: Expired due to Term

• Current Assignee: Stryker Corporation
• Original Assignee: Stryker Corporation
• Inventors: Kumar, Yashdeep, Malackowski, Donald
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US09/455,091
• Time in Patent Office: 372 Days
• Field of Search: 320/116, 320/119, 320/134, 320/150, 320/152, 320/160, 320/162
• US Class Current: 320/116
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H02J 2310/22 The load being a portable electronic device
• CPC Class Codes: H02J 2310/23 The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery charger (20) for charging batteries that evaluates the post-charge state of the batteries. A load resistor (70) and a temperature sensor (286) are associated with each battery. After the charging of the battery, a processor (124) receives signals indicating the voltage-at-load of the battery when it is connected to the load resistor and the battery temperature. A memory (282) internal to the battery stores historical voltage-at-load data for the battery. The processor based, the voltage-at-load, the battery temperature and the historical voltage-at-load data for the battery determines an average voltage-at-load for the battery. Based on the average voltage-at-load and data specific to that battery, the processor determines the charge state of the battery. Data representative of the charge state is presented on a display (30) integral with the charger. Data useful for determining both the average voltage-at-load and the charge state for the battery are found in a memory (70) in a module that is removably attached to the charger or in the battery memory (282).

Claims

1. A method for evaluating the quantity of energy stored in a charged battery, said method comprising the steps of:

tieing opposed terminals of the battery across a load resistor and measuring the voltage across the load resistor to produce a measured voltage-at-load of the battery;

measuring the temperature of the battery;

determining a temperature coefficient based on the temperature of the battery and a first set of reference data;

determining an adjusted voltage-at-load based on the measured voltage-at-load and the temperature coefficient; and

determining the stored energy in the battery based on the adjusted voltage-at-load and a second set of reference data.

2. The method for evaluating the stored energy of a battery of claim 1, wherein, after said step of determining the adjusted voltage-at-load, data representative of the adjusted voltage-at-load is stored in a memory integral with the battery as historical voltage-at-load data.

3. The method for evaluating the stored energy of a battery of claim 2, wherein:

the historical voltage-at-load data in the battery memory are read;

after said determination of the adjusted voltage-at-load, an average voltage-at-load value is calculated based on the adjusted voltage-at-load and the historical voltage-at-load data; and

said determination of stored energy is performed based on the average voltage-at-load and the second set of reference data.

4. The method for evaluating the stored energy of a battery of claim 1, further including the steps of:

calculating a battery utility rating based on the determined stored energy and a fixed energy value; and

presenting an indication of the battery utility rating on a display.

5. The method for evaluating the stored energy of a battery of claim 4, wherein the fixed energy value is a measure of the energy a new battery can store.

6. The method for evaluating the stored energy of a battery of claim 1, wherein said step of measuring the temperature of the battery is performed by monitoring the signal from a temperature sensor that is located inside the battery.

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

applying a charging current to the battery;

after said step of applying the charging current to the battery is completed, connecting opposed terminals of the battery across a load resistor;

measuring the voltage across the load resistor to produce a measured voltage-at-load for the battery;

determining the temperature of the battery;

determining the stored energy in the battery based on the measured voltage-at-load and the temperature of the battery; and

displaying an indication of the stored energy in the battery.

8. The method of charging a battery of claim 7, wherein said step of determining the stored energy in the battery is performed by:

determining an adjusted voltage-at-load for the battery based on the measured voltage-at-load and the temperature of the battery; and

determining the stored energy in the battery based on the adjusted voltage-at-load.

9. The method of charging a battery of claim 8, wherein:

said step of applying a charging current to the battery is performed by a current source located within a battery charger;

the battery charger includes a processor for performing said step of determining the adjusted voltage-at-load for the battery and said step of determining the stored energy in the battery;

said step of determining the adjusted voltage-at-load for the battery is performed based on a first set of reference data that is stored in a portable memory that is removably attached to the battery charger, wherein, when the portable memory is attached to the battery charger, the processor reads the data in the portable memory; and

said step of determining the stored energy in the battery is performed based on a second set of reference data that is stored in the portable memory and that is read by the processor.

