Method and apparatus for charging batteries with multiple output circuits

• US 7,750,600 B2
• Filed: 10/28/2008
• Issued: 07/06/2010
• Est. Priority Date: 08/10/2004
• Status: Active Grant

• Current Assignee: David A. Stanzel, Jon O. Reynolds
• Original Assignee: David A. Stanzel, Jon O. Reynolds
• Inventors: Reynolds, Jon O., Stanzel, David A.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US12/259,597
• Publication Number:
  US 20090102417A1
• Time in Patent Office: 616 Days
• Field of Search: 320/106, 320/110, 320/114, 320/138, 320/141
• US Class Current: 320/116
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/0018 using separate charge circuits
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/008 Plural converter units for generating at two or more independent and non-parallel outputs, e.g. systems with plural point of load switching regulators

Abstract

A method and apparatus for charging batteries includes using an input rectifier to receive an ac input and provide a dc signal. A converter receives the dc signal and provides a converter output. An output circuit receives the converter output and provides a battery charging signal. A controller preferably controls the converter to power factor correct. The system can include multiple output circuits, used either singly or at the same time, and designed for one or more voltages. They can be user removable. Preferably, the converter output has a magnitude independent of a range of frequencies and a range of magnitudes of the ac input, and the range can be, for example, at least a factor of two or at least two utility voltages. The controller includes a charging schedule module that receives feedback, such as voltage and/or current feedback and/or temperature feedback. The output circuit, such as a dc-dc converter, is controlled in response to the feedback in other embodiments. The battery type may be sensed or input by a user, and the charging done in response to the battery type. A defective battery sensor is preferably included, with a user-noticeable indicator.

Claims

1. A battery charging system, comprising:

an input circuit, configured to receive an input signal and to provide a first dc signal;

a plurality of user-removable output circuits, each configured to receive the first dc signal and each designed to provide a battery charging signal at a desired voltage and a desired current, wherein a chosen one of the plurality is connected at a time, wherein the desired voltage for a first one of the plurality of user-removable output circuits is different than the desired voltage for a second one of the plurality of user-removable output circuits; and

a controller, configured to provide at least one control signal to the chosen one output circuit.

2. The battery charging system of claim 1, wherein the input circuit includes a rectifier and a boost converter or a buck-boost converter, and further including an input controller that provides power factor correction.

3. The battery charging system of claim 2, wherein the first dc signal has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

4. The battery charging system of claim 1, wherein the controller includes a charging schedule module and receives at least one of a voltage feedback signal indicative of the voltage magnitude of the battery charging signal and a current feedback signal indicative of the current magnitude of the battery charging signal.

5. The battery charging system of claim 4, wherein the controller includes a battery selection input, and wherein the charging schedule module is responsive to the battery selection input.

6. The battery charging system of claim 5, wherein the battery selection input is connected to a user-selectable input.

7. The battery charging system of claim 5, wherein the battery selection input is connected to a battery sensor.

8. The battery charging system of claim 7, wherein the battery sensor includes an RFID sense circuit disposed to be sense an RFID tag on a battery being charged.

9. The battery charging system of claim 4, wherein the output circuit includes a switched converter.

10. The battery charging system of claim 4, wherein the switched converter is a pulse width or frequency modulated inverter.

11. The battery charging system of claim 4, wherein the switched converter is a pulse width or frequency modulated forward converter.

12. The battery charging system of claim 4, wherein the controller includes a defective battery sensor module that receives as an input a second at least one of the voltage feedback signal and the current feedback signal, and provides a user-noticeable output indicative of a defective battery.

13. A method of battery charging, comprising:

converting an input signal to a first dc signal; and

selecting one of a plurality of user-removable output circuits, each designed for a battery voltage, and using the selected output circuit, changing the first dc signal into a second dc signal having a current suitable for battery charging, wherein the battery voltage for a first one of the plurality of user-removable output circuits is different than the battery for a second one of the plurality of user-removable output circuits.

14. The method of claim 13, wherein converting includes boost converting and power factor correcting such that the first dc signal has a magnitude independent of a range of magnitudes of the input signal.

15. The method of claim 14, wherein the first dc signal has a substantially constant magnitude and the range of magnitudes spans a range of at least a factor of two.

