Portable generator and battery charger verification control method and system

• US 8,759,714 B2
• Filed: 07/06/2007
• Issued: 06/24/2014
• Est. Priority Date: 07/06/2007
• Status: Active Grant

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Fosbinder, Daniel C.
• Primary Examiner(s): Yuen, Henry
• Assistant Examiner(s): MATHEW, HEMANT MATHAI
• Application Number:
  US11/825,584
• Publication Number:
  US 20090008374A1
• Time in Patent Office: 2,545 Days
• Field of Search: 219/130.01, 219/130.1, 219/130.21, 219/133, 219/137.PS, 320/105, 320/106, 320/152, 324/427, 324/431, 324/433
• US Class Current: 219/130.21
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls
• CPC Class Codes: B23K 9/1006 Power supply

Abstract

A system may include a portable welding unit having an engine, a generator coupled to the engine, a compressor coupled to the engine, and a smart battery charger coupled to the generator. The smart battery charger may be configured to monitor a temperature of a battery, an ambient temperature, a battery charge time, or a combination thereof. The smart battery charger may also be configured to adjust an output based on a battery type, a battery voltage rating, a sensed feedback, a battery test, or a combination thereof.

Claims

1. A system, comprising:

a portable welding unit, comprising;

an engine;

a generator coupled to the engine;

a compressor mechanically and drivingly coupled to the engine;

a smart battery charger coupled to the generator, wherein the smart battery charger is configured to automatically adjust an output of the smart battery charger in response to a temperature feedback indicative of an ambient temperature, wherein the smart battery charger is configured to measure a voltage of a battery after a duration of time has elapsed without a current applied to the battery; and

a control panel comprising a switch, wherein the switch provides for selection among an AC welding output, a DC welding output, or a battery charger output from the portable welding unit.

2. The system of claim 1, wherein the smart battery charger comprises a plurality of charging modes that are executable based on user input, automatic closed loop control, or a combination thereof.

3. The system of claim 1, wherein the smart battery charger comprises a plurality of user inputs including a battery type selector, a battery voltage selector, a battery function selector, or a combination thereof.

4. The system of claim 1, wherein the smart battery charger is configured to monitor battery temperature, battery voltage, battery current, the ambient temperature, or a combination thereof, and the smart battery charger is configured to execute logic based on the monitored battery temperature, battery voltage, battery current, ambient temperature, or a combination thereof.

5. The system of claim 1, wherein the smart battery charger comprises battery test logic configured to test battery performance, or capability of the battery to retain a charge, or a combination thereof.

6. The system of claim 1, wherein the smart battery charger comprises battery reconditioning logic.

7. The system of claim 1, wherein the smart battery charger is configured to apply a current to the battery and to measure a voltage of the battery after the current is applied.

8. The system of claim 7, wherein the smart battery charger is configured to stop applying the current to the battery when the voltage of the battery after the duration of time is not greater than the voltage of the battery before the duration and to continue applying current to the battery when the voltage of the battery after the duration of time is greater than the voltage of the battery before the duration.

9. The system of claim 1, comprising a control panel having a welding control, a battery charging control, a jump starting control, or a combination thereof.

10. The system of claim 1, wherein the portable welding unit comprises a pair of cable connectors for connection to positive and negative terminals of the battery.

11. The system of claim 10, wherein the portable welding unit comprises one or more reels for winding the cable connectors inside the portable welding unit.

16. The system of claim 1, wherein the smart battery charger is configured to monitor the ambient temperature.

17. The system of claim 1, wherein the smart battery charger is configured to monitor a battery temperature as an indicator of the ambient temperature.

18. The system of claim 1, wherein the smart battery charger is configured to select a charging algorithm at least partially based on the temperature feedback indicative of the ambient temperature.

19. The system of claim 1, wherein the smart battery charger comprises a battery test mode configured to test the battery prior to starting a charge mode or a jump start mode.

12. A system, comprising:

a portable welding unit, comprising;

an engine;

a generator coupled to the engine;

a compressor mechanically and drivingly coupled to the engine;

a smart battery charger coupled to the generator, wherein the smart battery charger comprises a battery test mode configured to test a battery prior to starting a charge mode or a jump start mode, wherein the battery test mode comprises a voltage test mode that gradually increases in voltage to determine if the battery is acceptable for charging wherein the smart battery charger is configured to automatically adjust an output of the smart battery charger in response to a temperature feedback indicative of an ambient temperature, and wherein the smart battery charger is configured to measure a voltage of the battery after a duration of time has elapsed without a current applied to the battery.

13. The system of claim 12, wherein the smart battery charger is configured to automatically adjust a charging output, a jump start output, or both, in response to the voltage test mode.

14. The system of claim 12, wherein the smart battery charger is configured to read battery information from a radio frequency identification tag (RFID) tag disposed on the battery.

20. The system of claim 12, wherein the smart battery charger is configured to monitor the ambient temperature.

21. The system of claim 12, wherein the smart battery charger is configured to monitor a battery temperature as an indicator of the ambient temperature.

22. The system of claim 12, wherein the smart battery charger is configured to select a charging algorithm at least partially based on the temperature feedback indicative of the ambient temperature.

15. A system, comprising:

a portable welding unit, comprising;

an engine;

a generator coupled to the engine;

a compressor mechanically and drivingly coupled to the engine;

a smart battery charger coupled to the generator, wherein the smart battery charger is configured to selectively charge a battery in a constant current mode, a constant voltage mode, and a floating current and voltage mode wherein the smart battery charger is configured to automatically adjust an output of the smart battery charger in response to a temperature feedback indicative of an ambient temperature, and wherein the smart battery charger is configured to measure a voltage of the battery after a duration of time has elapsed without a current applied to the battery.

23. The system of claim 15, wherein the smart battery charger is configured to monitor the ambient temperature, a battery temperature as an indicator of the ambient temperature, or a combination thereof, wherein the smart battery charger is configured to select a charging algorithm at least partially based on the temperature feedback indicative of the ambient temperature.

24. The system of claim 15, wherein the smart battery charger comprises a battery test mode configured to test the battery prior to starting a charge mode or a jump start mode.

25. The system of claim 15, wherein the smart battery charger is configured to charge the battery in a multi-step charging mode, wherein the multi-step charging mode comprises the constant current mode, the constant voltage mode, and the floating current and voltage mode in a charging sequence.

26. A system, comprising:

a portable welding unit, comprising;

an engine;

a generator coupled to the engine;

a compressor mechanically and drivingly coupled to the engine; and

a smart battery charger coupled to the generator, wherein the smart battery charger is configured to automatically adjust an output of the smart battery charger in response to feedback from at least one sensor, the smart battery charger is configured to automatically adjust the output of the smart battery charger in response to a temperature feedback indicative of an ambient temperature, and the smart battery charger comprises a battery test mode configured to test a battery prior to starting a charge mode or a jump, and wherein the smart battery charger is configured to measure a voltage of the battery after a duration of time has elapsed without a current applied to the battery start mode.