Measuring battery clamps

• US 6,218,805 B1
• Filed: 05/05/2000
• Issued: 04/17/2001
• Est. Priority Date: 04/17/1998
• Status: Expired due to Term

• Current Assignee: Sak Auto Kabel AG (AK Holding AG)
• Original Assignee: Menico AG
• Inventors: Melcher, Domenic
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US09/446,177
• Time in Patent Office: 347 Days
• Field of Search: 320/103, 320/104, 320/105, 320/107, 320/111, 320/113, 320/115, 320/150
• US Class Current: 320/105
• CPC Class Codes: G01R 31/364 Battery terminal connectors with integrated measuring arrangements
• CPC Class Codes: G01R 31/3835 involving only voltage measurements

Abstract

A measuring battery clamp (1) with a fastening sleeve (2), with which it is firmly fixed to the positive pole connector (9) of a rechargeable battery (42) both thermally and electrically conducting, includes in its interior sensors (14, 21, 40), as well as means (16, 32, 33, 34) to process the signals generated by the sensors and to prepare them for passing on by means of a two-wire data line (13) to matching indicator units (28, 29). For the energy supply to the sensors (14, 21, 40) and to these means (16, 32, 33, 34), the measuring battery clamp (1) is also connected to the negative pole connector (47) of the battery (42) via a battery cable (12).

With the smallest installation outlay it is possible to bring to display various quantities relating to the battery, such as temperature, voltage, current, power or ampere-hour count on indicator units (28, 29) as well as being used to optimize the battery use during charging and discharging.

Claims

1. An electrical direct current system comprising:

a rechargeable battery having a first pole connector and a second pole connector, said first pole connector and second pole connector having different polarity;

a first battery cable communicating said first pole connector with one or more loads;

a second battery cable communicating said second pole connector with one or more loads;

a first connecting clamp having a first fastening sleeve of metal that is in contact with said first pole connector of said battery, whereby said first battery cable is joined to and is thermally and electrically conducting with said first fastening sleeve;

a second connecting clamp having a second fastening sleeve of metal that is in contact with said second pole connector of said battery, whereby said second battery cable is joined to and is thermally and electrically conducting with said second fastening sleeve;

wherein at least one of said first connecting clamp and said second connecting clamp is a measuring battery clamp, which includes a current sensor and a signal processing unit with an electrical output;

wherein said measuring battery clamp includes at least one second sensor with an output, wherein said second sensor delivers an electrical signal;

said signal processing unit having an electrical input for each of said at least one second sensors and said current sensor wherein said at least one of said second sensors and said current sensor is electrically connected to an output of a corresponding sensor selected from a group consisting of said at least one of said second sensors and said current sensor;

wherein said output is a data line, which makes an electrical connection to said output of said signal processing unit, said electrical connection leading out from an interior of said measuring battery clamp;

wherein said signal processing unit includes a processing means, whereby said processing means may determine the value of at least one physical quantity concerning said battery from a current and from a totality of signals transmitted to said signal processing unit from said at least one of said second sensors and said current sensor that are present; and

wherein said signal processing unit includes means for converting said at least one physical quantity into a suitable form and for passing onto said data line for onward transmission.

2. An electrical direct current system according to claim 1, wherein:

said interior of said measuring battery clamp is defined by a hollow space in a thick portion of said connecting clamp;

wherein, said hollow space defines an essentially gas and fluid tight enclosure.

3. An electrical direct current system according to claim 1 wherein:

said interior of said measuring battery clamp is formed and limited by a case that is connected to said fastening sleeve;

wherein said case defines an essentially gas and fluid tight enclosure.

4. An electrical direct current system according to claim 1, wherein:

energy supplied to said at least one of said second sensors and said current sensor and said signal processing unit is provided via an insulated battery cable that leads into the interior of the measuring battery clamp, wherein said measuring battery clamp is connected to said first pole connection; and

said insulated battery cable is in electrical communication to said second pole connection of the battery.

