Energy conserving charger controller, circuitry and method

• US 8,508,079 B1
• Filed: 12/27/2008
• Issued: 08/13/2013
• Est. Priority Date: 12/28/2007
• Status: Expired due to Fees

• Current Assignee: Innovation Capital Law Group
• Original Assignee: Innovation Capital Law Group
• Inventors: Corrado, Anhony P.
• Primary Examiner(s): Barnie, Rexford
• Assistant Examiner(s): PARRIES, DRU M
• Application Number:
  US12/344,508
• Time in Patent Office: 1,690 Days
• Field of Search: 307/131
• US Class Current: 307/131
• CPC Class Codes: H02J 5/00 Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• 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

Abstract

An energy-conserving charger controller system, including charge sensing circuitry and operational algorithm, reduces parasitic lost energy by automatically “learning” the unique charging signature of a consumer electronic device (CED) battery to determine and sense when a it is being charged or not, and implementing conversion (from mains AC to DC) to occur only when a device needs charge. The inventive system employs a current measurement circuit, a microprocessor controller including a timing circuit and control algorithm code structure, a TRIAC current switch and an on-board battery. The inventive system and method is universal, being independent of the charger design, and may be an independent device upstream of the charger (between it and the mains power supply), integrated with an AC adapter charger unit, integrated into a CED, or part of a power strip for individually and independently controlling each AC adapter plugged into the strip.

Claims

1. A charger controller system for use with AC/DC adapter charger devices for recharging batteries of consumer electronic devices, which AC/DC adapter chargers are stand-alone or integrated with said consumer electronic devices (CEDs), comprising in operative combination:

a) a current controlling circuit element in series with, and intermediate between, a mains AC supply of power and an AC output for an AC/DC adapter device having a DC output for providing charging current to a CED connected to said AC/DC adapter;

b) a current measuring circuit element connected downstream of said current controlling circuit element for measuring the current flow to said AC output and assessing the CED battery charge state;

c) a microprocessor having leads connected to said current measurement circuit for receiving signals from said current measurement circuit representative of current draw on said AC output and said CED battery charge state, said microprocessor having a programmable control algorithm code structure;

d) said microprocessor control algorithm code is structured to periodically assess the charge state of said CED battery and responsive thereto, to provide trigger signals to said current controlling circuit to enable, switch ON, or interrupt, turn OFF, flow of mains AC current to said AC output in response to the rate of current draw assessed charge state of said CED battery, said control algorithm code is structured to learn the measured charging load cycle of a CED battery which is connected to said AC/DC adapter DC output, and to provide, switch ON, full mains AC current to said AC output when said CED battery charge state requires charging power, turn OFF mains AC current to said AC output when said CED battery is no longer present or said CED battery charge state no longer requires charging power being in a trickle-charge maintenance mode, maintains said mains AC current OFF to prevent trickle-charge, and turns mains AC current ON again once the charge state of said CED battery is assessed as requiring full charging current;

e) a power storage device connected to said microprocessor to provide power to said microprocessor when mains power is absent; and

f) said system providing substantial energy savings as compared to uncontrolled AC adapter charger devices by preventing charger hysteresis and heat energy losses when said consumer electronic devices are not connected to otherwise uncontrolled AC adapter charger devices or the batteries of said CEDs are substantially fully charged or in a trickle-charge maintenance mode.

2. A charger controller system as in claim 1 wherein said power storage device is a rechargeable battery or super-capacitor, and said system includes a battery charging circuit powered by said mains power.

3. A charger controller system as in claim 1 wherein said current controlling circuit includes a current control element selected from a bidirectional triode thyristor and silicon-controlled rectifiers in inverse parallel orientation.

4. A charger controller system as in claim 1 wherein said control algorithm code is structured to periodically awaken said microprocessor from a sleep state in which said mains power to said AC outlet has been interrupted, trigger said current control circuit element to enable said mains power to flow to said AC outlet, check the value of the measured current flow as sensed by said current measurement circuit, and if the measured current corresponds to a value representative of when a CED battery is connected to and being charged by a connected AC/DC adapter charger, permit said mains power to flow uninterrupted, and if the measured current corresponds to a value representative of when a CED battery is not being charged by a connected AC/DC adapter charger or is in a trickle charge maintenance mode, interrupt said mains power and return to a sleep state for a pre-selected time period.

