Method and system for pulse charging of a lithium-based battery

• US 7,425,816 B2
• Filed: 05/24/2005
• Issued: 09/16/2008
• Est. Priority Date: 11/22/2002
• Status: Active Grant

• Current Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Original Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Inventors: Bublitz, Scott D., Johnson, Todd W., Glasgow, Kevin L., Rosenbecker, Jay J., Meyer, Gary D., Schuecher, Karl F., Weber, Andrew J.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US11/139,020
• Publication Number:
  US 20060071634A1
• Time in Patent Office: 1,211 Days
• Field of Search: 320/106, 320/110, 320/139, 320/141
• US Class Current: 320/141
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0032 disconnection of loads if battery is not under charge, e.g. in vehicle if engine is not running
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/0063 with circuits adapted for supplying loads from the battery
• CPC Class Codes: H02J 7/0071 with a programmable schedule
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A combination including a battery pack and a battery charger operable to supply a charging current to the battery pack. The battery pack includes a plurality of battery cells having a lithium-based chemistry and a present state of charge. The battery pack also includes a battery microcontroller that is operable to measure the present state of charge of at least one of the battery cells to produce battery cell present state of charge measurements. The battery charger includes a charger microcontroller that is operable to receive the battery cell present state of charge measurements from the battery microcontroller. The charger microcontroller is also operable to supply the charging current to the battery pack in pulses, wherein each pulse includes a first time interval where charging current is being supplied to the battery and a second time interval where charging current is being suspended from the battery.

Claims

1. A combination comprising:

a battery pack including

a first battery terminal,

a second battery terminal,

a plurality of battery cells, each of the battery cells having a lithium-based chemistry and a present state of charge, the battery cells being coupled to at least one of the first battery terminal and the second battery terminal, and

a battery microcontroller coupled to at least one of the first battery terminal and the second battery terminal, the microcontroller being operable to measure the present state of charge of at least one of the battery cells to produce battery cell present state of charge measurements; and

a battery charger operable to supply a charging current to the battery pack, the battery charger including

a first charger terminal configured to couple to at least one of the first battery terminal and the second battery terminal, the first charger terminal configured to supply charging current to the battery pack,

a second charger terminal configured to couple to at least one of the first battery terminal and the second battery terminal, and

a charger microcontroller coupled to the second charger terminal and operable to receive the battery cell present state of charge measurements from the battery microcontroller, the charger microcontroller also operable to supply the charging current to the battery pack in pulses, wherein each pulse includes a first time interval in which charging current is being supplied to the battery pack and a second time interval in which supply of charging current to the battery pack is suspended, the microcontroller being further operable to modify the first time interval of a pulse based at least in part on the battery cell present state of charge measurements received from the battery microcontroller.

2. The combination as set forth in claim 1 and wherein the chemistry is a Li-ion based chemistry.

3. The combination as set forth in claim 1 and wherein the charger microcontroller is further operable to modify the second time interval of a pulse based at least in part on the battery cell present state of charge measurements received from the battery microcontroller.

4. The combination as set forth in claim 1 and wherein the battery pack has a pack state of charge, the pack state of charge being the sum of each present state of charge of the plurality of battery cells, the battery microcontroller also operable to measure the pack state of charge to produce a pack state of charge measurement.

5. The combination as set forth in claim 4 and wherein the charger microcontroller is operable to measure the pack state of charge to produce a second pack state of charge measurement.

6. The combination as set forth in claim 5 and wherein the second pack state of charge measurement as measured by the charger microcontroller is greater than the pack state of charge measurement as measured by the battery microcontroller.

7. The combination as set forth in claim 5 and wherein the battery microcontroller sends the present state of charge measurements for each battery cell in the plurality of battery cells as a percentage of the pack state of charge as measured by the battery microcontroller.

8. The combination as set forth in claim 7 and wherein the charger microcontroller is operable to estimate the present state of charge of a battery cell during the first time interval of a first pulse to produce an estimated state of charge measurement of a battery cell based on the percentage and the second pack state of charge measurement as measured by the charger microcontroller, the charger microcontroller is also operable to modify the first time interval of a subsequent pulse based on the estimated state of charge measurement of a battery cell.

9. The combination as set forth in claim 1 and wherein the battery charger is further operable to modify the second time interval of a pulse.

10. A battery charger operable to supply a charging current to a lithium-based battery pack having a plurality of battery cells and a battery microcontroller, each of the battery cells having a lithium-based chemistry and a present state of charge, the battery microcontroller operable to measure the battery cell present state of charge of at least one of the battery cells, the battery charger comprising:

a charger microcontroller operable to receive the battery cell present state of charge from the battery microcontroller, the charger microcontroller also operable to supply the charging current to the lithium-based battery pack in pulses, wherein each pulse includes a first time interval and a second time interval, the first time interval being an interval in which charging current is supplied to the battery pack and the second time interval being an interval in which supply of charging current to the battery pack is suspended, the microcontroller being further operable to modify the first time interval of a pulse based at least in part on the battery cell present state of charge received from the battery microcontroller.

11. The battery charger as set forth in claim 10, and wherein the battery microcontroller is operable to measure each present state of charge of the plurality of battery cells, and wherein the charger microcontroller is operable to receive each battery cell state of charge.

12. The battery charger as set forth in claim 11, and wherein the battery pack has a pack voltage, the pack voltage being a sum of each of the present state of charge of the plurality of battery cells, the charger microcontroller also operable to receive the pack state of charge.

13. The battery charger as set forth in claim 10, and wherein the battery charger is further operable to modify the second time interval of a pulse.

14. A method of pulse charging a battery having a plurality of battery cells, the method comprising:

measuring a state of charge for each battery cell in the plurality of battery cells, each of the battery cells having a lithium-based chemistry;

applying a first pulse of charging current to the battery, the first pulse having a first time interval in which charging current is supplied to the battery and a second time interval in which supply of charging current to the battery is suspended; and

applying a second pulse of charging current to the battery, the second pulse having a third time interval in which charging current is supplied to the battery and a fourth time interval in which supply of charging current to the battery is suspended, the third time interval based at least in part on the state of charge of a battery cell and the third time interval being less than the first time interval.

15. The method of pulse charging as set forth in claim 14 and further comprising:

identifying a high battery cell state of charge among the states of charge of the plurality of battery cells.

16. The method of pulse charging as set forth in claim 15 and further comprising:

measuring a battery state of charge; and

estimating a state of charge for the battery cell identified as the high battery cell state of charge to produce an estimated state of charge for the battery cell.

17. The method of pulse charging as set forth in claim 16 and wherein third time interval is based at least in part on the estimated state of charge for the battery cell.

18. The method of pulse charging as set forth in claim 16 and further comprising:

establishing a battery cell state of charge threshold; and

computing an estimated time when the estimated state of charge for the battery cell reaches the battery cell state of charge threshold.

19. The method of pulse charging as set forth in claim 18 and wherein the third time interval is approximately equal the estimated time.

20. The method of pulse charging as set forth in claim 14 and further comprising:

maintaining a parameter value representing the third time interval; and

modifying the parameter value based at least in part on the state of charge of a battery cell.