Portable generator and battery charger verification control method and system

• US 10,576,573 B2
• Filed: 06/23/2014
• Issued: 03/03/2020
• 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): Abraham, Ibrahime A
• Assistant Examiner(s): Dodson, Justin C
• Application Number:
  US14/312,390
• Publication Number:
  US 20140299589A1
• Time in Patent Office: 2,080 Days
• Field of Search: 21913001, 2191301, 21913021, 219133, 219137 PS, 320105, 320106, 320152, 324427, 324431, 324433
• 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, in one embodiment, 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. A system, in another embodiment, may include a battery charger, wherein the battery charger is configured to monitor a temperature of a battery, an ambient temperature, a battery charge time, or a combination thereof. A system, in a further embodiment, may include at least one circuit having a welding control circuit and a battery charge circuit. The battery charge circuit may 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 portable welding unit, comprising:

an engine;

a generator coupled to the engine and configured to generate a weld output; and

a smart battery charger coupled to the generator, wherein the smart battery charger is configured to operate in a battery charge mode to charge a battery connected to the smart battery charger, and wherein the smart battery charger is configured to operate in a jump start mode to jump start a vehicle or a tool having the battery; and

wherein the smart battery charger comprises control circuitry configured to perform a battery verification procedure on the battery of the vehicle or the tool prior to jump starting the vehicle or the tool, and wherein the battery verification procedure comprises applying a test charge current to the battery, determining whether a voltage of the battery increases in response to the applied test charge current, and determining whether the voltage of the battery decreases after a duration of time elapses since the test charge current is applied.

2. The portable welding unit of claim 1, comprising a control panel having a switch, wherein the switch enables selection between the battery charge mode and the jump start mode.

3. The portable welding unit of claim 1, comprising a control panel having one or more user input controls, wherein the one or more user input controls enable selection between the battery charge mode, the jump start mode, and a welding mode during which the weld output is generated.

4. The portable welding unit of claim 3, wherein the one or more user input controls enable selection between a constant current battery charge mode, a constant voltage battery charge mode, and a floating current and voltage battery charge mode.

5. The portable welding unit of claim 1, wherein the device is a vehicle is an automobile.

6. The portable welding unit of claim 1, wherein the smart battery charger is configured to indicate at least one of a grade of the battery, the voltage of the battery, or a degree of chargeability of the battery during the battery verification procedure.

7. The portable welding unit of claim 1, wherein the battery verification procedure comprises determining whether the voltage of the battery is within a voltage range.

8. The portable welding unit of claim 1, wherein the smart battery charger is configured to recondition or delsulphate the battery.

16. The portable welding unit of claim 1, wherein the test charge current is terminated in response to a determination that the voltage of the battery increased in response to the applied test charge current.

19. The portable welding unit of claim 1, wherein the control circuitry is further configured to control an output of the smart battery charger in discrete steps in response to sensed feedback.

20. The portable welding unit of claim 19, wherein the output of the smart battery charger is a battery charging current.

21. The portable welding unit of claim 1, wherein the control circuitry is further configured to automatically adjust voltage and current levels depending on the voltage of the battery, a degree of charge in the battery, or a temperature of the battery in response to feedback from one or more sensors including a current sensor, a voltage sensor, a charging sensor, a temperature sensor, or combination thereof.

9. A portable welding unit, comprising:

an engine;

a generator coupled to the engine and configured to generate a weld output; and

a smart battery charger comprising control circuitry and coupled to the generator, wherein the control circuitry of the smart battery charger is configured to jump start a vehicle or a tool connected to the smart battery charger, and wherein the smart battery charger is configured to perform a battery verification procedure on a battery of the vehicle or the tool prior to jump starting the vehicle or the tool; and

wherein the battery verification procedure comprises applying a test charge current to the battery, determining whether a voltage of the battery increases in response to the applied test charge current, and determining whether the voltage of the battery decreases after a duration of time elapses since the test charge current is applied.

10. The portable welding unit of claim 9, wherein the smart battery charger is configured to indicate at least one of a grade of the battery, the voltage of the battery, or a degree of chargeability of the battery during the battery verification procedure.

11. The portable welding unit of claim 9, wherein the battery verification procedure comprises determining whether a voltage of the battery is within a voltage range.

12. The portable welding unit of claim 11, wherein the battery verification procedure comprises reading the voltage of the battery from a radio frequency identification (RFID) tag disposed on the battery.

13. The portable welding unit of claim 9, wherein the smart battery charger is configured to recondition or delsulphate the battery.

14. The portable welding unit of claim 9, wherein the vehicle is an automobile.

17. The portable welding unit of claim 9, wherein the test charge current is terminated in response to a determination that the voltage of the battery increased in response to the applied test charge current.

15. A portable welding unit, comprising:

an engine;

a generator coupled to the engine and configured to generate a weld output; and

a smart battery charger, comprising control circuitry, coupled to the generator, wherein the smart battery charger control circuitry is configured to operate in a battery charge mode to charge a battery connected to the smart battery charger, wherein the smart battery charger is configured to operate in a jump start mode to jump start a vehicle having the battery or a tool having a battery, and wherein the smart battery charger is configured to perform a battery verification procedure on the battery prior to charging the battery or jump starting the vehicle or the tool; and

wherein the battery verification procedure comprises applying a test charge current to the battery, determining whether a voltage of the battery increases in response to the applied test charge current, and determining whether the voltage of the battery decreases after a duration of time elapses since the test charge current is applied.

18. The portable welding unit of claim 15, wherein the test charge current is terminated in response to a determination that the voltage of the battery increased in response to the applied test charge current.