Hybrid battery charger

• US 9,643,503 B2
• Filed: 05/12/2016
• Issued: 05/09/2017
• Est. Priority Date: 10/24/2012
• Status: Active Grant

• Current Assignee: Schumacher Electric Corporation
• Original Assignee: Schumacher Electric Corporation
• Inventors: Chen, Xiao Ping, Heins, Matthew Adam, Zhu, Shenzhong
• Primary Examiner(s): Rodas, Richard Isla
• Assistant Examiner(s): Bui, Dung V
• Application Number:
  US15/153,164
• Publication Number:
  US 20160257210A1
• Time in Patent Office: 362 Days
• Field of Search: 320107
• CPC Class Codes: B60L 53/00 Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: H01F 27/28 Coils; Windings; Conductive connections
• CPC Class Codes: H01F 38/42 Flyback transformers
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• 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: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A hybrid battery charger is disclosed that includes a linear charger circuit for providing vehicle starting current and battery charging and a high frequency battery charging circuit that provides battery charging current. The linear charger circuit and the high frequency battery charging circuits are selectively enabled to provide vehicle starting current, maximum charging current and optimum efficiency.

Claims

1. A hybrid battery charger comprising:

a processor;

a set of output terminals to electrically couple with a battery;

a linear charger circuit to supply power to the battery;

a first switch operatively coupled to said processor to selectively couple said linear charger circuit to a power source;

a high frequency charger circuit to supply power to the battery, wherein the high frequency charger circuit is connected in parallel with the linear charger circuit; and

a second switch operatively coupled to said processor to selectively couple said high frequency charger circuit to said set of output terminals,

wherein the processor is configured to selectively control said first switch and said second switch to supply power to said battery from each of said linear battery charger circuit and said high frequency charger circuit.

2. The hybrid battery charger of claim 1, further comprising a voltage sense circuit to determine a voltage of the battery.

3. The hybrid battery charger of claim 2, wherein the processor opens said second switch when the voltage of the battery is less than a predetermined voltage, thereby prohibiting the supply of power from said high frequency charger circuit to said battery.

4. The hybrid battery charger of claim 1, further comprising a variable frequency drive circuit to control a switching frequency of the high frequency charger circuit.

5. The hybrid battery charger of claim 4, wherein the variable frequency drive circuit controls the switching frequency of the high frequency charger circuit as a function of a load current across said set of output terminals.

6. The hybrid battery charger of claim 5, wherein the variable frequency drive circuit decreases the switching frequency of the high frequency charger circuit when the load current is less than a predetermined current.

7. The hybrid battery charger of claim 5, wherein the variable frequency drive circuit varies the switching frequency of the high frequency charger circuit between 20 KHz and 100 KHz.

8. The hybrid battery charger of claim 6, wherein the variable frequency drive circuit skips one or more switching cycles when the load current is (i) zero or (ii) not detected.

9. The hybrid battery charger of claim 1, wherein the processor opens said first switch when said linear battery charger circuit is not charging the battery, thereby prohibiting the supply of power from the power source to the linear battery charger circuit.

10. The hybrid battery charger of claim 2, wherein the processor enters a sleep mode when the voltage of the battery is greater than a predetermined voltage.

11. The hybrid battery charger of claim 2, wherein the processor current limits the high frequency battery charger circuit when the voltage of the battery is less than a predetermined voltage, indicating that the battery is deeply discharged.

12. The hybrid battery charger of claim 1, wherein each of said linear battery charger circuit and said high frequency charger circuit supply power to said battery until a predetermined condition is met, whereupon the processor opens said second switch, thereby prohibiting the supply of power from said high frequency charger circuit to said battery.

13. The hybrid battery charger of claim 1, wherein said hybrid battery charger includes at least three modes of operation, and wherein, in a first mode of operation, said linear battery charger circuit provides a starting current to said battery.

14. The hybrid battery charger of claim 13, wherein, in a second mode of operation, said linear battery charger circuit provides a charging current to said battery.

15. The hybrid battery charger of claim 14, wherein, in a third mode of operation, said high frequency battery charger circuit provides a charging current to said set of output terminals.

16. The hybrid battery charger of claim 15, further including a fourth mode of operation in which both the linear charger circuit and the high frequency charger circuit simultaneously provide a charging current to said set of output terminals.

17. The hybrid battery charger of claim 12, wherein said predetermined condition relates to a rate of change of a battery voltage, dV/dt, of the battery, wherein said predetermined condition is met when the rate of change is at or below 0.1 volt/hour.

18. The hybrid battery charger of claim 12, wherein said predetermined condition relates to a charging current, wherein said predetermined condition is met when the charging current is at or below 7 amps DC.

19. The hybrid battery charger of claim 1, wherein said high frequency charging circuit includes a flyback transformer to provide power to said processor during a low voltage condition.

20. The hybrid battery charger of claim 19, wherein the processor has a plurality of low voltage modes, including a wait power mode, an active halt power mode, and a halt low power mode.