Low power indication circuit for lead acid battery pack

• US 6,313,611 B1
• Filed: 05/24/2000
• Issued: 11/06/2001
• Est. Priority Date: 06/04/1999
• Status: Expired due to Term

• Current Assignee: Snap-On Technologies Incorporated (Snap-On Incorporated)
• Original Assignee: Snap-On Technologies Incorporated (Snap-On Incorporated)
• Inventors: Becker, Thomas P., Mowry, Michael R.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): TOATLEY, GREGORY J
• Application Number:
  US09/578,536
• Time in Patent Office: 531 Days
• Field of Search: 320/132, 320/134, 320/136, 320/162
• US Class Current: 320/136
• CPC Class Codes: G01R 19/16542 for batteries charge condition monitoring in G01R31/36
• CPC Class Codes: G01R 31/379 for lead-acid batteries
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A lead-acid battery pack has an electronically-controlled power switch connected in series with the battery. A voltage monitor/controller is connected in series with a normally-open ON/OFF switch across the battery, the controller controlling a ramped pulse width modulator which provides a switch control signal to the power switch. The controller is program controlled so that, a fraction of a second after the ON/OFF switch is closed, the modulator will provide a constant DC level control signal to the power switch to hold it closed. If the battery voltage drops below a first level for several seconds, the modulator will produce a PWM switch control signal of gradually decreasing pulse width and duty cycle until the power switch is permanently open. This gradual decrease of power delivered from the battery will occur immediately upon the battery voltage dropping below a second level lower than the first level.

Claims

1. A battery pack comprising:

a battery having at least one cell having a positive terminal and a negative terminal,

an electronically controlled power switch coupled in series with the battery and having a control input for controlling operation of the switch between a full power delivery condition and a zero power delivery condition, and

a control circuit connected across the battery and having an output coupled to the control input of the power switch and generating at the output a switch control signal,

the control circuit including a processor and a normally-open selective ON/OFF switch connected in series across the battery, the processor operating under control of a stored program for monitoring battery voltage and for shifting the switch control signal from a normal state, which holds the power switch in its full power delivery condition, to a modulated state, which gradually shifts the power switch from its full power delivery condition to its zero power delivery condition,

the program including a routine which delays monitoring of the battery voltage for a predetermined time period after closure of the ON/OFF switch.

2. The battery pack of claim 1, wherein the battery includes plural cells connected in series.

3. The battery pack of claim 1, wherein the battery is a lead-acid battery.

4. The battery pack of claim 1, wherein the processor is a microcontroller.

5. The battery pack of claim 4, wherein the predetermined routine delays generation of the switch control signal for the predetermined time period after closure of the ON/OFF switch.

6. The battery pack of claim 5, wherein the predetermined time period is less than one second.

7. The battery pack of claim 1, wherein the switch control signal in its modulated state is a pulsating signal.

8. The battery pack of claim 7, wherein the control circuit includes a ramped pulse width modulator connected between the processor and the power switch and generating the switch control signal so that, in its normal state, the switch control signal is a constant predetermined DC voltage level and, in its modulated state, is a pulse-width modulated signal of gradually decreasing pulse width and pulse duty cycle.

9. A battery pack comprising:

a positive terminal and a negative terminal,

a battery having at least one cell and coupled to the positive and negative terminals,

a control circuit connected to the battery and to the positive and negative terminals and monitoring battery voltage level,

the control circuit including a processor operating under control of a stored program for controlling power flow from the battery to the terminals between a full power delivery condition and a zero power delivery condition,

the program including a routine for controlling shifting from the full power delivery condition to the zero power delivery condition when battery voltage drops below a predetermined level and remains below that level for a predetermined time period.

10. The battery pack of claim 9, wherein the battery includes plural cells connected in series.

11. The battery pack of claim 9, wherein the battery is a lead-acid battery.

12. The battery pack of claim 9, wherein the predetermined time period is a first time period, the control circuit including a normally-open ON/OFF switch connected in series with the processor across the battery, the program routine including a portion delaying monitoring of battery voltage for a predetermined second time period after closure of the ON/OFF switch.

13. The battery pack of claim 12, wherein the first time period is several seconds and the second time period is less than one second.

14. The battery pack of claim 9, wherein the predetermined level is a first level, the program routine including a portion for controlling shifting from the full power delivery condition to the zero power delivery condition immediately upon the battery voltage dropping below a predetermined second level lower than the first level.

15. The battery pack of claim 9, wherein the control circuit includes means for shifting gradually from the full-power delivery condition to the zero power delivery condition.

16. The battery pack of claim 15, and further comprising an electronically-controlled power switch coupled in series between the battery and the positive terminal and having a control input for controlling operation of the switch between the full power delivery condition and the zero power delivery condition, the control circuit including a ramped pulse width modulator connected between the processor and the control input of the power switch and degenerating a switch control signal, the switch control signal being a constant predetermined DC voltage level in the full power delivery condition and, in the zero power delivery condition, being a pulse-width-modulated signal of gradually decreasing pulse width and pulse duty cycle.

17. A method of indicating that a lead-acid battery is in need of recharge, comprising:

connecting the battery to a load,

then waiting a predetermined time period and then monitoring battery voltage while the battery is connected to a load, and

gradually reducing power delivered from the battery to the load when the battery voltage is below a predetermined level as an indication to the user of low battery charge state.

18. The method of claim 17, wherein the predetermined level is a first level, the gradual reduction of power beginning only after the battery voltage has been at the first level for a predetermined time period, and further comprising immediately beginning gradual reduction of power delivery upon the battery voltage reaching a second predetermined level lower than the first level.

19. The method of claim 17, wherein the gradual reduction of power is accomplished by pulse-width-modulation of the power.