5. A charger controller system as in claim 4 which is configured as a stand alone device, including a male prong assembly for plugging said device into a mains power outlet, and a female outlet configured to receive the male prong assembly of an AC/DC adapter charger.

6. A charger controller system as in claim 4 which is integrated with at least one of an AC adapter charger device and a CED having onboard AC/DC adapter charger elements.

7. A microprocessor for controlling flow of current to an AC load, said micro-processor being interposed between said load and an AC mains power supply line, comprising:

a) a circuit including;

i) a low power input;

ii) at least one measured current draw signal input;

iii) a trigger signal output;

iv) a clock;

v) a memory structure; and

vi) a control algorithm having a programmable code structure which causes said microprocessor to selectively output trigger signals to a current control circuit element in accord with the functional events of;

periodically awakening said microprocessor from a sleep state in which said mains power to said AC load has been interrupted, triggering said current control circuit element to enable said mains power to flow to said AC load, checking the value of the measured mains power current draw signal input, and if the measured current corresponds to a value representative of when a load is present and drawing mains power, permits said mains power to flow uninterrupted, and if the measured current draw signal input corresponds to a value representative of when a load is not present or drawing current representative of trickle-charge maintenance mode of said AC load, interrupts said mains power and returns to a sleep mode.

8. A microprocessor as in claim 7 wherein said control algorithm includes programmable code structure to cause said microprocessor to selectively output trigger signals in accord with the functional events of:

a) detecting an initial application of mains power current draw by said load;

b) triggering full power to said load;

c) periodically evaluating current draw until a first step change in current draw is detected, said step change being selected from a low load draw to a high load draw, and a high load draw to a low load draw;

d) continuing to periodically evaluate said current draw until a second said step change in current draw is detected, said first and second step change comprising a cycle of step change;

e) writing said first and said second step changes as two state levels corresponding to high current state level and low current state level to said memory structure in said microprocessor;

f) continuing to periodically evaluate said current draw to detected a pre-selected, N-number of said cycles of step changes;

g) calculating the average of the high current and low current state levels;

h) storing said average state levels as learned state levels, high and low set points in a database structure of said microprocessor;

i) after said N-number of cycles, entering said microprocessor into a reduced power, sleep mode, during which the microprocessor is awakened in accord with a timing signal from said microprocessor clock, to sample the current draw; and

j) where said sampled current draw equals or exceeds said high set point returning to said sleep state, and where said sampled current draw equals or is below said low set point, providing a trigger signal to enable mains power to flow.

9. A microprocessor as in claim 8 wherein said pre-selected N-number of cycles ranges from 2 to about 10.

10. A microprocessor as in claim 9 wherein said current draw sampling occurs at periods in the range of from about 1 to about 15 minutes.

11. A method of conserving electrical energy by reducing the loss of electrical energy by an AC adapter charger connected to a mains line power supply for recharging a CED battery when said CED battery is either not connected to said charger or at or near the full charge capacity of said battery, whether said AC adapter charger is stand alone or integrated with said CED, comprising the steps of:

a) automatically monitoring the draw of current of said AC adapter charger by periodic awakening of a battery-powered microprocessor having control algorithm code structure that cyclically evaluates measured current draw until a step change in current draw is detected, either from a low charge rate state to high charge rate or high charge rate state to low charge rate state;

b) permitting current to flow from said mains line power supply to said AC adapter charger when said monitored current draw step change is representative of charging load current draw on said AC adapter charger;

c) automatically interrupting current flow from said mains line to said AC adapter charger so that there is zero mains current flow, when said current draw step change is monitored to be representative of substantial absence of charging load on said AC adapter as when said CED battery is not connected or is in a trickle charge maintenance mode;

d) permitting said microprocessor to revert to a sleep mode after a preselected number of cyclic evaluations of step change from high charge rate state to low charge rate state; and

e) reducing parasitic hysteresis and heat electrical energy loss, in an amount being substantially the difference between said zero current flow and flow to said AC adapter charger when it is connected to mains yet there is no CED battery being charged or said CED battery is in a trickle charge maintenance mode.

