Method and apparatus for monitoring battery voltage

• US 5,708,348 A
• Filed: 11/20/1995
• Issued: 01/13/1998
• Est. Priority Date: 11/20/1995
• Status: Expired due to Fees

• Current Assignee: Paradise Machining Corporation
• Original Assignee: Warren Johnson
• Inventors: Frey, Mitchell B., Hobart, Kirk L., Renick, Christopher A.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US08/561,034
• Time in Patent Office: 785 Days
• Field of Search: 320/20, 320/21, 320/22, 320/23, 320/30, 320/31, 320/32, 320/35, 320/39
• US Class Current: 320/145
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process

Abstract

A battery monitoring method and apparatus for delivering current to a battery, particularly a lead-acid battery, in standby condition after it has been charged and in such a manner as to maintain the rated ideal charge on the battery at the ambient temperature while minimizing damage to the battery cells. In particular, the apparatus and method apply pulses of current of variable width when the battery voltage hovers about its ideal voltage, apply continuous current when the battery voltage is below its ideal voltage by a certain amount thereby to raise the voltage toward its ideal voltage, and turn off the current when the battery voltage exceeds an upper limit indicative of overcharging or when the battery voltage is at a lower limit indicative of a defective battery or reversed connections.

Claims

1. A method for monitoring the voltage on a battery so as to supply the battery with charging current when the battery voltage is between upper and lower thresholds respectively above and below an ideal voltage for the battery, comprising:

providing a reference voltage that is related to such ideal battery voltage,

establishing a voltage which represents the actual voltage of the battery being monitored,

comparing the established voltage with the reference voltage, and

supplying current in pulses to the battery when the established voltage is representative of a battery voltage above said lower threshold.

2. A method of maintaining the voltage on a battery within a range from an upper threshold voltage slightly above its ideal standby voltage to a lower threshold voltage slightly below its ideal standby voltage, comprising the steps of:

supplying a continuous flow of current to the battery when the battery voltage is below said lower threshold thereby to raise the battery voltage to within said range,

supplying current in pulses to the battery when the battery voltage is within said range, and

completely shutting off the supply of current to the battery when the battery voltage exceeds said upper threshold thereby to avoid trickle-charging of the battery.

3. The method of claim 2, including the further step of:

varying the length of the current pulses from a maximum pulse length when the battery voltage is at said lower threshold to a minimum pulse length when the battery voltage is at said upper threshold.

4. The method of claim 2 including the further step of:

stopping the flow of current to the battery when the battery voltage is lower than said lower threshold by an amount indicative of a defective battery or reversed battery connections.

5. The method of claim 2, wherein said method of maintaining the voltage on a battery is performed after the battery has been charged to its ideal standby voltage.

6. The method of claim 2,

wherein the supplying step supplies current at a lower than normal battery charging amperage.

7. A method for monitoring the charge on a battery and for maintaining such charge between upper and lower threshold voltages, fully below the ideal, fully charged voltage for the battery and for shutting off charging current to the battery when the battery voltage falls below a minimum voltage less than said lower threshold and at which the battery is considered defective, comprising the steps of:

providing a reference voltage that is related to such ideal voltage,

sensing the voltage of the battery being monitored to provide a sensed voltage,

comparing the sensed voltage with the reference voltage to provide a first signal representing a battery voltage above said ideal voltage, a second signal representing a battery voltage below said ideal voltage, and a third signal representing a battery voltage at or below said minimum voltage,

supplying current to the battery in response to said second signal but shutting off the supply of current in response to said first signal whereby current flow into the battery oscillates between on and off conditions as the battery voltage respectively falls below and rises above said ideal voltage, and

shutting off the supply of current to the battery in response to the third signal.

