Adaptive battery charging

• US 7,872,450 B1
• Filed: 12/29/2004
• Issued: 01/18/2011
• Est. Priority Date: 12/29/2004
• Status: Expired due to Fees

• Current Assignee: Schneider Electric IT Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Lee, Franklin, Owens, William L., Orlando, James D., Cohen, Daniel C.
• Primary Examiner(s): Koval; Melissa J
• Assistant Examiner(s): Boateng; Alexis
• Application Number:
  US11/025,554
• Time in Patent Office: 2,211 Days
• Field of Search: 320/134, 320/149, 320/103, 320/111, 320/150, 320/137, 320/151, 320/152, 320/156, 320/157, 320/159, 320/160, 320/161, 320/162, 320/163, 320/164, 320/136, 320/135, 307/66, 307/46
• US Class Current: 320/134
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence

Abstract

A system includes an input configured to connect to a power source providing an input voltage, an output configured to connect to a load and to transfer power from the power source to the load, a battery selectively coupled to the input to receive current from the power source, a detector configured to indicate whether the input voltage drops more than a threshold amount, and a processor configured to regulate the selective coupling of the battery to the input to regulate a charging current supplied to the battery, the processor configured to regulate the selective coupling such that if a first charge current induces a drop in the input voltage beyond the threshold amount, then the processor will change the charging current to a second charge current that is lower than the first charge current.

Claims

1. A method for use in a battery charging system, the method comprising:

providing power from a power source to a load, the provided power having an input voltage;

providing current from the power source to a battery at a first level;

monitoring a voltage associated with the input voltage to determine if the input voltage drops below a threshold voltage; and

reducing the current supplied from the power source to the battery in response to detecting that the input voltage dropped below the threshold voltage such that the current supplied to the battery is provided at a second level that is below the first level.

2. The method of claim 1 further comprising:

gradually increasing the current supplied from the power source to the battery from the second level toward a desired level.

3. The method of claim 2 wherein gradually increasing the current supplied from the power source to the battery includes repeatedly reducing the desired level in response to determinations of drops in the input voltage below the threshold voltage and gradually increasing the current supplied to the battery from levels below the reduced desired levels toward a present desired level until the current supplied to the battery reaches the present desired level.

4. The method of claim 3 wherein reducing the desired level includes reducing the desired level by a predetermined amount.

5. The method of claim 3 wherein reducing the desired level includes reducing the desired level by an amount determined based on an amount of energy provided to the load.

6. The method of claim 3 further comprising:

evaluating whether a time period has elapsed from a time when the desired level is reduced; and

setting the desired level to a maximum desired level if the time period has elapsed.

7. The method of claim 2 wherein gradually increasing the current supplied from the power source to the battery includes increasing the current by predetermined amounts.

8. The method of claim 1 wherein the desired level is greater than an initial level.

21. The method of claim 3 further comprising:

increasing the desired level in response to the current supplied to the battery reaching the present desired level.

22. The method of claim 21 wherein the desired level is increased until the desired level reaches a predetermined maximum level.

9. A system comprising:

an input configured to connect to a power source providing an input voltage;

an output configured to connect to a load and to transfer power from the power source to the load;

a battery;

a connection mechanism, coupled to the input and the battery, configured to selectively couple the input to the battery to selectively provide current from the power source to the battery; and

a processor, coupled to the connection mechanism, configured to regulate the selective coupling of the battery to the input to regulate a charging current supplied to the battery such that when the charging current is at a first level and the input voltage drops below a threshold voltage level, the processor will change the charging current to a second level that is lower than the first level.

10. The system of claim 9 wherein the processor is further configured to gradually increase the charging current toward a desired level in the absence of the input voltage dropping below the threshold voltage.

11. The system of claim 9 wherein the processor is configured to limit the charging current to a predetermined highest level.