10. The method of charging a battery of claim 7, wherein:

said step of applying a charging current to the battery is performed by a current source located within a battery charger;

the battery charger includes a processor for performing said step of determining the stored energy of the battery; and

said step of determining the stored energy in the battery is performed by the processor based on reference data that is stored in a portable memory that is removably attached to the battery charger, wherein, after the portable memory is attached to the battery charger, the processor reads the reference data from the portable memory.

11. The method of charging a battery of claim 10, wherein:

prior to said step of applying charging current to the battery, the battery is placed in a module that is removably attached to the battery charger; and

the portable memory in which the reference data are stored is attached to the module and the processor reads the reference data from the portable memory after the module is attached to the battery charger.

12. The method of charging a battery of claim 10, wherein, the portable memory in which the reference data are stored is mounted in the battery and, after the battery is coupled to the battery charger, the processor reads the reference data from the portable memory.

13. The method of charging a battery of claim 7, wherein:

after said step of measuring the voltage-at-load for the battery is performed, an adjusted voltage-at-load is calculated based on the measured voltage-at-load and the temperature of the battery;

data representative of the adjusted voltage-at-load is stored in a memory integral with the battery as historical voltage-at-load data;

after a subsequent charging of the battery, after said step of calculating the adjusted voltage-at-load is executed, an average voltage-at-load is calculated based on the adjusted voltage-at-load and the historical voltage-at-load data; and

said step of determining the stored energy in the battery is performed based on the calculated average voltage-at-load.

14. The method of charging a battery of claim 7, wherein:

after said step of determining the stored energy in the battery is executed, battery utility is calculated based on the determined stored energy and a fixed energy value; and

in said step of displaying an indication of the stored energy in the battery, the calculated battery utility is displayed.

15. A charger for providing energization current to a battery, said charger having:

a base unit having a display;

a current source disposed in said base unit configured to be connected to the battery for supplying a charging current to the battery;

a load resistor and a switch, said switch being connected to the battery and said load resistor for selectively connecting the battery across said load resistor; and

a processor unit disposed in said base unit, said processor unit being connected to;

said current source for regulating the application of current by said current source to the battery;

said switch for selectively actuating said switch to selectively tie the battery across said load resistor;

a temperature sensor associated with the battery;

said load resistor for receiving a signal representative of the voltage across the load resistor; and

to said display, and

said processor unit;

actuates said switch to tie the battery across said load resistor;

receives from the load resistor a signal representative of the voltage across the load resistor;

receives from the temperature sensor a signal representative of the temperature of the battery;

determines the stored energy of the battery based on the voltage across said load resistor and the temperature of the battery; and

causes said display to present an indication of the stored energy of the battery.

16. The battery charger of claim 15, wherein, said processor unit:

calculates an adjusted voltage-at-load for the battery based on the voltage across the load resistor and the temperature of the battery; and

determines the stored energy of the battery based on the adjusted-voltage-at-load of the battery.

17. The battery charger of claim 16, wherein:

said base unit further includes a connector for releasably receiving a memory that is associated with the battery;

said processor unit is connected to the battery memory through said connector for reading data from the memory and is further configured to calculate the adjusted voltage-at-load for the battery based on data read from the memory and to determine the stored energy of the battery based on data read from the memory.

18. The battery charger of claim 16, wherein:

said base unit further includes a connector for releasably receiving a memory that is integral with the battery;

said processor unit is connected to the battery memory through said connector for writing data into and reading data from the memory and is further configured to;

write into the battery memory data representative of the adjusted voltage-at-load for the battery as historical voltage-at-load data;

read from the battery the historical voltage-at-load data;

calculate an average voltage-at-load for the battery based on an immediately preceding adjusted voltage-at-load determined for the battery and the historical voltage-at-load data; and

determine the stored energy of the battery based on the average voltage-at-load.

19. The battery charger of claim 15, wherein:

said base unit is formed with an opening for releasably receiving a module, said module having a socket for receiving the battery and conductors through which current from said current source is applied to the battery;

a memory is attached to said module, said memory containing reference data; and

said processor unit is connected to said module memory for reading the reference data and is configured to determine the stored energy of the battery based on the voltage across said load resistor, the temperature of the battery and the reference data read from said module memory.

