Ferroresonant flux coupled battery charger

• US 4,656,412 A
• Filed: 07/08/1985
• Issued: 04/07/1987
• Est. Priority Date: 07/08/1985
• Status: Expired due to Fees

• Current Assignee: California Institute of Technology
• Original Assignee: California Institute of Technology
• Inventors: McLyman, Colonel W. T.
• Primary Examiner(s): Salce, Patrick R.
• Assistant Examiner(s): NOT, DEFINED
• Application Number:
  US06/753,023
• Time in Patent Office: 638 Days
• Field of Search: 363/17, 363/75, 323/306, 323/309, 320/21, 320/22, 320/39
• US Class Current: 320/139
• CPC Class Codes: B60L 2220/20 DC electrical machines
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/90 involving detection or optimisation of position, e.g. alignment
• CPC Class Codes: H02J 7/00712 the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/12 using magnetic devices having controllable degree of saturation, i.e. transductors
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10S 320/28 Regulating transformer, e.g. high leakage, ferro-resonant
• CPC Class Codes: Y10S 320/34 Robot, hybrid, recreational or emergency vehicle

Abstract

A battery charger for incorporation into an electric-powered vehicle is disclosed. The charger includes a ferroresonant voltage-regulating circuit for providing an output voltage proportional to the frequency of an input AC voltage. A high frequency converter converts a DC voltage supplied, for example, from a rectifier connected to a standard AC outlet, to a controlled frequency AC voltage which is supplied to the input of the ferroresonant circuit. The ferroresonant circuit includes an output, a saturable core transformer connected across the output, and a first linear inductor and a capacitor connected in series across the saturable core transformer and tuned to resonate at the third harmonic of the AC voltage from the high frequency converter. The ferroresonant circuit further includes a second linear inductor connected between the input of the ferroresonant circuit and the saturable core transformer. The output voltage from the ferroresonant circuit is rectified and applied across a pair of output terminals adapted to be connected to the battery to be charged. A feedback circuit compares the voltage across the output terminals with a reference voltage and controls the frequency of the AC voltage produced by the high frequency converter to maintain the voltage across the output terminals at a predetermined value. The second linear inductor provides a highly reactive load in the event of a fault across the output terminals to render the charger short-circuit proof.

Claims

1. A ferroresonant voltage-regulating circuit having a pair of input terminals and a pair of output terminals for use in a battery charger or the like comprising:

(a) a nonlinear saturable core transformer connected across the output terminals;

(b) a first linear inductor and a resonating capacitor connected in series across the nonlinear transformer; and

(c) a second linear inductor connected between one of the input terminals and the nonlinear transformer, the second linear inductor, resonating capacitor and nonlinear transformer being arranged to resonate at a predetermined frequency in excess of 400 Hz, the first inductor and resonating capacitor being arranged to resonate at the third harmonic of the predetermined frequency, the second linear inductor being further arranged to present a highly reactive load across the input terminals in the event of a fault across the output terminals to render the circuit short-circuit proof.

2. The ferroresonant voltage-regulating circuit of claim 1 wherein the nonlinear transformer is an autotransformer having a centertap and two end terminals, the centertap and one end terminal being connected across the output of the ferroresonant circuit.

3. The ferroresonant voltage-regulating circuit of claim 2 wherein the resonating capacitor and first linear inductor are connected across the two end terminals of the nonlinear transformer and the predetermined frequency is about 20 kHz.

4. The ferroresonant voltage-regulating circuit of claim 1 wherein the nonlinear transformer has a single winding, the single winding being connected across the output of the ferroresonant circuit.

5. The ferroresonant voltage-regulating circuit of claim 1 wherein the saturable core transformer includes a toroidal core, a winding and a heat-dissipating bracket, the heat-dissipating bracket including a portion in contact with the outer periphery of the core, the winding surrounding the core and at least the portion of the bracket which surrounds the core.

6. The ferroresonant voltage-regulating circuit of claim 5 wherein the heat-dissipating bracket includes a foot portion extending from the core and arranged to be secured to a heat sink.

7. In a circuit for providing charging current to a battery or the like from an AC source, the combination which comprises:

(a) first rectifier means adapted to be connected to the AC source for providing a DC output voltage;

(b) high-frequency converter means having an input connected to the first rectifier means, and an output, the high-frequency converter means being arranged to convert the DC output voltage from the first rectifier means into an AC output voltage having a frequency within a predetermined range;

(c) ferroresonant means having an input connected to the output of the high frequency converter means, and an output, the ferroresonant means including a non-linear saturable core transformer connected across the output thereof, a resonating capacitor and a first linear inductor connected in series across the saturable core transformer and a second linear inductor connected in series between the input of the ferroresonant means and the saturable core transformer, the saturable core transformer being arranged to saturate when the output voltage from the high frequency converter means reaches less than its peak value, the voltage level at which saturation takes place being dependent upon the frequency of the output voltage from the high-frequency converter means, the values of the resonating capacitor, the second linear inductor and the saturable core transformer being chosen to provide resonance at the frequency of the AC output voltage from the high-frequency converter means, the value of the first inductor being chosen to cause the resonating capacitor and first inductor to resonate at the third harmonic of the output voltage from the high-frequency converter means;

