System and method for managing distribution of vehicle power in a multiple battery system

• US 8,004,242 B1
• Filed: 03/13/2009
• Issued: 08/23/2011
• Est. Priority Date: 03/13/2009
• Status: Active Grant

• Current Assignee: MCE Purkey's FE LLC
• Original Assignee: Ph Ingenuities, LLC
• Inventors: Purkey, Bruce A., Henningson, Dale B.
• Primary Examiner(s): LEDYNH, BOT L
• Application Number:
  US12/381,571
• Time in Patent Office: 893 Days
• Field of Search: 320/130, 320/132, 702/63
• US Class Current: 320/132
• CPC Class Codes: B60R 16/033 characterised by the use of electrical cells or batteries for propulsion puposes B60K1/04; supplying batteries to, or removing batteries from, vehicles B60S5/06; testing of charge state G01R31/36
• CPC Class Codes: H02J 2310/46 for ICE-powered road vehicles
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle
• CPC Class Codes: H02J 7/1423 with multiple batteries
• CPC Class Codes: H02J 7/32 for charging batteries from a charging set comprising a non-electric prime mover rotating at constant speed
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A vehicle incorporates a crank battery, a rechargeable auxiliary battery, and an onboard electrical power source separate from the crank battery and the auxiliary battery. A battery charge controller manages a supply of electrical energy to the auxiliary battery to charge the auxiliary battery. The battery charge controller includes a first comparator for monitoring a voltage level of the crank battery, and a second comparator for monitoring a voltage level of the onboard electrical power source. A first switching device electrically couples the crank battery and the auxiliary battery to charge the auxiliary battery when the voltage level of the crank battery exceeds a first voltage threshold, and electrically decouples the crank battery and the auxiliary battery when the voltage level of the crank battery is below the first voltage threshold. A second switching device electrically couples the onboard power source and the auxiliary battery to charge the auxiliary battery when: (i) the voltage level of the crank battery is below the first voltage threshold and (ii) the voltage level of the onboard power source exceeds a second voltage threshold; and electrically decouples the onboard power source and the auxiliary battery when the voltage level of the onboard power source is below the second voltage threshold.

Claims

1. In a vehicle comprising a crank battery, a rechargeable auxiliary battery, and an onboard electrical power source separate from said crank battery and said auxiliary battery, a battery charge controller for managing a supply of electrical energy to said auxiliary battery to charge said auxiliary battery, said battery charge controller comprising:

means for monitoring a voltage level of said crank battery;

means for monitoring a voltage level of said onboard electrical power source;

means for electrically coupling said crank battery and said auxiliary battery to charge said auxiliary battery when the voltage level of said crank battery exceeds a first voltage threshold, and for electrically decoupling said crank battery and said auxiliary battery when the voltage level of said crank battery is below said first voltage threshold; and

means for electrically coupling said onboard power source and said auxiliary battery to charge said auxiliary battery when;

(i) the voltage level of said crank battery is below said first voltage threshold and (ii) the voltage level of said onboard power source exceeds a second voltage threshold, and for electrically decoupling said onboard power source and said auxiliary battery when the voltage level of said onboard power source is below said second voltage threshold.

2. A battery charge controller according to claim 1, wherein said first voltage threshold is greater than 12.2 volts.

3. A battery charge controller according to claim 2, wherein said second voltage threshold is greater than 13.2 volts.

4. A battery charge controller according to claim 1, wherein said onboard electrical power source comprises an electrical system of an onboard refrigeration unit.

5. A battery charge controller according to claim 4, wherein the electrical system of said refrigeration unit comprises a battery and an alternator.

6. A battery charge controller according to claim 1, wherein said means for electrically coupling said crank battery and said auxiliary battery, and for electrically coupling said onboard power source and said auxiliary battery comprises at least one switching device.

7. A battery charge controller according to claim 6, wherein said switching device comprises a relay.

8. A battery charge controller according to claim 1, wherein said means for monitoring a voltage level of said crank battery, and for monitoring a voltage level of said onboard electrical power source comprises a microprocessor-based control module.

9. A battery charge controller according to claim 1, wherein said rechargeable auxiliary battery is electrically connected to a vehicle liftgate.

10. In a heavy duty vehicle comprising a tractor/trailer combination, a vehicle power line electrically interconnecting said tractor and said trailer, a crank battery carried by said tractor and electrically connected to said vehicle power line, a rechargeable auxiliary battery carried by said trailer, a voltage converter carried by said trailer and electrically connected to said auxiliary battery, and an onboard electrical power source carried by said trailer and separate from said crank battery, said auxiliary battery, and said voltage converter, a charge controller for managing a supply of electrical energy to said voltage converter to charge said auxiliary battery, said charge controller comprising:

means for monitoring a voltage level of said crank battery;

means for monitoring a voltage level of said onboard electrical power source;

means for electrically coupling said crank battery and said voltage converter to charge said auxiliary battery when the voltage level of said crank battery exceeds a first voltage threshold, and for electrically decoupling said crank battery and said voltage converter when the voltage level of said crank battery is below said first voltage threshold; and

means for electrically coupling said onboard power source and said voltage converter to charge said auxiliary battery when;

(i) the voltage level of said crank battery is below said first voltage threshold and (ii) the voltage level of said onboard power source exceeds a second voltage threshold, and for electrically decoupling said onboard power source and said voltage converter when the voltage level of said onboard power source is below said second voltage threshold.

11. A battery charge controller according to claim 10, wherein said vehicle power line comprises a plurality of electrical conductors, and a multi-pin connector interconnecting conductors of said tractor and said trailer.

12. A battery charge controller according to claim 11, wherein said connector comprises a SAE J560 seven-pin connector.

13. A battery charge controller according to claim 10, wherein said first voltage threshold is greater than 12.2 volts.

14. A battery charge controller according to claim 13, second voltage threshold is greater than 13.2 volts.

15. A battery charge controller according to claim 10, wherein said onboard electrical power source comprises an electrical system of an onboard refrigeration unit.

16. A battery charge controller according to claim 15, wherein the electrical system of said refrigeration unit comprises a battery and an alternator.

17. A battery charge controller according to claim 10, wherein said means for electrical coupling said crank battery and said voltage converter, and for electrically coupling said onboard power source and said voltage converter comprises at least one switching device.

18. A battery charge controller according to claim 17, wherein said switching device comprises a relay.

19. A battery charge controller according to claim 10, wherein said means for monitoring a voltage level of said crank battery, and for monitoring a voltage level of said onboard electrical power source comprises a microprocessor-based control module.

20. A battery charge controller according to claim 10, wherein said rechargeable auxiliary battery is electrically connect to a vehicle liftgate.