Method and apparatus for adaptive and corrective determination of battery run-time in uninterruptible power systems

• US 5,615,129 A
• Filed: 02/21/1995
• Issued: 03/25/1997
• Est. Priority Date: 02/21/1995
• Status: Expired due to Term

• Current Assignee: Waukesha Electric Systems, Inc.
• Original Assignee: General Signal Power Systems, Inc. (Schneider Electric SE)
• Inventors: Walsh, Timothy, Stich, Frederick A., Hubert, Thomas G.
• Primary Examiner(s): Cosimano, Edward R.
• Assistant Examiner(s): SHAH, KAMINI S
• Application Number:
  US08/390,972
• Time in Patent Office: 763 Days
• Field of Search: 340/636, 364/569, 364/492, 320/48, 307/66, 324/426
• US Class Current: 700/297
• CPC Class Codes: G04C 10/00 Arrangements of electric power supplies in time pieces circuits G04G19/00; mounting, assembling of components of electromechanical watches G04C3/008, of electronic watches G04G17/00
• CPC Class Codes: G04G 19/10 Arrangements for supplying back-up power
• CPC Class Codes: H02J 9/062 for AC powered loads
• CPC Class Codes: H02J 9/067 using multi-primary transformers, e.g. transformer having one primary for each AC energy source and a secondary for the loads
• CPC Class Codes: Y10S 320/21 State of charge of battery

Abstract

The run-time available from an uninterruptible power system is accurately determined both during supply of power from the battery to the load and during the time where power is supplied directly from an AC power system to the load. During power outages, where power is supplied from the battery through the inverter to the load, the remaining run-time is first estimated by calculation and then corrected by modification of the calculated value according to the reciprocal of the run-time slope. Alternatively, a scaling factor is used as part of the first run-time calculations and a correction factor which applies more corrective weight as the time on inverter progresses may be used. During power outages and when power is supplied from the AC power system to the load the maximum available run-time is extrapolated from a table of values representing maximum available run-times at various levels of power being supplied to the load from a fully charged battery. These values are updated after inverter runs to reflect actual system run-times. The maximum run-times are thereby adapted to reflect battery aging and other unique characteristics of the system.

Claims

1. A method of determining the run-time during which power can be supplied from a battery through an inverter of an uninterruptible power supply to a load while such power is being supplied to the load, comprising the steps of:

(a) determining a calculated remaining run-time t_R (n) available during which the battery can supply power to the load for a current iteration n of the run-time determination;

(b) determining a corrected remaining run-time t_R '"'"'(n) in accordance with the expression;

##EQU17## where;

t_S is a time period between iterations of the run-time determination, and

t_R (n-1) is the calcuate remaining run-time determined during a next previous iteration of the run-time determination; and

(c) setting an estimated determined run-time t_RD (n) to the corrected run-time t_R '"'"'(n) if the corrected run-time does not vary by more than a selected correction factor from a corrected run-time t_R '"'"'(n-1) determined during a next previous iteration of the run-time determination, otherwise setting t_RD (n) to an estimated determined run-time t_RD (n-1) from a previous iteration of the run-time determination less an amount of time t_S elapsed since the previous iteration.

2. The method of claim 1 wherein the step of determining the calculated remaining run-time comprises the steps of:

(a) determining the power level supplied to the load;

(b) measuring the battery voltage while the battery supplies power to the load; and

(c) determining the calculated remaining run-time in accordance with the expression ##EQU18## where;

K_l and K₂ are predetermined constants,

V_LL is the lower limit of battery voltage below which the battery should not supply power,

V_FC is the full charge voltage of the battery,

V_B is the measured battery voltage while the battery supplies power to the load, and

P_out (INV) is the average power level supplied to the load while the battery supplies power to the load.

3. The method of claim 2 wherein V_LL is varied depending on the power level supplied to the load.

4. The method of claim 2 wherein V_FC is varied at a start of a period where the battery is supplying power to the load depending on V_B and V_LL at the start of the period.

5. The method of claim 1 further including the additional steps of calculating a moving average of estimated determined run-times t_RD (n) from a plurality of iterations of the run-time determination and providing a display to an operator of the moving average of the estimated determined run-times t_RD (n).

