Battery recharging system with state of charge detection that initially detects whether a battery to be charged is already at or near full charge to prevent overcharging

• US 5,642,031 A
• Filed: 02/28/1994
• Issued: 06/24/1997
• Est. Priority Date: 02/28/1994
• Status: Expired due to Term

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Brotto, Daniele C.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US08/203,541
• Time in Patent Office: 1,212 Days
• Field of Search: 320/20, 320/21, 320/22, 320/23, 320/24, 320/31, 320/32, 320/39, 320/40, 320/43, 320/44, 320/45
• US Class Current: 320/156
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• CPC Class Codes: Y10S 320/12 Precharging analysis, e.g. determining presence of battery

Abstract

A state of charge test is first performed on the battery by applying a current pulse and then observing the voltage decay characteristics which result. Batteries which are initially nearly fully charged exhibit a larger voltage decay than batteries which are not as fully charged. The result of this initial state of charge test is used to determine how to best terminate battery charging. In this way battery overcharging is prevented regardless of the initial state of charge of the battery.

Claims

1. A method of charging a battery comprising:

detecting the state of charge prior to charging;

initiating charging while monitoring the battery voltage variation with time;

terminating charging in accordance with the following;

(a) if the detected state of charge prior to charging is above a predetermined level, terminating charging in response to a fall in the value of the first derivative of the voltage variation with time; and

(b) if the detected state of charge prior to charging is below a predetermined level, terminating charging in response to a change from a rising to a falling value of the first derivative of the voltage variation with time.

2. The method of claim 1 wherein said detecting step is performed by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the decay as an indication of the state of charge of the battery.

3. The method of claim 1 wherein said detecting step is performed by applying a current to said battery for a predetermined time and after said predetermined time sampling the battery voltage at least twice to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

4. The method of claim 1 wherein said detecting step is performed by applying a current to said battery for a first predetermined time and after said first predetermined time sampling the battery voltage during a second period of time to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

5. The method of claim 4 wherein said second period of time begins after a predetermined delay following the end of said first period of time.

6. The method of claim 5 wherein said predetermined delay is selected such that said second time period begins after change in battery voltage due to battery impedance has substantially abated.

7. The method of claim 1 wherein said detecting step is performed by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is above a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is not above said predetermined decay, then the detected state of charge is deemed below said predetermined level.

8. The method of claim 1 wherein said detecting step is performed by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is not below a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is below said predetermined decay, then the detected state of charge is deemed below said predetermined level.

9. The method of claim 1 wherein the battery voltage variation with time is determined by periodically measuring battery voltage and computing a value indicative of first derivative of voltage with respect to time.

10. The method of claim 1 wherein said fall in the value of the first derivative of the voltage variation with time corresponds to a first occurrence of an inflection point in the battery voltage curve.

11. The method of claim 10 wherein said change from a rising to a falling value of the first derivative of the voltage variation with time corresponds to a second inflection point in the battery voltage curve.

12. The method of claim 1 wherein terminating charging in response to a change from a rising to a falling value of the first derivative of the voltage variation with time is performed by detecting when the rate of change in battery voltage first rises, then falls and then again rises, terminating charging in response to the latter occurrence of the falling rate of change.

13. The method of claim 1 wherein said detecting step is performed by applying a predetermined current to said battery for a predetermined time and thereafter sampling the battery voltage decay characteristics.

14. The method of claim 13 wherein said predetermined current is greater than one ampere.

15. The method of claim 13 wherein said predetermined time is less than one second.

16. A method of charging a battery comprising:

detecting the state of charge prior to charging by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the decay as an indication of the state of charge of the battery;

controlling charging in accordance with the following;

(a) if the detected state of charge prior to charging is above a predetermined level, terminating charging; and

(b) if the detected state of charge prior to charging is below a predetermined level, initiating charging while monitoring the battery voltage variation with time, and terminating charging in response to a change from a rising to a falling value of the first derivative of the voltage variation with time.

17. The method of claim 16 wherein said detecting step is performed by applying a current to said battery for a predetermined time and after said predetermined time sampling the battery voltage at least twice to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

18. The method of claim 16 wherein said detecting step is performed by applying a current to said battery for a first predetermined time and after said first predetermined time sampling the battery voltage during a second period of time to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

19. The method of claim 18 wherein said second period of time begins after a predetermined delay following the end of said first period of time.

20. The method of claim 19 wherein said predetermined delay is selected such that said second time period begins after change in battery voltage due to battery impedance has substantially abated.

21. The method of claim 16 wherein said detecting step is performed by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is above a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is not above said predetermined decay, then the detected state of charge is deemed below said predetermined level.

