Battery charger with automatic voltage detection

• US 9,874,611 B2
• Filed: 11/15/2016
• Issued: 01/23/2018
• Est. Priority Date: 07/16/2009
• Status: Active Grant

• Current Assignee: Schumacher Electric Corporation
• Original Assignee: Schumacher Electric Corporation
• Inventors: Whiting, John, Heins, Matthew A.
• Primary Examiner(s): DIAO, M BAYE
• Application Number:
  US15/352,217
• Publication Number:
  US 20170059659A1
• Time in Patent Office: 434 Days
• Field of Search: 320162, 320107, 320149, 324426
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00041 in response to measured battery parameters, e.g. voltage, current or temperature profile
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/005 Detection of state of health [SOH]
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery charger is disclosed that is configured to be connected to an external battery by way of external battery cables. In accordance with an important aspect of the invention, the battery charger is configured with automatic voltage detection which automatically determines the nominal voltage of the battery connected to its battery charger terminals and charges the battery as a function of the detected nominal voltage irrespective of the nominal voltage selected by a user. Various safeguards are built into the battery charger to avoid overcharging a battery. For battery chargers with user-selectable nominal battery voltage charging modes, battery charger is configured to over-ride a user-selected battery voltage mode if it detects that the battery connected to the battery charger terminals is different than the user-selected charging mode.

Claims

1. A method of supplying current to a battery in a battery system having a processor to determine a nominal voltage of the battery, the method comprising:

measuring, via a sensor, a first voltage of the battery across a pair of battery cables;

comparing, via the processor, the first voltage to a first predetermined value to determine whether the nominal voltage of the battery is a first nominal voltage;

determining, via the processor, the nominal voltage of the battery to be the first nominal voltage if the first voltage is greater than the first predetermined value;

supplying, via the pair of battery cables, a test current to the battery if said first voltage is not greater than the first predetermined value;

measuring, via the sensor, a second voltage across the pair of battery cables in response to the test current;

comparing the second voltage to a second predetermined value to determine, via the processor, whether the nominal voltage of the battery is the first nominal voltage or a second nominal voltage, wherein the first nominal voltage is greater than the second nominal voltage; and

supplying a charge current to the battery as a function of the first nominal voltage or the second nominal voltage as determined by the processor.

2. The method of claim 1, wherein the first nominal voltage is 12 volts DC and the second nominal voltage is 6 volts DC.

3. The method of claim 1, wherein the first nominal voltage is 24 volts DC and the second nominal voltage is 12 volts DC.

4. The method of claim 1, further including the step of determining whether the battery is connected to the pair of battery cables by measuring a third voltage across the pair of battery cables.

5. The method of claim 4, wherein the battery is determined to be connected to the pair of battery cables if the third voltage is greater than a third predetermined value.

6. The method of claim 5, wherein third predetermined value is at least 0.01 volts DC.

7. The method as recited in claim 1, wherein the test current is forced through the battery for a predetermined period of time.

8. The method as recited in claim 7, wherein the processor determines the nominal voltage of the battery to be the first nominal voltage if the second voltage is not less than the second predetermined value.

9. The method as recited in claim 8, wherein the processor determines the nominal voltage of the battery to be the second nominal voltage if the second voltage is less than the second predetermined value.

10. The method as recited in claim 9, wherein the second predetermined value is about 11 volts DC.

11. The method as recited in claim 10, wherein the second voltage is a peak ripple voltage.

12. The method as recited in claim 7, wherein the predetermined period of time is about 1 second.

13. A battery system to supply current to a battery via a pair of battery cables, the battery system comprising:

an automatic voltage detection system to determine a nominal voltage of the battery, wherein the automatic voltage detection system is configured to (1) measures a first voltage of the battery across the pair of battery cables, (2) compare, the first voltage to a first predetermined value to determine whether the nominal voltage of the battery is a first nominal voltage, (3) determine the nominal voltage of the battery to be the first nominal voltage if the first voltage is greater than the first predetermined value, (4) measure a second voltage across the pair of battery cables if said first voltage is not greater than the first predetermined value, and (5) compare the second voltage to a second predetermined value to determine whether the nominal voltage of the battery is the first nominal voltage or a second nominal voltage, wherein the first nominal voltage is greater than the second nominal voltage; and

a system to supply current to the battery as a function of the first nominal voltage or the second nominal voltage as determined by the automatic voltage detection system.

14. The battery system of claim 13, wherein the second voltage is measured in response to a test current supplied through said battery.

15. The battery system of claim 14, wherein the test current is forced through the battery for a predetermined period of time.

16. The battery system of claim 15, wherein the predetermined period of time is about 1 second.

17. The battery system of claim 14, wherein the automatic voltage detection system is configured to determine that the nominal voltage of the battery is (1) the first nominal voltage if the second voltage is greater than the second predetermined value and (2) the second nominal voltage if the second voltage is not greater than the second predetermined value.

18. The battery system of claim 16, wherein the first nominal voltage is 12 volts DC, the second nominal voltage is 6 volts DC, and the second predetermined value is about 11 volts DC.

19. The battery system of claim 18, wherein the second voltage is a peak ripple voltage.

20. A battery system to supply current to a battery via a pair of battery cables, the battery system comprising:

a sensor to measure a voltage of the battery across the pair of battery cables;

a processor operatively coupled with the sensor to determine a nominal voltage of the battery, wherein the processor is configured to (1) receive, via the sensor, a first voltage of the battery across the pair of battery cables, (2) compare the first voltage to a first predetermined value, wherein the processor is configured to determine that the nominal voltage of the battery is a first nominal voltage when the first voltage is greater than the first predetermined value, (3) receive, via the sensor, a second voltage across the pair of battery cables if said first voltage is not greater than the first predetermined value, wherein the second voltage is measured in response to a test current supplied through said battery, and (4) compare the second voltage to a second predetermined value to determine whether the nominal voltage of the battery is the first nominal voltage or a second nominal voltage, wherein the first nominal voltage is greater than the second nominal voltage; and

a charger circuit to supply a charging current to the battery as a function of the first nominal voltage or the second nominal voltage as determined by the processor.

21. The battery system of claim 20, wherein the test current is forced through the battery for a predetermined period of time.

22. The battery system of claim 21, wherein the predetermined period of time is about 1 second.

23. The battery system of claim 20, wherein the processor is configured to determine that the nominal voltage of the battery is (1) the first nominal voltage when the second voltage is greater than the second predetermined value and (2) the second nominal voltage when the second voltage is not greater than the second predetermined value.

24. The battery system of claim 23, wherein the first nominal voltage is 12 volts DC and the second nominal voltage is 6 volts DC.

25. The battery system of claim 23, wherein the second voltage is a peak ripple voltage.