Battery charging circuit generating an oscillating triangular waveform to remove sulphate from battery plates

• US 8,269,465 B2
• Filed: 09/25/2008
• Issued: 09/18/2012
• Est. Priority Date: 09/27/2007
• Status: Active Grant

• Current Assignee: Pulsetech Products Corporation
• Original Assignee: Pulsetech Products Corporation
• Inventors: Smith, Pete Ward, Huffman, James Earl, Sykes, David Lee, Calcote, Clyde Ray
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): Hernandez, Manuel
• Application Number:
  US12/238,143
• Publication Number:
  US 20090085524A1
• Time in Patent Office: 1,454 Days
• Field of Search: 320/139, 320/141, 320/145, 327/131, 327/132, 327/133, 327/134, 327/135, 327/136, 327/137, 327/138, 327/139, 327/140, 363/20, 363/21.01, 363/21.08, 363/21.1
• US Class Current: 320/141
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process

Abstract

A circuit charges and maintains a battery. The circuit includes a microprocessor for receiving a current sense signal and a voltage sense signal. The microprocessor generates control signals for selectively operating the circuit in a charging mode and in a maintenance mode. The circuit includes a current sense circuit for measuring the battery'"'"'s current consumption and generating the current sense signal responsive to the measured current consumption. The circuit includes a voltage sense circuit for measuring the battery'"'"'s voltage and generating the voltage sense signal responsive to the measured battery voltage. The circuit includes a waveform generator circuit for receiving the control signals, and operating in response thereto to apply a charging signal to the battery when in the charging mode and to deactivate the charging signal when in the maintenance mode. The charging signal has an oscillating triangular waveform superimposed on a DC bias signal.

Claims

1. A circuit for charging a battery, comprising:

a microprocessor configured to receive a current sense signal and a voltage sense signal, the microprocessor further configured to generate control signals for selectively operating the circuit for charging the battery in a charging mode and a maintenance mode;

a current sense circuit configured to measure the battery'"'"'s current consumption and generate the current sense signal responsive to the measured current consumption;

a voltage sense circuit configured to measure the battery'"'"'s voltage and generate the voltage sense signal responsive to the measured battery voltage;

a waveform generator circuit configured to receive the control signals, and operate in response thereto to apply a charging signal to the battery when in the charging mode and to deactivate the charging signal when in the maintenance mode; and

a monitoring circuit configured in the maintenance mode to monitor a settling voltage of the battery in the absence of the charging signal,

wherein the charging signal has an oscillating sawtooth current waveform superimposed on a DC bias; and

wherein the oscillating sawtooth current waveform is characterized by a plurality of consecutive current pulses, each current pulse having a rise portion and a fall portion, wherein the fall portion of each current pulse comprises a first linear portion having a first slope followed by a second linear portion having a second slope different from the first slope, and wherein linearity for the second slope of the second linear portion is consistent from pulse to pulse in the sawtooth current waveform.

2. The circuit according to claim 1, wherein the microprocessor operates the circuit for charging the battery in the charging mode if the measured battery voltage is less than a first threshold voltage.

3. The circuit according to claim 1, wherein the microprocessor transfers operation of the circuit for charging the battery to the maintenance mode if the measured voltage exceeds the first threshold voltage and the measured current consumption is less than a first threshold current.

4. The circuit according to claim 3, wherein the microprocessor applies the oscillating sawtooth current waveform superimposed on the DC bias if the settling voltage is less than a second threshold voltage.

5. The circuit according to claim 1, wherein the microprocessor is configured to control the waveform generator circuit so as to generate the oscillating sawtooth current waveform.

6. The circuit according to claim 1, wherein the sawtooth current waveform has a frequency between 30 KHz and 50 KHz.

7. The circuit according to claim 1, wherein the waveform generator circuit comprises:

a pulse transformer having primary and secondary windings, the primary winding to which is applied the pulse control signals;

a transistor in series with a first resistor coupled between the secondary winding and a ground; and

an R-C network formed by a second and a third resistor and a capacitor, the R-C network coupled to a base junction of the transistor to output the sawtooth current waveform, the R-C network coupled to the secondary winding via a first and a second diode, respectively.

8. The circuit according to claim 7, further comprising a third diode coupling the battery to the secondary winding, the battery being charged by the application of the sawtooth current waveform.