22. The method of claim 16 wherein said detecting step is performed by applying a current to said battery, then removing the applied current and measuring the battery voltage decay after removing the current and using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is not below a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is below said predetermined decay, then the detected state of charge is deemed below said predetermined level.

23. The method of claim 16 wherein the battery voltage variation with time is determined by periodically measuring battery voltage and computing a value indicative of the first derivative of voltage with respect to time.

24. The method of claim 16 wherein said detecting step is performed by applying a predetermined current to said battery for a predetermined time and thereafter sampling the battery voltage decay characteristics.

25. The method of claim 24 wherein said predetermined current is greater than one ampere.

26. The method of claim 24 wherein said predetermined time is less than one second.

27. The method of determining the state of charge of a battery comprising:

applying a current to said battery;

thereafter removing the applied current; and

measuring the battery voltage decay after removing the current and using the voltage decay as an indication of the state of charge of the battery.

28. The method of claim 27 further comprising applying a current to said battery for a predetermined time and after said predetermined time sampling the battery voltage at least twice to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery.

29. The method claim 27 further comprising applying a current to said battery for a first predetermined time and after said first predetermined time sampling the battery voltage during a second period of time to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery.

30. The method of claim 29 wherein said second period of time begins after a predetermined delay following the end of said first period of time.

31. The method of claim 30 wherein said predetermined delay is selected such that said second time period begins after change in battery voltage due to battery impedance has substantially abated.

32. The method of claim 27 further comprising using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is above a predetermined decay, then the state of charge of the battery is deemed above a predetermined level indicative of a substantially fully charged condition; and

(b) if the voltage decay is not above said predetermined decay, then the state of charge of the battery is deemed below said predetermined level.

33. The method of claim 27 wherein said step of using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is not below a predetermined decay, then the detected state of charge is deemed above a predetermined level indicative of a substantially, fully charged condition; and

(b) if the voltage decay is below said predetermined decay, then the detected state of charge is deemed below said predetermined level.

34. The method of controlling the charging operation of a battery charger comprising:

applying a current to said battery;

thereafter removing the applied current; and

measuring the battery voltage decay after removing the current and using the voltage decay as an indication of the state of charge of the battery; and

if the detected state of charge is above a predetermined level, terminating the charging operation;

if the detected state of charge is below a predetermined level, permitting the charging operation to proceed.

35. The method of claim 34 further comprising applying a current to said battery for a predetermined time and after said predetermined time sampling the battery voltage at least twice to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery.

36. The method of claim 34 further comprising applying a current to said battery for a first predetermined time and after said first predetermined time sampling the battery voltage during a second period of time to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery.

37. The method of claim 36 wherein said second period of time begins after a predetermined delay following the end of said first period of time.

38. The method of claim 37 wherein said predetermined delay is selected such that said second time period begins after change in battery voltage due to battery impedance has substantially abated.

39. The method of claim 34 further comprising using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is above a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is not above said predetermined decay, then the detected state of charge is deemed below said predetermined level.

40. The method of claim 34 wherein said step of using the voltage decay as an indication of state of charge as follows:

(a) if the voltage decay is not below a predetermined decay, then the detected state of charge is deemed above said predetermined level; and

(b) if the voltage decay is below said predetermined decay, then the detected state of charge is deemed below said predetermined level.

41. A method of charging a battery comprising the steps of:

detecting the state of charge of the battery prior to charging by applying a current to said battery for a relatively brief period of time, removing the applied current, and then measuring the battery voltage decay as an indication of the state of charge of the battery; and

controlling charging of the battery in accordance with the initially detected state of charge of the battery.

42. The method of claim 41 wherein said controlling step includes:

initiating charging of the battery; and

controlling the termination of charging in accordance with the initially detected state of charge of the battery.

43. The method of claim 42 wherein said detecting step is performed by applying a current to said battery for a predetermined time and after said predetermined time sampling the battery voltage at least twice to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

44. The method of claim 42 wherein said detecting step is performed by applying a current to said battery for a first predetermined time and after said first predetermined time sampling the battery voltage during a second period of time to determine a time rate of change in battery voltage and using said time rate of change as an indication of the state of charge of the battery prior to charging.

45. The method of claim 44 wherein said second period of time begins after a predetermined delay following the end of said first period of time.

46. The method of claim 45 wherein said predetermined delay is selected such that said second time period begins after change in battery voltage due to battery impedance has substantially abated.

47. The method of claim 42 wherein said controlling charge termination step is performed by monitoring battery voltage variation with time and terminating charge as follows:

(a) if the voltage decay is above a predetermined level, terminating charging in response to a fall in the first derivative of the battery voltage variation with time; and

(b) if the voltage decay is below said predetermined level, terminating charging in response to a change from a rising to a falling value of the first derivative of the battery voltage variation with time.