6. The method of claim 1 further including the additional steps of determining a rate of change of the level of power supplied to the load while the battery supplies power to the load and setting the estimated determined run-time t_RD (n) equal to the calculated run-time t_R (n) if the rate of change of the level of power supplied to the load is changing by greater than a selected rate.

7. The method of claim 1 further including the additional steps of setting the estimated determined run-time t_RD (n) equal to the estimated determined run-time (n-1) from a next previous iteration of the run-time determination less the amount of time elapsed since the last iteration if the calculated remaining run-time t_R (n) is less than 0, the calculated remaining run-time t_R (n) is greater than the calculated run-time t_R (n-1) determined during the next previous iteration, or the calculated remaining run-time t_R (n) is greater than a predetermined maximum battery run-time.

8. The method of claim 1 further including the additional steps of determining if the battery is in a fully charged state before start of the inverter supplying power to the load and determining a rate of change of the level of power supplied to the load and wherein:

(a) the corrected remaining run-time t_R '"'"'(n) is not determined during a first iteration of the run-time determination following the start of the inverter supplying the power to the load;

(b) if the battery is in a fully charged state at the first iteration, the estimated determined run-time t_RD (n) is set to a pre-determined maximum remaining run-time at the power output level;

(c) if the power level supplied to the load at the first iteration is changing at a rate greater than a selected rate, the estimated determined run-time t_RD (n) is set at a remaining run-time determined prior to the start of the inverter supplying power to the load; and

(d) otherwise, at the first iteration the estimated terminated run-time t_RD (n) is set at the calculated run-time t_R (n).

9. The method of claim 8 wherein the maximum remaining run-time at the power level supplied to the load is determined by extrapolation from a table of one or more predetermined maximum run-times and wherein the table is updated after an inverter run period where the inverter starts supplying power to the load from a fully charged battery then stops supplying power to the load, based on a last run-time displayed during the inverter run period and a duration of the inverter run period.

10. The method of claim 1 further including the additional steps of:

(a) determining when power is available from an AC power system,

(b) measuring and storing the then existing values of the power supplied to the load P_out (INV) and the battery terminal voltage V_B ;

(c) discontinuing the supply of power from the battery to the load and supplying power from the AC power system to the load when power is available from the AC power system;

(d) measuring the open circuit battery voltage V_B(OC)M after power is no longer supplied from the battery to the load;

(e) then recharging the battery at a known rate from the AC power system;

(f) determining the power level supplied to the load P_OUT (LINE) while power is supplied to the load from the AC power system;

(g) determining a constant K₃ after power is no longer supplied from the battery to the load in accordance with the following expression;

##EQU19## (h) determining an estimate of the open circuit battery voltage V_B(OC)C in accordance with the following expression;

space="preserve" listing-type="equation">V.sub.B(OC)C =V.sub.B(OC)M +((K.sub.4)*Δ

t))

where K₄ is a predetermined constant indicative of the rate of recharge of the battery and Δ

t is the total time elapsed since the battery has started to be charged;

(i) then determining an estimated battery voltage under load V_BC in accordance with the expression

space="preserve" listing-type="equation">V.sub.BC =[V.sub.B(OC)M ]V.sub.B(OC)C -K.sub.3 XP.sub.OUT (LINE);

(j) then determining an estimated run-time t_R (LINE) during supply of power to the load from the AC power system in accordance with the expression;

##EQU20## (k) setting the estimated determined run-time t_RD (n) to the estimated run-time t_R (LINE).

11. The method of claim 10 wherein if the estimated determined run-time t_RD (n) is greater than a predetermined maximum available run-time at the power level supplied to the load P_OUT (LINE) then the estimated determined run-time t_RD (n) is set equal to the predetermined maximum available run-time at P_OUT (LINE).

12. The method of claim 11 wherein the maximum available run-time at the power output level is determined by extrapolation from a table of values of predetermined maximum run-times at various power output levels and wherein the table is updated after an inverter run period where the inverter starts supplying power to the load from a fully charged battery and stops supplying power to the load, based on a last run-time displayed during the inverter run period and a duration of the inverter run period.