12. An electrical energy conservation method as in claim 11 applied to operation of a charger controller device having a bidirectional triode thyristor controlling circuit, a current measurement circuit, a microprocessor having a timer and a programmable control algorithm code structure, and a battery for providing power to said microprocessor during sleep periods, which includes the steps of:

a) when primary power is first applied, the microprocessor enables full power thru the bidirectional triode thyristor to said CED battery under charge;

said microprocessor operating in a prolonged period of “

sleep”

mode under power from its battery, entering a “

learning”

mode upon detection of a current draw that exceeds a minimum factory set level as no mains current draw is present until it is connected to a source of mains primary power;

b) said microprocessor control algorithm code structure includes at least one instruction set for evaluating measured current draw until said step change in current draw is detected, either from a low charge rate state to high charge rate or high charge rate state to low charge rate state;

c) said microprocessor writes the said two state levels, high current and low current draw, to temporary memory storage;

d) said microprocessor repast steps a)-c) for 2-10 cycles;

e) said microprocessor calculates average of high charge rate state, learned level A, and low rate state, learned level B;

f) said microprocessor writes the “

learned”

state levels, levels A and B, to a separate memory location on the microprocessor, storing said learned state levels in a learned state database;

g) said microprocessor enters a sleep mode wherein it only checks current draw on a periodic basis to determine if level A or B is present;

in this “

sleep”

mode the mains power is turned on periodically for very short time periods to ascertain whether the current draw levels are one of the two “

learned”

states;

i) if a high current state, level A, is determined, inventive controller device enables full power under constant microprocessor monitoring to determine when the invention reaches the low current draw state;

ii) When the low current state, level B, is determined the microprocessor turns primary power OFF, interrupts mains power, and re-enters “

sleep”

mode;

h) if during step g) above, said microprocessor determines that the current draw is representative of neither learned level A or level B, then steps a) e) are repeated and a new set of levels, e.g., level C and level D, are determined and set into memory per steps e) and f);

this condition could represent that the charger is used for one or more different devices undergoing charging, or that a different AC adapter charger is plugged into the inventive device AC outlet; and

i) during step g), the measured current draw is now compared to the pre-selected, N number, of stored-in-memory states and the charging of the “

new”

CED is enabled per step g) by appropriate triggering of the bidirectional triode thyristor.

13. An electrical energy conservation method as in claim 11 which includes the steps of:

a) detecting an initial application of mains power current draw by said load;

b) triggering full power to said load;

c) periodically evaluating current draw until a first step change in current draw is detected, said step change being selected from a low load draw to a high load draw, and a high load draw to a low load draw;

d) continuing to periodically evaluate said current draw until a second said step change in current draw is detected, said first and second step change comprising a cycle of step change;

e) writing said first and said second step changes as two state levels corresponding to high current state level and low current state level to a memory structure in a controller microprocessor;

f) continuing to periodically evaluate said current draw to detected a pre-selected, N-number of said cycles of step changes;

g) calculating the average of the high current and low current state levels;

h) storing said average state levels as learned state levels, high and low set points in a database structure of said microprocessor;

i) after said N-number of cycles, entering said microprocessor into a reduced power, sleep mode, during which the microprocessor is awakened in accord with a timing signal from said microprocessor clock, to sample the current draw; and

j) where said sampled current draw equals or exceeds said high set point returning to said sleep state, and where said sampled current draw equals or is below said low set point, providing a trigger signal to enable mains power to flow.

14. An electrical energy conservation method as in claim 13 wherein said pre-selected N-number of cycles ranges from 2 to about 10.

15. An electrical energy conservation method as in claim 14 wherein said current draw sampling occurs at periods in the range of from about 1 to about 15 minutes.

16. An electrical energy conservation method as in claim 11 which includes the steps of automatically learning said AC adapter charger'"'"'s unique charging signature, subsequently sensing when said CED battery is being charged or not, and automatically enabling mains current to flow only when said CED battery requires being charged.