Method for stepping current output by a battery charger

• US 8,044,640 B2
• Filed: 10/07/2008
• Issued: 10/25/2011
• Est. Priority Date: 10/07/2008
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Wohltmann, Brian K., Cruise, Nathan
• Primary Examiner(s): Nguyen; Vinh
• Application Number:
  US12/246,890
• Publication Number:
  US 20100085021A1
• Time in Patent Office: 1,113 Days
• Field of Search: None
• US Class Current: 320/162
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter

Abstract

A battery charger is provided for implementing a charging method having a stepped output current. The battery charger includes: a power supply circuit that receives an AC input signal and outputs a DC output signal. The power supply circuit includes a power supply controller configured to receive a feedback signal indicative of current being output by the power supply circuit via an amplifier and operates to control current output by the power supply circuit in accordance with the feedback signal. A charger controller is interfaced with the power supply controller to implement a charging method having a stepped output current. The charger controller may set the output current level by adjusting gain of an operational amplifier having a negative feedback configuration with the feedback signal input to a non-inverting input terminal of the operational amplifier, where the charger controller sets the output current level by changing the resistance at an inverting input terminal of the operational amplifier.

Claims

1. A battery charger, comprising:

a power supply circuit receiving an AC input signal and operable to output a DC output signal;

a power supply controller configured to receive a feedback signal indicative of current being output by the power supply circuit via an amplifier and operable to control current output by the power supply circuit in accordance with the feedback signal; and

a charger controller interfaced with the power supply controller and the amplifier to implement a charging method having a stepped output current, where charger controller sets level of the output current by adjusting gain of the amplifier.

2. The battery charger of claim 1 wherein the power supply circuit includes a transformer and a power switch coupled to a primary winding of the transformer and the power supply controller is connected to the power switch to control the current flow through the transformer and thereby control the output current of the power supply circuit.

3. The battery charger of claim 1 wherein the amplifier is further defined as an operational amplifier having a negative feedback configuration with the feedback signal input to a non-inverting input terminal of the operational amplifier and the charger controller sets the output current level by changing the resistance at an inverting input terminal of the operational amplifier.

4. The battery charger of claim 3 further comprises two or more resistors arranged in parallel with each other and each of said resistors connected between the inverting input terminal of the operational amplifier and the charger controller.

5. The battery charger of claim 4 wherein the charger controller selectively couples one or more of the resistors to the inverting input terminal, thereby changing resistance at the inverting input terminal of the operational amplifier.

6. The battery charger of claim 4 wherein each of the resistors are coupled between a different pin of the charger controller and the inverting input terminal of the operational amplifier.

7. The battery charger of claim 6 wherein a switch is interposed between each of the resistors and the correspond pin of the charger controller.

8. The battery charger of claim 1 wherein the charger controller is adapted to receive an indicator of voltage of a battery coupled to the battery charger.

9. The battery charger of claim 8 wherein the charger controller sets the output current to a first level when the battery voltage is below a pre-charge threshold and sets the output current to a second level when the battery voltage exceeds the pre-charge threshold, where the first level is less than the second level.

10. The battery charger of claim 8 wherein the charger controller sets the level of the output current to a second level and resets the level of the output to a third level that is less than the second level after the battery voltage exceeds a target threshold.

11. The battery charger of claim 8 wherein the charger controller sets the output current to a first level when the battery voltage is below a pre-charge threshold and sets the output current to a second level when the battery voltage exceeds the pre-charge threshold, where the first level is less than the second level.

12. The battery charger of claim 8 wherein the charger controller sets the level of the output current to a second level and resets the level of the output to a third level that is less than the second level after the battery voltage exceeds a target threshold.

13. The battery charger of claim 1 wherein the feedback signal is input to a non-inverting input terminal of the operational amplifier and the charger controller sets the output current level by changing the resistance at an inverting input terminal of the operational amplifier.

14. The battery charger of claim 1 wherein the charger controller is adapted to receive an indicator of voltage of a battery coupled to the battery charger.

16. The battery charger of claim 13 further comprises two or more resistors arranged in parallel with each other and each of said resistors connected between the inverting input terminal of the operational amplifier and the charger controller.

17. The battery charger of claim 16 wherein the charger controller selectively couples one or more of the resistors to the inverting input terminal, thereby changing resistance at the inverting input terminal of the operational amplifier.

18. The battery charger of claim 17 wherein each of the resistors are coupled between a different pin of the charger controller and the inverting input terminal of the operational amplifier.

19. The battery charger of claim 18 wherein a switch is interposed between each of the resistors and the correspond pin of the charger controller.

15. A battery charger

a power supply circuit receiving an AC input signal and operable to output a DC output signal, the power supply circuit having a transformer and a power switch coupled to a primary winding of the transformer to control the current flow through the transformer;

a power supply controller configured to receive a feedback signal indicative of current being output by the power supply circuit via an operational amplifier having a negative feedback configuration, the power supply controller coupled to the power switch and operable to control the power switch in accordance with the feedback signal; and

a charger controller interfaced with the power supply controller to implement a charging method having a stepped output current, where charger controller sets level of the output current by changing resistance at an inverting input terminal of the operational amplifier.