Double source battery charger

• US 9,651,014 B2
• Filed: 10/22/2013
• Issued: 05/16/2017
• Est. Priority Date: 10/22/2012
• Status: Active Grant

• Current Assignee: Techtronic Outdoor Products Technology Ltd. (Techtronic Industries Company Limited)
• Original Assignee: Techtronic Outdoor Products Technology Ltd. (Techtronic Industries Company Limited)
• Inventors: Brandon, George, Atta, Mina William
• Primary Examiner(s): Rodas, Richard Isla
• Assistant Examiner(s): Sharief, Mohammed J
• Application Number:
  US14/060,269
• Publication Number:
  US 20140110951A1
• Time in Patent Office: 1,302 Days
• Field of Search: 320104, 320138
• CPC Class Codes: F02N 11/0862 characterised by the electrical power supply means, e.g. battery
• CPC Class Codes: F02N 11/0866 comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: H02J 2207/10 Control circuit supply, e.g. means for supplying power to the control circuit
• CPC Class Codes: H02J 2207/40 adapted for charging from various sources, e.g. AC, DC or multivoltage
• 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 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle

Abstract

A system and method for a double source battery charger of an engine-generator. The double source battery charger of the engine-generator includes an electric starter and a battery. The electric starter is selectively energized by the battery to start an engine of the engine-generator. The double source charger maintains the battery at a desired charge such that the battery has sufficient charge to energize the electric starter. The double source battery charger is selectively coupled to one of two power sources to charge the battery: an alternator of the engine-generator and an external AC source, such as a standard 120 Volt or 240 Volt wall outlet. As a result, the battery is charged by either power from a wall outlet or, if the generator is running, by power provided from the alternator.

Claims

1. A method of charging a battery in a generator having a double source battery charger, an electric starter motor, an internal combustion engine, and an external power connector, the method comprising:

coupling the battery to the electric starter motor to start the internal combustion engine;

driving an alternator, by the internal combustion engine, to produce alternator output power;

detecting at least one selected from the group consisting of a presence of the alternator output power and an absence of external power from the external power source connector and, in response, controlling a switch to connect the alternator to the double source battery charger;

charging the battery, by the double source battery charger, using the alternator output power from the alternator;

detecting at least one selected from the group consisting of an absence of the alternator output power and a presence of external power from the external power connector, and, in response, controlling the switch to connect the external power source connector to the double source battery charger; and

charging the battery, by the double source battery charger, using the external power from the external power connector.

2. The method of claim 1, wherein the step of detecting at least one selected from the group consisting of the presence of the alternator output power and the absence of external power from the external power source connector includes energizing a coil of a relay by the alternator output power.

3. The method of claim 2, wherein, in the step of controlling the switch to connect the alternator to the double source battery charger, the energized coil controls the switch.

4. The method of claim 1,

wherein the step of detecting at least one selected from the group consisting_of the presence of the alternator output power and the absence of external power from the external power source connector includes monitoring, by a controller, at least one selected from the group consisting of the alternator output and the external power connector,

wherein, in the step of controlling the switch to connect the alternator to the double source battery charger, the controller controls the switch.

5. The method of claim 1, further comprising:

determining a voltage level of the battery; and

controlling the double source battery charger to charge the battery based on the voltage level.

6. The method of claim 1, wherein charging the battery includes

charging the battery in a constant current charging mode initially, and

subsequently, charging the battery in a constant voltage charging mode.

7. A generator having a double source battery charger, the generator comprising:

a battery;

an internal combustion engine;

an electric starter motor selectively coupled to the battery to start the internal combustion engine;

an alternator having a rotor driven by the internal combustion engine and a stator in which alternator output power is induced when the rotor is driven, the alternator output power provided at an alternator output;

an external power source connector operable to be coupled to an external power source and to provide external power at a connector output;

a switch having a first input coupled to the alternator output, a second input coupled to the connector output, and a switch output; and

a battery charger coupled to the battery and operable to charge the battery, the battery charger having a power input coupled to the switch output such that the battery charger is selectively coupled, via the switch, to one selected from the group consisting of the alternator output and connector output to charge the battery using one selected from the group consisting of the alternator output power and the external power,

wherein the switch couples the battery charger to the alternator output power based on detecting at least one selected from the group consisting of a presence of the alternator output power and an absence of external power from the external power source connector and wherein the switch couples the battery charger to the connector output based on detecting at least one selected from the group consisting of an absence of the alternator output power and a presence of external power from the external power connector.

