Method and apparatus for charging batteries

• US 5,680,031 A
• Filed: 03/26/1996
• Issued: 10/21/1997
• Est. Priority Date: 03/26/1996
• Status: Expired due to Term

• Current Assignee: Minit Charger, LLC
• Original Assignee: Norvik Traction, Inc.
• Inventors: Field, Robert B., Pavlovic, Vladimir S., Nor, Jiri K.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): SHIN, KYUNG E
• Application Number:
  US08/621,930
• Time in Patent Office: 574 Days
• Field of Search: 320/21, 320/22, 320/23, 320/24, 320/48, 320/30, 320/31, 320/32, 320/39, 324/430, 324/429, 324/433
• US Class Current: 320/145
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process

Abstract

A charger for charging a rechargeable battery. The charger comprising a circuit for producing a charging current having a variable level and a control circuit for controlling the charging current. During a first charging period the current is maintained at a level to rapidly charge the battery at a rate in amperes which is greater than the capacity of the battery in ampere-hours. The controller includes means for interrupting the charging current for a predetermined interruption interval. During the interruption interval, the charging current is maintained at a non-zero value. The controller also includes means for determining a resistance free voltage for the battery. During a subsequent charging period, the charging current is controlled in response to the value of the resistance free voltage.

Claims

1. An apparatus for charging a rechargeable battery, said apparatus comprising:

generator means for generating a charging current having a variable level, and during a first charging period said current having a level to rapidly charge the battery at a rate in amperes greater than the capacity in ampere-hours of the battery;

controller means for controlling said generator means, said controller means including,

(a) means for varying said charging current for a predetermined variation interval and during said variation interval said charging current being maintained at a non-zero, non-negative value;

(b) means for determining a resistance free voltage value for the battery during said variation interval;

(c) means for comparing a reference voltage to said resistance free voltage value for the battery;

(d) means for controlling the level of said charging current in response to said resistances free voltage.

2. The apparatus as claimed in claim 1, wherein said charging current is periodically interrupted at a rate dependent on the charge state of said battery.

3. The apparatus as claimed in claim 1, wherein said variation interval has a duration of up to about 500 milliseconds.

4. The apparatus as claimed in claim 1, wherein said means for varying varies said charging current when said resistance free voltage reaches predetermined percentages of said reference voltage.

5. The apparatus as claimed in claim 4, wherein said predetermined percentages comprise 92%, 96%, 98% and 99%.

6. The apparatus as claimed in claim 5, wherein said variation interval has a duration of up to about 500 milliseconds.

7. The apparatus as claimed in claim 1, wherein said means for determining the resistance free voltage value includes means for inputting high and low voltage readings and high and low current readings during said variation interval, and means for calculating a resistance free voltage value from said input voltage and current readings.

8. The apparatus as claimed in claim 1, wherein said means for determining the resistance free voltage value includes means for inputting high and low voltage readings and high and low current readings during said variation interval, and means for calculating an internal resistance for the battery from said input voltage and current readings.

9. The apparatus as claimed in claim 8, wherein said means for determining the resistance free voltage value further includes means for calculating a resistance free voltage value from said internal resistance value and said high voltage and current readings.

10. The apparatus as claimed in claim 7, wherein said resistance free voltage is calculated according to the expression:

##EQU3##

11. The apparatus as claimed in claim 8, wherein said internal resistance value is calculated according to the expression:

space="preserve" listing-type="equation">R=(V.sub.Hi -V.sub.Low)/(I.sub.Hi -I.sub.Low).

12. The apparatus as claimed in claim 9, wherein said resistance free voltage is calculated according to the expression:

space="preserve" listing-type="equation">V.sub.RF =V.sub.Hi -R I.sub.Hi.

13. The apparatus as claimed in claim 3, wherein said current comprises two or more levels during said variation interval, and said levels having predetermined durations.

14. The apparatus as claimed in claim 13, wherein during said variation interval said current has a fall and rise time in the range of about from 0.01 C/ms to 10 C/ms.

15. The apparatus as claimed in claim 1, wherein said means for determining a resistance free voltage includes means for reading a value for said resistance free voltage, and said reading being started 1 ms after commencement of said variation interval.

16. The apparatus as claimed in claim 1, wherein said means for controlling the current includes means for providing a current with a constant level for a predetermined time.

17. The apparatus as claimed in claim 1, wherein said means for controlling maintains the level of said charging current so that the resistance free voltage for the battery approaches the reference voltage.

18. The apparatus as claimed in claim 17, wherein said means for controlling the level of said charging current includes means for incrementally decreasing the level of said charging current when said resistance free voltage approaches said reference voltage.

19. A method for charging a rechargeable battery comprising the steps of:

(a) generating a charging current having a variable level;

(b) maintaining said charging current during a first charging period at a level to rapidly charge the battery at a rate in amperes greater than the capacity in ampere-hours of the battery;

(c) changing said charging current for a predetermined variation interval;

(d) maintaining said charging current at a non-zero, non-negative value during said variation interval;

(e) determining a resistance free voltage value for the battery after said change; and

(f) varying the level of said charging current in response to said resistance free voltage value determined in step (e).

20. The method as claimed in claim 19, wherein said step of varying the level of said charging current comprises comparing said resistance free voltage value for the battery to a reference voltage and decreasing the level of said charging current if said resistance free voltage value exceeds said reference voltage.

21. The method as claimed in claim 19, wherein said charging current is changed at a rate dependent on the charge state of the battery.

22. The method as claimed in claim 21, wherein said variation interval has a duration of up to about 500 milliseconds.

23. The method as claimed in claim 19, wherein said step of changing said charging current comprises changing the level of said charging current when said resistance free voltage determined for the battery reaches predetermined percentages of a reference voltage.

24. The method as claimed in claim 23, wherein said predetermined percentages comprise 92%, 96%, 98% and 99%.

25. The method as claimed in claim 24, wherein said variation interval has a duration of up to about 500 milliseconds.

27. The method as claimed in claim 19, further includes the step of determining an internal resistance for the battery comprising inputting high and low voltage readings and high and low current readings for the battery during said variation interval, and calculating an internal resistance value for the battery from the input voltage and current readings according to the expression,

28. The method as claimed in claim 27, wherein said step for determining a resistance free voltage value for the battery comprises calculating a value for the resistance free voltage according to the expression:

space="preserve" listing-type="equation">V.sub.RF =V.sub.Hi -R I.sub.Hi.

26. The method as claimed in claimed 19, wherein said step for determining a resistance free voltage value for the battery comprises inputting high and low voltage readings and high and low current readings for the battery during said variation interval, and calculating a resistance free voltage value from said input voltage and current readings according to the expression:

##EQU4##

29. A method for determining a resistance free voltage value during the charging cycle when a charging current is applied to a rechargeable battery, said method comprising the steps of:

(a) varying said charging current for a predetermined interval;

(b) inputting high and low voltage readings and high and low current readings for the battery during said predetermined interval; and

(c) calculating a resistance free voltage value from said input voltage and current readings according to the expression;

##EQU5##

30. The method as claimed in claim 29, wherein said step of varying the charging current comprises reducing the magnitude of said charging current to a non-negative value during said predetermined interval.

31. The method as claimed in claim 30, wherein said charging current is varied at a rate dependent on the charge state of the battery.

32. The method as claimed in claim 31, wherein said predetermined interval has a duration of up to about 500 milliseconds.

33. The method as claimed in claim 29, wherein said step of varying the charging current comprises reducing the magnitude of said charging current to a plurality of non-negative values of predetermined durations during said predetermined interval.