(d) second rectifier means having an input connected to the output of the ferroresonant means, and an output for providing charging current, the second linear inductor being arranged to present a highly reactive load across the output of the high-frequency converter means in the event of a short across the output of the second rectifier means to render the charging circuit short-circuit proof;

(e) means coupled to one of said ferroresonant means and second rectifier means for comparing a voltage representative of the output voltage from the second rectifier means with a predetermined value and for generating an error signal representative of the difference in the values; and

(f) means responsive to the error signal and coupled to the high frequency converter means for controlling the frequency of the AC output voltage from the high-frequency converter means to reduce the error signal.

8. The battery-charging circuit of claim 7 wherein the nonlinear transformer is an autotransformer having a centertap and two end terminals, the centertap and one end terminal being connected across the output of the ferroresonant circuit.

9. The battery-charging circuit of claim 8 wherein the resonating capacitor and first linear inductor are connected across the two end terminals of the nonlinear transformer.

10. The battery-charging circuit of claim 7 wherein the nonlinear transformer has a single winding, the single winding being connected across the output of the ferroresonant circuit.

11. In a circuit for providing charging current to a battery or the like from an AC source, the combination which comprises:

(a) first rectifier means adapted to be connected to the AC source for providing a DC output voltage;

(b) high-frequency converter means having an input connected to the first rectifier means, and an output, the high-frequency converter means being arranged to convert the DC output voltage from the first rectifier means into an AC output voltage having a frequency within a predetermined range;

(c) ferroresonant means having an input connected to the output of the high frequency converter means, and an output, the ferroresonant means including a non-linear saturable core transformer connected across the output thereof, the saturable core transformer being arranged to saturate when the output voltage from the high frequency converter means reaches less than its peak value, the voltage level at which saturation takes place being dependent upon the frequency of the output voltage from the high-frequency converter means;

(d) second rectifier means having an input, and an output providing charging current;

(e) a linear transformer connected between the output of the ferroresonant circuit and the input of the second rectifier means, the linear transformer having a pair of separable mating core sections with a primary winding wound on one core section and a secondary winding wound on the other core section so that energy is coupled from the primary winding to the secondary winding only when the core sections are placed adjacent each other;

(f) means coupled to one of said ferroresonant means and second rectifier means for comparing a voltage representative of the output voltage from the second rectifier means with a predetermined value and for generating an error signal representative of the difference in the values; and

(g) means responsive to the error signal and coupled to the high frequency converter means for controlling the frequency of the output voltage from the high-frequency converter means to reduce the error signal.

12. The battery-charging circuit of claim 11 wherein each core section of the linear transformer is one-half of a pot core configuration having an E-shaped cross-section with a cylindrical central portion and an annular outer portion joining a cylindrical base portion.

13. The battery-charging circuit of claim 12 wherein each of the windings is in the form of a ribbon.

14. The battery-charging circuit of claim 12, wherein each of the windings is in the form of a spirally-formed printed circuit.

15. The battery-charging circuit of claim 11 wherein one core section comprises a cylindrical base portion and a centrally-located frustoconical portion protruding outwardly from the base portion, and the other core section comprises a cylindrical base portion and an annular portion protruding from the base, the annular portion having an internal taper matching the taper of the frustoconical portion.

16. In a circuit for providing charging current to a battery or the like from an AC source, the combination which comprises:

(a) first rectifier means adapted to be connected to the AC source for providing a DC output voltage;

(b) high-frequency converter means having an input connected to the first rectifier means, and an output, the high-frequency converter means being arranged to convert the DC output voltage from the first rectifer means into an AC output voltage having a frequency witin a predetermined range;

(c) ferroresonant means having an input connected to the output of the high frequency converter means, and an output, the ferroresonant means including a non-linear saturable core transformer connected across the output thereof, the saturable core transformer having a toroidal core and a winding and being arranged to saturate when the output voltage from the high frequency converter means reaches less than its peak value, the voltage level at which saturation takes place being dependent upon the frequency of the output voltage from the high-frequency converter means;

(d) a heat-dissipating bracket having a portion thereof in contact with the outer periphery of the toroidal core and the winding of the saturable core transformer for transferring heat away from the core and winding;

(e) second rectifier means having an input connected to the output of the ferroresonant means, and an output for providing charging current;

(f) means coupled to one of said ferroresonant means and second rectifier means for comparing a voltage representative of the output voltage from the second rectifier means with a predetermined value and for generating an error signal representative of the difference in the values; and

(g) means responsive to the error signal and coupled to the high frequency converter means for controlling the frequency of the output voltage from the high-frequency converter means to reduce the error signal.

17. The battery-charging circuit of claim 16 including a heat sink and wherein the heat-dissipating bracket surrounds the toroidal core and includes a foot portion extending from the core and arranged to be secured to the heat sink.