8. A method of maintaining a charge on a battery after the battery has been charged to a voltage which is equal or close to its ideal standby voltage by controlling the supply and interruption of current flow to the battery, comprising:

providing a reference voltage that is related to such ideal voltage;

sensing the voltage of the battery to provide first and second sensed voltages representative of the actual voltage of the battery being monitored;

comparing the first sensed voltage with the reference voltage to provide first and second signals respectively depending on whether the first sensed voltage is greater or less than the reference voltage, said first and second signals respectively representing maximum and intermediate battery voltages above an upper threshold slightly greater than said ideal voltage and below a lower threshold slightly less than said ideal voltage;

comparing the second sensed voltage with the reference voltage to provide a third signal when the second sensed voltage is less than the reference voltage, said third signal representing a minimum battery voltage less than said intermediate battery voltage;

supplying current to the battery in response to said second signal;

interrupting the flow of current to the battery in response to the first and third signals,

said comparing step causing an oscillation between said first and second signals when the first sensed voltage is nearly equal to the reference voltage thereby to supply current to the battery in pulses between said upper and lower thresholds.

9. A method for maintaining an ideal full charge on a lead-acid battery by supplying the battery with charging current when the battery voltage is between upper and lower threshold voltages respectively above and below said ideal charge and when the battery voltage is between the lower threshold voltage and a predetermined minimum voltage representing a defective battery or crossed wires, and so as not to supply current to the battery when the battery voltage is above the upper threshold or below the predetermined minimum, comprising:

providing a reference voltage that has a predetermined relationship to such ideal battery voltage at the ambient temperature of the battery and thereby to said upper and lower threshold voltages at such temperatures,

sensing the voltage of the battery being monitored to provide a first monitoring voltage which represents the actual voltage of the battery when it is in a range from above said upper threshold voltage to said predetermined minimum voltage,

sensing the voltage of the battery being monitored to provide a second monitoring voltage which represents the actual voltage of the battery below said predetermined minimum voltage,

comparing the first and second monitoring voltages with the reference voltage,

supplying current to the battery when said comparison with the first monitoring voltage indicates that the battery voltage is between said predetermined minimum voltage and said upper threshold voltage, and

ceasing the supply of current to the battery when said comparison with the first monitoring voltage indicates that the battery voltage is above said upper threshold voltage and when said comparison with the second monitoring voltage indicates that the battery voltage is below said predetermined minimum voltage.

10. The method of claim 9,

wherein said supplying step includes supplying current continuously to the battery when said comparison indicates that the battery voltage is between said predetermined minimum voltage and said lower threshold, and

wherein said supplying step further includes supplying current to the battery in pulses when said comparison indicates that the battery voltage is between said lower and upper thresholds.

11. The method of claim 10,

wherein said supplying step includes reducing the width of the pulses as said comparison indicates that the battery voltage is increasing from said lower threshold voltage to said upper threshold voltage and increasing the width of the pulses as said comparison indicates that the battery voltage is decreasing from said upper threshold to said lower threshold.

12. An apparatus for monitoring a battery to maintain its voltage within a range from an upper threshold voltage slightly above its ideal standby voltage and a lower threshold voltage slightly below its ideal standby voltage, comprising:

means for supplying a continuous flow of current to the battery when the battery voltage is below said lower threshold thereby to raise the battery voltage to within said range,

means for supplying current in pulses to the battery when the battery voltage is within said range, and

means for completely shutting off the supply of current to the battery when the battery voltage exceeds said upper threshold thereby to avoid trickle-charging of the battery.

13. The apparatus of claim 12, including:

means for varying the length of the current pulses from a maximum pulse length when the battery voltage is at said lower threshold to a minimum pulse length when the battery voltage is at said upper threshold.

14. The apparatus of claim 13 including;

means for stopping the flow of current to the battery when the battery voltage is lower than said lower threshold by an amount indicative of a defective battery or reversed battery connections.

15. The apparatus of claim 14,

wherein said supplying and interrupting means includes first, second and third comparators, said third comparator including means for turning the supply of current on and off, said first comparator including means for causing the third comparator to oscillate between said on and off conditions when the battery voltage is between said upper and lower thresholds and to turn off when the battery voltage is above said upper threshold, and said second comparator including means for overriding said first comparator and disabling said third comparator when said battery voltage is lower than said predetermined amount.