13. The method of claim 10 wherein if the last estimated determined run-time t_RD (n) during inverter operation is less than a selected low run-time alarm value or the power level supplied to the load P_out (INV) is below a minimum power level then K₃ is not determined but is set to a previous value of K₃.

14. The method of claim 10 wherein if P_OUT (LINE) has changed by less than a selected amount from the power level supplied to the load while the load was supplied with power from the inverter P_OUT (INV) and the estimated run-time t_R (LINE) is less than a last estimated determined run-time while the load was supplied with power from the inverter then the estimated determined run-time t_RD (n) is set equal to the last estimated determined run-time while the load was supplied with power from the inverter.

15. An uninterruptible power system connectable to AC power system lines at its input terminals and to a load at its output terminals, comprising:

(a) an auxiliary power supply battery;

(b) a power supply path from the input terminals to the output terminals to normally supply power from an AC power system connected to the input terminals to a load connected to the output terminals;

(c) means, including an inverter, responsive to control signals for interrupting the supply of power through the power supply path from the AC power system lines to the load and for selectively providing AC power from the battery to the power supply path through the inverter and thence to the load;

(d) control means for providing control signals, upon occurrence of a line fault on the AC power system lines, to the means responsive to control signals to cause the supply of power to the load to be transferred from the AC power system to the battery and from the battery back to the AC power system when power is available therefrom;

(e) means for determining a calculated remaining run-time t_R (n) available during which the battery can supply power to the load for a current iteration n of a run-time determination;

(f) means for determining a corrected remaining run-time t_R '"'"'(n) in accordance with the expression;

##EQU21## where;

t_S is a time period between iterations of the run time determination, and

t_R (n-1) is the calculated remaining run-time determined during a next previous iteration of the run-time determination; and

(g) means for setting an estimated determined run-time t_RD (n) to the corrected run-time t_R '"'"'(n) if the corrected run-time does not vary by more than a selected correction factor from a corrected run-time t_R '"'"'(n-1) determined during a next previous iteration of the run-time determination, otherwise setting t_RD (n) to an estimated determined run-time t_RD (n-1) from a previous iteration of the run-time determination less an amount of time t_S elapsed since the previous iteration.

16. The uninterruptible power system of claim 15 wherein:

(a) the control means further includes means for determining the power level supplied to the load during supply of power to the load from the battery and for measuring the battery voltage while the battery supplies power to the load; and

(b) the means for determining the calculated remaining run-time t_R (n) calculates in accordance with the expression;

##EQU22## where;

K₁ and K₂ are predetermined constants,

V_LL is the lower limit of battery voltage below which the battery should not supply power,

V_FC is the full charge voltage of the battery,

V_B is the measured battery voltage while the battery supplies power to the load, and

P_out (INV) is the average power level supplied to the load while the battery supplies power to the load.

17. The uninterruptible power system of claim 16 including additionally means for varying V_LL depending on the power level supplied to the load.

18. The uninterruptible power system of claim 16 including additionally means for varying V_FC at a start of a period where the battery is supplying power to the load depending on V_B and V_LL at the start of the period.

19. The uninterruptible power system of claim 15 further including means for calculating a moving average of estimated determined run-times t_RD (n) from a plurality of iterations of the run-time determination and for providing a display to an operator of the moving average of the estimated determined run-times t_RD (n).

20. The uninterruptible power system of claim 15 further including means for determining a rate of change of the level of power supplied to the load while the battery supplies power to the load and for setting the estimated determined run-time t_RD (n) equal to the calculated run-time t_R (n) the rate of change of the level of power supplied to the load is changing by greater than a selected rate.

21. The uninterruptible power system of claim 15 further including means for setting the estimated determined run-time t_RD (n) equal to the estimated determined run-time t_RD (n-1) from a next previous iteration of the run-time determination less the amount of time elapsed since the last iteration if the calculated remaining run-time t_R (n) is less than zero, the calculated remaining run-time t_R (n) is greater than the calculated run-time t_R (n-1) determined during the next previous iteration, or the calculated remaining run-time t_R (n) is greater than a predetermined maximum battery run-time.