9. A circuit for charging a battery, comprising:

a microprocessor configured to receive a current sense signal and a voltage sense signal, the microprocessor further configured to generate a first control signal and a second control signal;

a current sense circuit configured to measure the battery'"'"'s current consumption and generate the current sense signal responsive to the measured current consumption;

a voltage sense circuit configured to measure the battery'"'"'s voltage and generate the voltage sense signal responsive to the measured battery voltage; and

a waveform generator circuit configured to receive the first and second control signals and a DC bias, the waveform generator circuit further configured to generate an output signal for application to the battery when in a charging mode as selected by the first and second control signals, the output signal including an oscillating sawtooth current waveform superimposed on the DC bias, wherein the oscillating sawtooth current waveform is characterized by a plurality of consecutive current pulses, each current pulse having a rise portion and a fall portion, wherein the fall portion of each current pulse comprises a first linear portion having a first slope followed by a second linear portion having a second slope different from the first slope, and wherein linearity for the second slope of the second linear portion is consistent from pulse to pulse in the sawtooth current waveform, the waveform generator circuit further configured to deactivate the oscillating sawtooth current waveform superimposed on the DC bias when in a maintenance mode as selected by the first and second control signals.

10. The circuit according to claim 9, wherein the first control signal turns on an oscillator circuit and the second control signal switches in the DC bias when in the charging mode if the measured battery voltage is less than a first threshold voltage.

11. The circuit according to claim 9, wherein the first control signal turns OFF an oscillator circuit and switches out the DC bias if the measured voltage exceeds a first threshold voltage and the measured current consumption is less than a first threshold current.

12. The circuit according to claim 11, wherein, during the maintenance mode, the first control signal turns ON the oscillating sawtooth current waveform and the second control signal switches ON the DC bias if a settling voltage of the battery measured during maintenance mode is less than a second threshold voltage.

13. The circuit according to claim 9, wherein the sawtooth current waveform has a frequency between 30 KHz and 50 KHz.

14. The circuit according to claim 9, wherein the waveform generator circuit further comprises:

a pulse transformer having primary and secondary windings, the primary winding to which is applied the pulse control signals;

a transistor in series with a first resistor coupled between the secondary winding and the ground; and

an R-C network formed by a second and a third resistor and a capacitor, the R-C network coupled to a base junction of the transistor to enable the circuit for charging the battery to output the sawtooth current waveform, the R-C network coupled to the secondary winding via a first and a second diode, respectively.

15. The circuit according to claim 9, further comprising a third diode coupling an external battery to the secondary winding, the external battery being charged by the application of the sawtooth current waveform.

16. A circuit, comprising:

a current sense circuit configured to measure a current consumption of a battery during charging and generate a current sense signal;

a voltage sense circuit configured to measure a voltage of the battery and generate a voltage sense signal;

a signal generator configured to apply a signal to the battery, the signal generator comprising;

a first circuit configured to generate an oscillating sawtooth current waveform, wherein the oscillating sawtooth current waveform is characterized by a plurality of consecutive current pulses, each current pulse having a rise portion and a fall portion, wherein the fall portion of each current pulse comprises a first linear portion having a first slope followed by a second linear portion having a second slope different from the first slope, and wherein linearity for the second slope of the second linear portion is consistent from pulse to pulse in the sawtooth current waveform; and

a second circuit configured to generate a DC bias;

a control circuit responsive to the current sense signal and the voltage sense signal;

the control circuit configured to control the signal generator to apply the signal to the battery with the oscillating sawtooth current waveform superimposed on the DC bias if the voltage sense signal indicates a voltage less than a first threshold, the control circuit further configured to control the signal generator to inhibit the oscillating sawtooth current waveform superimposed on the DC bias if the voltage exceeds the first threshold and if the current sense signal indicates the current consumption is less than a second threshold.

17. A circuit, comprising:

a signal generator configured to apply a charging signal to a battery, the signal generator comprising;

a first circuit configured to generate a DC bias;

a second circuit configured to generate an oscillating sawtooth current waveform;

a third circuit configured to superimpose the oscillating sawtooth current waveform on the DC bias;

wherein the oscillating sawtooth current waveform is characterized by a plurality of consecutive current pulses and wherein each current pulse has a rise portion and a fall portion, wherein the fall portion of each current pulse comprises a first linear portion having a first slope followed by a second linear portion having a second slope different from the first slope, and wherein linearity for the second slope of the second linear portion is consistent from pulse to pulse of the consecutive current pulses.

18. The circuit of claim 17 further comprising:

a control circuit operating responsive to a sensed battery current and a sensed battery voltage, the control circuit configured to superimpose the oscillating sawtooth current waveform on the DC bias if the sensed battery voltage is less than a first threshold, the control circuit further configured to inhibit superimposition of the oscillating sawtooth current waveform on the DC bias if the sensed battery voltage exceeds the first threshold and if the sensed current is less than a second threshold.