16. The apparatus of claim 15, further including:

voltage reference means providing a temperature-sensitive voltage and a fixed voltage;

battery voltage sensing means for providing sensed voltages representative of the voltage of the battery being monitored,

said first and second comparators being responsive to said voltage sensing means and to said temperature-sensitive voltage,

said third comparator being responsive to said first and second comparators and to said fixed voltage,

said sensing means also including a fourth comparator responsive to the voltage of the battery being monitored and further including means for maintaining the voltage of the sensing means at substantially the same level irrespective of the rated voltage of the battery,

whereby said first and second comparators turn the third comparator on and off depending on the voltages sensed.

17. The apparatus of claim 13 including;

wherein said varying means includes means for continuously varying the duty cycle of the pulses between 0% when the sensed voltage is at the upper threshold and 100% when the sensed voltage is at the lower threshold.

18. The apparatus of claim 12,

wherein the supplying means supplies current at a lower than normal battery charging amperage.

19. An apparatus for monitoring the voltage on a lead-acid battery so as to supply the battery with charging current when the battery voltage is between upper and lower threshold voltages respectively above and below an ideal voltage for the battery and when the battery voltage is between the lower threshold voltage and a predetermined minimum voltage representing a defective battery or crossed wires, and so as not to supply current to the battery when the battery voltage is above the upper threshold or below the predetermined minimum, comprising:

means for providing a temperature -dependent reference voltage that has a predetermined relationship to such ideal battery voltage and thereby to said upper and lower threshold voltages and a fixed reference voltage,

first means for sensing the voltage of the battery being monitored to provide a first monitoring voltage which represents the actual voltage of the battery when it is in a range of voltages from above said upper threshold voltage to said predetermined minimum voltage,

second means for sensing the voltage of the battery being monitored to provide a second monitoring voltage which represents the actual voltage of the battery below said predetermined minimum voltage,

controlling comparator means responsive to the first and second sensing means for respectively comparing the first and second monitoring voltages with the temperature-dependent reference voltage to provide output signals representative of the voltages sensed, and

switching comparator means responsive to the controlling comparing means for comparing said output signals with the fixed reference voltage to supply current to the battery when the first monitoring voltage is representative of a battery voltage between said upper threshold voltage and said minimum voltage, to cease the supply of current to the battery when the first monitoring voltage is representative of a battery voltage above said upper threshold voltage and to cease the supply of current to the battery when the second monitoring voltage is representative of a battery voltage below said predetermined minimum voltage.

20. The apparatus of claim 19,

wherein said switching comparator means is capable of supplying current continuously to the battery when said comparison indicates that the battery voltage is between said predetermined minimum voltage and said lower threshold, and

wherein said controlling comparator means provides an oscillating output which causes said switching comparator means to supply current to the battery in pulses when said comparison indicates that the battery voltage is between said lower and upper thresholds.

21. The apparatus of claim 20,

wherein said switching comparator means includes means for reducing the width of the pulses as said comparison indicates that the battery voltage is increasing from said lower threshold voltage to said upper threshold voltage.

22. An apparatus for monitoring the voltage on a battery and for supplying charging current to the battery through a charging circuit so as to maintain the voltage of the battery near its ideal voltage for the temperature of the battery and as long as the battery voltage is above a defective level of voltage, comprising:

means for providing a reference voltage that has a predetermined relationship to said ideal voltage at the temperature of the battery,

means for sensing the voltage of the battery being monitored to provide a sensed voltage, and

means for comparing the sensed voltage with the reference voltage to control the flow of current in the charging circuit so that there is continuous current flow when the sensed voltage is under a predetermined lower threshold below the reference voltage, so that the current flows in pulses of having a decreasing duty cycle as the sensed voltage rises from said lower threshold past the reference voltage to a predetermined upper threshold above the reference voltage, and so that there is no current flow when the sensed voltage is above said upper threshold and also when the sensed voltage is at or below said defective level of voltage.