8. The generator of claim 7, further comprising:

a coil coupled to the alternator output, wherein the switch and coil form a relay such that,

when the coil is energized by the alternator output power, the switch couples the alternator output to the switch output, and

when the coil is not energized by the alternator output power, the switch couples the connector output to the switch output.

9. The generator of claim 7, further comprising:

a coil coupled to the connector output, wherein the switch and coil form a relay such that,

when the coil is energized by the external power, the switch couples the connector output to the switch output, and

when the coil is not energized by the external power, the switch couples the alternator output to the switch output.

10. The generator of claim 7, further comprising a controller having a sensor operable to monitor at least one selected from the group consisting of the alternator output and the connector output, and to control the switch based on the monitoring.

11. The generator of claim 7, further comprising a battery monitoring module operable to determine a voltage level of the battery and provide the voltage level to a controller.

12. The generator of claim 11, wherein the controller is operable to control the battery charger to charge the battery based on the voltage level.

13. The generator of claim 7, further comprising a controller operable to control the battery charger to charge the battery in at least one selected from the group consisting of a constant current charging mode, a constant voltage charging mode, and a float mode.

14. The generator of claim 7, further comprising;

a starter switch to control the electric starter motor selectively coupled to the battery to start the internal combustion engine;

a fuel tank coupled to the internal combustion engine to supply fuel thereto;

a generator output module coupled to the alternator output; and

an alternating current (AC) outlet coupled to generator output module, the AC outlet configured to connect to an external AC load.

15. The generator of claim 14, further comprising:

a frame supporting the battery, the internal combustion engine, the electric starter motor, the alternator, the fuel tank, and the battery charger; and

a folding handle coupled to the frame via a hinge.

21. The generator of claim 7, further comprising a pull starter cord to start the engine.

22. The generator of claim 7, further comprising:

a frame having,

a base portion on which the internal combustion engine is supported, and

a fuel tank above the internal combustion engine, wherein the external power source connector is located at a height higher than the base portion and lower than the fuel tank.

23. The generator of claim 14, wherein the external power source connector is located on a first face of the generator and the AC outlet is located on a second face of the generator.

16. A method of charging a battery in a generator having a double source battery charger, the generator further including an internal combustion engine, an electric starter motor selectively coupled to the battery to start the internal combustion engine, an alternator driven by the internal combustion engine to produce alternator output power, and an external power source connector operable to be coupled to an external power source to provide external power, the method comprising:

detecting whether at least one selected from the group consisting of the alternator is producing alternator output power and the external power source connector is providing external power;

connecting, via a double throw switch, one selected from the group consisting of the alternator and the external power source connector to an input of the double source battery charger based on the detection; and

charging the battery, by the double source battery charger, using power received at the input from the connected one selected from the group consisting of the alternator and the external power source connector.

17. The method of claim 16, wherein the step of detecting includes energizing a coil of a relay by one selected from the group consisting of the alternator output power and the external power.

18. The method of claim 17, wherein, in the step of connecting, the energized coil controls the double throw switch to connect the one selected from the group consisting of the alternator and the external power source connector to the input of the double source battery charger.

19. The method of claim 16,

wherein the step of detecting includes monitoring, by a controller, at least one selected from the group consisting of the alternator output and the external power source connector,

wherein, in the step of connecting, the controller controls the double throw switch to connect the one selected from the group consisting of the alternator and the external power source connector to the input of the double source battery charger.

20. The method of claim 16, wherein the step of charging further comprises:

charging the battery in a constant current charging mode initially, and

subsequently, charging the battery in a constant voltage charging mode.