5. An electrical direct current system according to claim 1 further comprising:

a low resistance shunt resistor between said fastening sleeve and said first battery cable; and

wherein

said current sensor delivers a signal that corresponds to a voltage across said shunt resistor, wherein said signal is proportional to a current flow (I).

6. An electrical direct current system according to claim 1, wherein:

said current sensor includes a resistor comprised of Permalloy fixed in the immediate vicinity of current flow (I); and

said current sensor delivers a signal, which results from the dependency of the electrical resistance of said Permalloy on a strength of a magnetic field, wherein said signal is proportional to said current flow (I).

7. An electrical direct current system according to claim 1, wherein:

said current sensor includes a Hall-probe fixed in a vicinity of a current flow (I);

said current sensor delivers a signal that corresponds to a Hall voltage proportional to a strength of a magnetic field, wherein said signal is proportional to the current flow (I).

8. An electrical direct current system according to claim 1, wherein:

said current sensor includes a Hall-probe fixed in a vicinity of a current flow (I);

wherein said Hall probe generates a Hall voltage that is proportional to a strength of a magnetic field that is proportional to said current flow (I); and

further comprising;

a compensating circuit for generating a compensating voltage, with which said Hall voltage can be compensated to zero; and

said current sensor delivers a signal, that corresponds to said compensating voltage.

9. An electrical direct current system according to claim 1, wherein:

said measuring battery clamp additionally includes a sensor in said interior of said measuring battery clamp for sensing a terminal voltage (U);

said signal processing unit includes means for multiplying two physical quantities for calculating a product of the terminal voltage (U) and the current (I); and

wherein said product can be transferred by said signal processing unit to said data line for onward transmission.

10. An electrical direct current system according to claim 1, wherein:

said measuring battery clamp includes a time meter in said interior of said measuring battery clamp;

said signal processing unit includes a microprocessor for calculating an integral of a physical quantity over time, the microprocessor approximating an integral of a current (I) over time by summing a multiplicity of products of discrete measurements of the current (I) between certain time intervals and an individual time interval; and

wherein said integral can be transferred by the signal processing unit to the data line for onward transmission.

11. An electrical direct current system according to claim 1, wherein:

said measuring battery clamp includes means in said interior of said measuring battery clamp for an integration of a physical quantity over time;

said means for integration including a voltage to frequency converter and an electronic forwards-backwards counter;

said output of said current sensor is connected to an input of the voltage to frequency converter;

an output of the voltage to frequency converter is connected to an input of the forwards-backwards counter;

a frequency proportional to a current (I) from the frequency converter is passed to the forwards-backwards counter with a positive prefix during charging of the battery, with a negative prefix during discharge, for counting;

the output of the forwards-backwards counter is connected to an input of the signal processing unit; and

an integral of current flow over time is determined by the signal processing unit and can be passed for onward transmission to at least one indicator unit.

12. An electrical direct current system according to claim 1, wherein:

a means of output from the signal processing unit includes a bus transceiver;

said bus transceiver is connected to the data line leading out from the measuring battery clamp;

the data line is two-wire at maximum; and

a second bus transceiver is present at each of at least one receiver of incoming data on the data line.

13. An electrical direct current system according to any one of the claims 1 to 12 inclusive, wherein:

the measuring battery clamp includes a temperature sensor in said interior of said measuring battery clamp; and

further comprising;

electronic control means that are connected to an energy supply source;

the electronic control means are connected via a second data line to the data line of the measuring battery clamp;

a control means for accepting data from the data line;

said control means for limiting a charging current from the energy source to the battery to an optimal value that is dependent on a temperature of the battery so as not to exceed said optimal value.

14. An electrical direct current system according to any one of the claims 1 to 12 inclusive, wherein:

at least one indicator unit is present for displaying values of physical quantities;

each of the indicator units is connected to the data line; and

control means are available in each of the indicator units for accepting and displaying data from the data line.

15. An electrical direct current system according to claim 1, further comprising:

a higher ranking computer;

said computer connected via the data line to the direct current system; and

wherein data can be transmitted via the data line between the computer and the direct current system in at least one direction.