12. The system of claim 9 wherein the processor is configured to:

gradually increase the charge current to the battery from the second level to a desired level;

repeatedly reduce the desired level in response to drops in the input voltage below the threshold voltage during the gradual increasing of the charge current; and

gradually increase the charge current supplied to the battery from levels below the reduced desired level toward a present desired level until the current supplied to the battery reaches the present desired level.

13. The system of claim 12 wherein the processor is further configured to reduce the desired level by a predetermined amount.

14. The system of claim 12 wherein the processor is further configured to reduce the desired level by an amount determined based on amount of power provided to the load.

15. The system of claim 12 wherein the processor is further configured to:

evaluate whether a time period has elapsed from a time when the desired level is reduced; and

set the desired level to a maximum desired level if the time period has elapsed.

16. The system of claim 15 wherein the time period is at least as long as an expected maximum duration of a maximum current draw by the load.

17. The system of claim 9 wherein the processor is further configured to increase the charge current by predetermined increments.

18. An uninterruptible power supply (UPS) configured to couple to a power source that provides an input voltage, and to a load, the UPS comprising:

an input configured to couple to the power source;

an output configured to couple to the load; and

a battery charger coupled to the input to receive the input voltage and comprising;

a battery;

a monitor connected and capable of monitoring a voltage associated with the input voltage and capable of determining that the input voltage drops below a threshold voltage;

coupling means for selectively providing power from the power source to the load and a range of charge current amounts from the power source to the battery; and

means for directing the coupling means to reduce the current supplied from the power source to the battery in response to the monitor detecting that the input voltage drops below the threshold voltage such that the current supplied to the battery is provided at a reduced level below a first level and greater than an initial level.

19. The system of claim 18 wherein the directing means is further for directing the coupling means to increase the current from the power source to the battery from the reduced level toward a desired level in the absence of the input voltage dropping below the threshold voltage.

20. The system of claim 19 wherein the directing means is further for reducing the desired level in response to the input voltage dropping below the threshold voltage and for increasing the desired level to a maximum level in response to a time period elapsing from a time of a most recent reduction in the desired level without the input voltage dropping below the threshold voltage.

23. An adaptive battery charging system comprising:

a system input configured to couple to an external power source providing an input voltage;

a system output configured to couple the input voltage to a load;

a battery;

a connection mechanism, coupled to the system input and the battery, configured to provide charging current to the battery from the system input; and

means, coupled to the connection mechanism, for controlling the connection mechanism to increase an amount of the charging current provided to the battery as a function of input voltage while ensuring that a sufficient power is provided from the power supply to the load.

24. The system of claim 23 wherein the connection mechanism is a Pulse Width Modulated (PWM) switch.

25. The system of claim 23 wherein the control means is configured to ramp up the amount of charging current from a lower level to an upper level.

26. The system of claim 25 wherein the control means is configured to respond to the input voltage dropping below an acceptable threshold voltage by setting the upper level to a level below a present level.

27. The system of claim 26 wherein the control means, is configured to at least one of the following:

(1) set the lower level to a predetermined level;

(2) set the lower level as a function of a charging current level that induces the input voltage to drop below the threshold voltage;

(3) set the upper level as a function of a charging current level that induces the input voltage to drop below the threshold voltage.

28. The system of claim 27 wherein the control means is configured to gradually increase the current supplied from the power source to the battery from the lower level to a desired upper level in the absence of the input voltage dropping below the threshold voltage, repeatedly reduce the desired upper level in response to determinations of drops in the input voltage below the threshold voltage, and gradually increase the charging current from the lower level toward a present desired upper level until the charging current reaches the present desired upper level.

29. The system of claim 28 wherein the control means is configured to respond to the charging current reaching the present desired upper level by increasing the present desired upper level until the desired upper level reaches a predetermined maximum level.

30. The system of claim 29 wherein the control means is configured to respond to a time period elapsing from a time when the upper level is decreased by increasing the upper level.

31. The system of claim 30 wherein the control means is configured to increase the upper level to either a dynamically determined level or to a predetermined maximum level.