16. The method of claim 13, further comprising controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal.

17. The method of claim 16, wherein the controlling a charging current is responsive to a user-selectable input.

18. The method of claim 16, wherein the controlling is responsive to sensing a battery to be charged.

19. The method of claim 18, wherein sensing includes sensing an RFID tag on the battery.

20. The method of claim 18, wherein converting includes one of buck-boost converting and boost converting.

21. The method of claim 20, wherein changing includes switching a converter.

22. The method of claim 21, further comprising monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

23. A battery charging system, comprising:

converter means for receiving an input signal and providing a converter output; and

a plurality of user-removable output means for receiving the converter output and providing a battery charging signal, wherein each output means is further for providing the battery charging at a desired voltage, wherein a selected one of the plurality is connected to the converter means at one time, wherein the desired voltage for a first one of the plurality of user-removable output means is different than the desired voltage for a second one of the plurality of user-removable output means.

24. The battery charging system of claim 23, further comprising an output control means for controlling the selected one output means, connected to the selected one output means.

25. The battery charging system of claim 24, further comprising a converter control means for controlling the converter to provide power factor correction and to provide the converter output at a desired voltage, and connected to the converter.

26. The battery charging system of claim 25, wherein the converter means includes one of a boost and a buck-boost converter, and wherein the converter output has a magnitude independent of a range of magnitudes of the input signal.

27. The battery charging system of claim 26, wherein the output control means further is for controlling a charging current in response to at least one of a voltage feedback signal and a current feedback signal.

28. The battery charging system of claim 27, wherein the output control means is responsive to a user-selectable input.

29. The battery charging system of claim 23, further comprising means for sensing a battery to be charged, and controlling the charging current in response thereto.

30. The battery charging system of claim 29 wherein the means for sensing a battery includes means for sensing an RFID tag.

31. The battery charging system of claim 29, wherein each output means includes a dc-dc converter.

32. The battery charging system of claim 29, wherein each output means includes a pulse width or frequency modulated inverter.

33. The battery charging system of claim 29, wherein output means includes a pulse width or frequency modulated forward converter.

34. The battery charging system of claim 29, further comprising means for monitoring a battery for being capable of being charged properly, and providing an indication if the battery cannot be charged properly.

35. A battery charging system, comprising:

an input circuit, configured to receive an input signal and to provide a first dc signal;

a plurality of output circuits, each configured to receive the first dc signal and each designed to provide a battery charging signal at a desired voltage and a desired current, wherein the desired voltage for a first one of the plurality of output circuits is different than the desired voltage for a second one of the plurality of output circuits, and

a controller, configured to provide at least one control signal to each of the plurality of output circuits.

36. The battery charging system of claim 35, wherein the input circuit includes a rectifier and a boost converter or a buck-boost converter, and further including an input controller that provides power factor correction.

37. The battery charging system of claim 35, wherein the controller includes a battery selection input, and wherein a charging schedule module is responsive to the battery selection input.

38. The battery charging system of claim 37, wherein the battery selection input is connected to a battery sensor.

39. The battery charging system of claim 38, wherein the battery sensor includes an RFID sense circuit disposed to be sense an RFID tag on a battery being charged.

40. A method of battery charging, comprising:

converting an input signal to a first dc signal; and

using a plurality of output circuits, each designed for a battery voltage, to change the first dc signal into a plurality of charging dc signals suitable for battery charging, wherein the battery voltage for a first one of the plurality of output circuits is different than the battery voltage for a second one of the plurality of output circuits.

41. The method of claim 40, wherein converting includes boost converting and power factor correcting such that the first dc signal has a magnitude independent of a range of magnitudes of the input signal.

42. The method of claim 41, wherein the controlling is responsive to sensing a battery to be charged.

43. The method of claim 42, wherein sensing includes sensing an RFID tag on the battery.

44. A battery charging system, comprising:

converter means for receiving an input signal and providing a converter output; and

a plurality of output means for receiving the converter output and providing a plurality of battery charging signals, wherein the battery charging signal for a first one of the plurality of output means has a first voltage that is different than a second voltage of the battery charging signal for a second one of the plurality of output means.

45. The battery charging system of claim 44, further comprising an output control means for controlling the plurality of output means, connected to each of the plurality of the output means.

46. The battery charging system of claim 45, further comprising a converter control means for controlling the converter to provide power factor correction and to provide the converter output at a desired voltage, and connected to the converter means.

47. The battery charging system of claim 44, further comprising means for sensing at least one battery to be charged, and controlling a charging current in response thereto.

48. The battery charging system of claim 47 wherein the means for sensing a battery includes means for sensing an RFID tag.