22. The uninterruptible power system of claim 15 further including means for determining if the battery is in a fully charged state before a start of the inverter supplying power to the load and for determining a rate of change of the level of power supplied to the load and wherein the means for determining the corrected remaining run-time does not determine a corrected run-time t_R '"'"'(n) during a first iteration of the run-time determination following the start of the inverter supplying the power to the load, and if the battery is in a fully charged state at the first iteration, the estimated determined run-time t_RD (n) is set by the means for setting to a pre-determined maximum remaining run-time at the power output level, and if the power level supplied to the load is changing at a rate greater than a selected rate, the estimated determined run-time t_RD (n) is set at a remaining run-time determined prior to the start of the inverter supplying power to the load, and otherwise, the estimated determined run-time t_RD (n) is set at the calculated run-time t_R (n).

23. The uninterruptible power system of claim 22 including means for extrapolating the maximum remaining run-time from predetermined values in a memory table of maximum available run-times for selected output power levels, and for updating the maximum available run-time values after an inverter run period where the inverter starts supplying power to the load from a fully charged battery then stops supplying power to the load, based on a last run-time displayed during the inverter run period and a duration of the inverter run period.

24. The uninterruptible power system of claim 15 wherein the control means further includes:

means for determining when power is available from an AC power system, for measuring and storing the then existing values of the power supplied to the load P_out (INV) and the battery terminal voltage V_B, for discontinuing the supply of power from the battery to the load and supplying power from the AC power system to the load when power is available from the AC power system, for measuring the open circuit battery voltage V_B(OC)M after power is no longer supplied from the battery to the load, for recharging the battery at a known rate from the AC power system, for determining the power level supplied to the load P_OUT (LINE) from the AC power system, for determining a constant K₃ after power is no longer supplied from the battery to the load in accordance with the following expression;

##EQU23## for determining an estimate of the open circuit battery voltage V_B(OC)C in accordance with the following expression;

space="preserve" listing-type="equation">V.sub.B(OC)C =V.sub.B(OC)M +((K.sub.4)*Δ

t))

where K₄ is a predetermined constant indicative of the rate of recharge of the battery and Δ

t is the total time elapsed since the battery has started to be charged, for determining an estimated battery voltage under load V_BC in accordance with the expression;

space="preserve" listing-type="equation">V.sub.BC =V.sub.B(OC)C -K.sub.3 xP.sub.OUT (LINE),

for determining an estimated run-time t_R (LINE) during supply of power to the load from the AC power system in accordance with the expression;

##EQU24## and for setting the estimated determined run-time t_RD (n) to the estimated run-time t_R (LINE).

25. The uninterruptible power system of claim 24 wherein if the estimated determined run-time t_RD (n) is greater than a predetermined maximum available run-time at the power level supplied to the load P_OUT (LINE) then the estimated determined run-time t_RD (n) is set equal to the predetermined maximum available run-time at P_OUT (LINE).

26. The uninterruptible power system of claim 24 wherein if the last estimated determined run-time t_RD (n) during inverter operation is less than a selected low run-time alarm value or the power level supplied to the load P_out (INV) is below a minimum power level then K₃ is not determined but is set to a previous value of K₃.

27. The uninterruptible power system of claim 24 wherein if P_OUT (LINE) has changed by less than a selected amount from the power level supplied to the load while the load was supplied with power from the inverter P_OUT (INV) and the estimated run-time t_R (LINE) is less than a last estimated determined run-time while the load was supplied with power from the inverter then the estimated determined run-time t_RD (n) is set equal to the last estimated determined run-time while the load was supplied with power from the inverter.

28. A method of determining the run-time during which power can be supplied from a battery through an inverter of an uninterruptible power supply to a load while such power is being supplied to the load, comprising the steps of:

(a) measuring the battery voltage V_B while the battery supplies power to the load;

(b) calculating a base equation reference at an iteration of the run-time determination N near a start of power being supplied from the battery to the load in accordance with the expression;

##EQU25## where;

Base(N) is the base equation reference at the Nth iteration of the run-time calculation,

V_B (N) is the measured battery voltage at the Nth iteration,

V_LL (N) iS the lower limit of battery voltage below which the battery should not supply power at the Nth iteration, and

V_FC (N) is the full charge voltage of the battery;

(c) computing a scaling factor K_S at an iteration n of the run-time determination in accordance with the following expression;