20. The battery charger of claim 19, wherein said load resistor is secured to said module.

21. A charger for charging a rechargeable battery, said charger including:

a base unit, said base unit having a socket for receiving the battery;

a current source disposed in said base unit for applying a charging current to the battery; and

a processor disposed in said base unit, said processor being connected to;

said current source;

a load resistor and a switch that selectively connects the battery across the load resistor;

a temperature sensor that monitors the temperature of the battery; and

a memory that is removably attached to said base unit,

said memory storing reference data, and said processor;

reads the reference data in the memory;

controls said current source to regulate the charging of the battery by said current source;

selectively actuates the switch to selectively tie the battery across the load resistor;

determines from the load resistor a measured voltage-at-load for the battery;

determines an adjusted voltage-at-load for the battery based on the measured voltage-at-load, the temperature of the battery as indicated by the temperature sensor and the reference data read from the memory; and

determines the stored energy of the battery based on the adjusted voltage-at-load for the battery and the reference data read from the memory.

22. The charger of claim 21, wherein the socket is part of a module that is removably attached to said base unit and said memory in which the reference data are stored is attached to said module.

23. The charger of claim 21, wherein the socket is part of a module that is removably attached to said base unit and said load resistor is attached to said module.

24. The charger of claim 21, wherein:

a memory is integrally associated with the battery; and

said processor is configured to write data to and read data from the battery memory and said processor determines the stored energy of the battery by;

writing into the battery memory data representative of the adjusted voltage-at-load for the battery as historical voltage-at-load data;

after an adjusted-voltage-at-load determination is made, calculating an average voltage-at-load for the battery based on the adjusted voltage-at-load and historical voltage-at-load data read from the battery memory; and

determining the stored energy of the battery based on the average voltage-at-load and the reference data.

25. The charger of claim 24, wherein the reference data are stored in the battery memory and said processor is configured to read the reference data from the battery memory.

26. The charger of claim 21, wherein the battery has a memory integrally associated with the battery, the reference data are stored in the battery memory and said processor is configured to read the reference data from the battery memory.

27. A module for use with a battery charger, said module including:

a shell defining a socket for receiving a battery;

a securement mechanism attached to said shell, said securement mechanism configured to releasably fit said shell to the battery charger;

a plurality of conductive members attached to said shell for establishing a conductive path between the battery charger and the battery over which a charging current is applied to the battery; and

over which the voltage across the battery can be measured; and

a memory unit secured to said shell;

said memory unit storing reference data readable by the battery charger from which, for a given voltage-at-load of the battery, and a given temperature the stored energy of the battery can be determined.

28. The module of claim 27, wherein the reference data in the memory unit provides information includes:

a first set of data from which, for a given battery temperature and a given measured voltage-at-load, an adjusted voltage-at-load can be determined; and

a second set of data from which, from the adjusted voltage-at-load, the stored energy of the battery can be determined.

29. The module of claim 27, further including a load resistor in said shell and a switch in said shell for selectively connecting the battery across said load resistor.

30. A rechargeable battery pack comprising:

a housing;

at least one rechargeable cell disposed in said housing;

a first set of terminals attached to said housing that are attached to said at least one rechargeable cell, wherein energy is applied to said at least one rechargeable cell through said first set of terminals and current is drawn from said at least one rechargeable cell through said first set of terminals;

a temperature sensor disposed in said housing from providing a signal representative of the temperature of said battery;

a memory disposed in said housing, said memory containing reference data readable by a processor from which, for a given voltage-at-load of said at least one rechargeable cell and for a given battery temperature, the energy stored in said at least one rechargeable cell can be determined; and

a second set of terminals attached to said housing and connected to said memory wherein the reference data in the memory are read through said second set of terminals.

31. The battery of claim 30, wherein, the reference data in said memory includes:

a first set of data from which, for a given battery temperature and measured voltage-at-load, an adjusted voltage-at-load can be determined; and

a second set of data from which, for the adjusted voltage-at-load, the stored energy of the battery can be determined.

32. The battery of claim 30, wherein said battery further includes a data field in which data indicting the number of times the battery has been charged are stored.

33. The battery of claim 30, wherein said battery further includes a plurality of data storage fields in which data representative of the energy stored in the battery after charging are stored.

34. The battery of claim 30, wherein one of said first data terminals functions as a ground terminal for signals exchanged over said second set of data terminals.