23. The apparatus of claim 22,

wherein the means for providing a reference voltage provides a temperature-sensitive reference voltage and a fixed reference voltage;

wherein the sensing means includes first sensing means for providing a sensed voltage representative of the battery voltage above its defective level and second sensing means for providing a sensed voltage representative of a battery voltage at or below said defective voltage;

wherein said supplying means includes a switch having an on condition in which it conducts current to the battery and an off condition in which it blocks current flow to the battery;

wherein said comparing means includes a switching voltage comparator, a primary voltage comparator, and a secondary voltage comparator, each of said comparators having an positive input, a negative input and an output and means for providing a high signal on its output when the signal on its negative input is less than the signal on its positive input and a low signal on its output when the signal on its negative input is greater than the signal on its positive input;

wherein the negative input of the primary comparator and the positive input of the secondary comparator are respectively connected to the first and second sensing means;

wherein the positive input of the primary comparator and the negative input of the secondary comparator are connected to the temperature-sensitive voltage;

wherein the positive input of the switching comparator is connected to the fixed reference voltage; and

wherein the outputs of the primary and secondary comparators are connected to the negative input of the switching comparator.

24. The apparatus of claim 23, including

means for oscillating the output signal of the primary comparator between high and low signals when the signals on its inputs are nearly equal.

25. The apparatus of claim 24,

wherein said secondary comparing means is capable of overriding said primary comparing means to disable said switching comparator when the battery voltage is at said predetermined minimum voltage without interfering with the oscillating means when the battery voltage is above said minimum voltage.

26. The apparatus of claim 24,

wherein said oscillating means causes oscillation of said output signal when said input signal on said negative input changes in magnitude from below to above the input signal on the positive input and within a range of less than 0.5 volt on either side of the positive input.

27. The apparatus of claim 26,

wherein said oscillating means causes said output signal to vary in duration from a maximum duration when the negative input signal is less than the positive input by about 0.2 volt to a minimum duration when the negative input signal is greater that the positive input by about 0.2 volt thereby to cause the current conducted through the switch to flow in pulses having a pulse width of a duration corresponding to the output signal of the primary comparator.

28. The apparatus of claim 22, including:

means for providing a signal which is illuminated in response to the current flowing through the charging circuit and which either is on continuously, pulses, or is off depending on the current flow in the charging circuit as controlled by the comparing means.

29. The apparatus of claim 22, including:

means operative with the sensing means for providing sensed voltages of batteries having different nominal rated voltages.

30. The apparatus of claim 22 in which the monitor is adapted to monitor batteries of different sizes having different voltages, further including:

means responsive to the voltage of the battery being monitored and operative with the voltage sensing means to maintain the sensed voltage at a level which enables its comparison with the reference voltage irrespective of the voltage of the battery.

31. The apparatus of claim 22, further including:

means responsive to the voltage of the battery being monitored for changing the charging voltage to be applied to the battery when current is supplied thereto.

32. The apparatus of claim 31,

wherein said responsive means includes a relay, and including

means for regulating the voltage applied to the relay irrespective of the charging voltage applied to the battery.

33. The apparatus of claim 23, further including:

isolating means for preventing the output of the primary comparator from affecting the output of the secondary comparator while allowing the output of the secondary comparator to affect the output of the primary comparator.

34. The apparatus of claim 33,

wherein said isolating means includes diodes connected to the outputs of the primary and secondary comparators and to the negative input of the switching comparator.

35. An apparatus for monitoring the voltage on a battery so as to supply the battery with charging current when the battery voltage is between upper and lower thresholds respectively above and below an ideal voltage for the battery, comprising:

means for providing a reference voltage that is related to such ideal battery voltage,

means for establishing a voltage which represents the actual voltage of the battery being monitored,

means for comparing the established voltage with the reference voltage, and

means for supplying current in pulses to the battery when the established voltage is representative of a battery voltage above said lower threshold.