##EQU26## where;

t_S is a time period between iterations of the run-time determination, and

Base(n) is the base equation calculated at the nth iteration of the run-time calculation;

(d) setting a converged scaling factor K_S '"'"' equal to the scaling factor K_S for the nth iteration when the scaling factors for two consecutive iterations of the run-time determination converge to within a selected amount;

(e) computing a correction factor K_C for an iteration n of the run-time determination in accordance with the following expression;

##EQU27## (f) setting a corrected run-time t_R '"'"'(n) for the nth iteration of the run-time determination equal to the product of the converged scaling factor K_S '"'"'the correction factor K_C and the base equation calculated at the nth iteration of the run-time calculation Base(n).

29. The method of claim 28 further including the additional steps of determining when a fully charged battery begins to supply power to a load and determining when the battery has reached a peak voltage level and wherein the Nth iteration of the run-time determination is after the fully charged battery begins to supply power to the load and the battery has reached the peak voltage level.

30. The method of claim 28 wherein V_LL is varied depending on a measurement of the power level supplied to the load.

31. The method of claim 28 wherein V_FC is varied at a start of a period where a fully charged battery is supplying power to the load depending on V_B and V_LL.

32. The method of claim 31 wherein V_FC is varied after the battery has reached a peak voltage level.

33. An uninterruptible power system connectable to AC power system lines at its input terminals and to a load at its output terminals, comprising:

(a) an auxiliary power supply battery;

(b) a power supply path from the input terminals to the output terminals to normally supply power from an AC power system connected to the input terminals to a load connected to the output terminals;

(c) means, including an inverter, responsive to control signals for interrupting the supply of power through the power supply path from the AC power system lines to the load and for selectively providing AC power from the battery to the power supply path through the inverter and thence to the load;

(d) control means for providing control signals, upon occurrence of a line fault on the AC power system lines, to the means responsive to control signals to cause the supply of power to the load to be transferred from the AC power system to the battery and from the battery back to the AC power system when power is available therefrom, the control means further including means for measuring the battery voltage V_B while the battery supplies power to the load,

for calculating a base equation reference at an iteration of a run-time determination N near a start of power being supplied from the battery to the load in accordance with the expression;

##EQU28## where;

Base(N) is the base equation reference at the Nth iteration of the run-time calculation,

V_B (N) is the measured battery voltage at the Nth iteration,

V_LL (N) iS the lower limit of battery voltage below which the battery should not supply power at the Nth iteration, and

V_FC (N) is the full charge voltage of the battery;

for computing a scaling factor K_S at an iteration n of the run-time determination in accordance with the following expression;

##EQU29## where;

t_S is a time period between iterations of the run-time determination, and

Base(n) is the base equation calculated at the nth iteration of the run-time calculation;

for setting a converged scaling factor K_S '"'"' equal to the scaling factor K_S for the nth iteration when the scaling factors for two consecutive iterations of the run-time determination converge to within a selected amount;

for computing a correction factor K_C for an iteration n of the run-time determination in accordance with the following expression;

##EQU30## for setting a corrected run-time t_R '"'"'(n) for the nth iteration of the run-time determination equal to the product of the converged scaling factor K_S '"'"' the correction factor K_C and the base equation calculated at the nth iteration of the run-time calculation Base(n).

34. The uninterruptible power system of claim 33 including additionally means for measuring a level of power supplied to the load and for varying V_LL depending on the level of power supplied to the load.

35. The uninterruptible power system of claim 33 including additionally means for varying V_FC at a start of a period where a fully charged battery is supplying power to the load depending on V_B and V_LL.

36. A method for determining the maximum run-time during which power can be supplied from a battery to a load, comprising the steps of:

(a) storing one or more starting values, each starting value representing the maximum run-time from a fully charged battery supplying power to a selected percentage of a full load;

(b) extrapolating maximum run-times from the starting values;

(c) calculating a remaining run-time available while power is being supplied to the load from the battery;

(d) updating the starting values by extrapolation from the calculated remaining run-time available, wherein updating the starting values includes extrapolating a calculated run-time from an end of a period in which power was supplied to the load from a battery which was fully charged at a start of the period plus the duration of the period.