High frequency battery charger and method of operating same

• US 7,564,223 B2
• Filed: 08/29/2005
• Issued: 07/21/2009
• Est. Priority Date: 01/25/2002
• Status: Active Grant

• Current Assignee: Vector Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Randolph, Bruce, Vetitoe, Roy Scott, Krieger, Michael
• Primary Examiner(s): Ullah; Akm E
• Assistant Examiner(s): Tran; Nguyen
• Application Number:
  US11/212,880
• Publication Number:
  US 20060001401A1
• Time in Patent Office: 1,422 Days
• Field of Search: 320/129, 320/128, 320/139, 324/426, 324/433, 324/427, 324/429
• US Class Current: 320/139
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/007 Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/342 The other DC source being a battery actively interacting with the first one, i.e. battery to battery charging with circuits for polarity protection H02J7/0034

Abstract

A high frequency battery charger for charging a target battery is provided. The battery charger includes a charging circuit including a high frequency transformer, a switch switching the high frequency transformer, a filter coupled to the high frequency transformer for passing a DC voltage signal and a controller providing a high frequency driving signal to the switch. Measuring circuitry measures at least one of a voltage or a current at the target battery. A microprocessor receives the measured voltage or current and calculates diagnostics of the target battery based on at least one of the measured voltage or current.

Claims

1. A high frequency battery charger for charging a target battery, comprising:

a charging circuit including a high frequency transformer, a switch switching the high frequency transformer, a filter coupled to the high frequency transformer for passing a DC voltage signal and a controller providing a high frequency driving signal to the switch;

measuring circuitry for measuring at least one of a voltage or a current at the target battery; and

a microprocessor receiving the measured voltage or current and calculating diagnostics of the target battery based on at least one of the measured voltage or current, wherein the microprocessor is programmed to;

provide a test current that is lower than a charging current from the battery charger to the target battery;

detect if the test current is present at the target battery;

indicate a fault if the test current is not detected at the target battery; and

increase the test current a predetermined amount and return to the detecting step if the test current is detected at the target battery.

2. The charger of claim 1, further comprising connectors coupled to the charging circuit and adapted to be connected to the target battery for providing the DC voltage signal to the target battery, the measuring circuitry being coupled to the connectors to measure at least one of the voltage or the current.

3. The charger of claim 1, wherein the diagnostics include at least one of an overtime fault, a shorted cell fault, a bad battery fault, or an open cell fault.

4. The charger of claim 1, wherein the microprocessor determines a charging time of the target battery.

5. The charger of claim 4, wherein the microprocessor detects the overtime fault in dependence on the charging current being greater than a predetermined current, the charging time being longer than a predetermined time, and the voltage of the battery being less than or equal to a predetermined voltage after the predetermined time.

6. The charger of claim 5, wherein the predetermined current is 2 amps, the predetermined time is 18 hours and the predetermined voltage is 12 volts.

7. The charger of claim 4, wherein the microprocessor detects the shorted cell battery fault in dependence on the battery voltage being less than or equal to a predetermined voltage after a predetermined time.

8. The charger of claim 7, wherein the predetermined time is 1 hour and the predetermined voltage is 11 volts.

9. The charger of claim 3, wherein the microprocessor detects the bad battery fault when no target battery voltage is measured.

10. The charger of claim 3, wherein the microprocessor detects the open cell battery fault in dependence on at least the charging current being less than a predetermined current after a predetermined time.

11. The charger of claim 1 further comprising:

means for coupling a resistance in parallel with the battery; and

means for correlating the measured.voltage to a cold cranking amps (CCA) value.

12. The charger of claim 3 further comprising a display for displaying representations corresponding to the calculated diagnostics.

13. The charger of claim 12, wherein the representations include fault codes.

14. A high frequency battery charger for charging a target battery, comprising:

a high frequency transformer;

means for switching the high frequency transformer;

means coupled to the high frequency transformer for passing a DC voltage signal;

means for providing a high frequency driving signal to the switch;

means for measuring at least one of a voltage or a current at the target battery; and

means for receiving the measured voltage or current and calculating diagnostics of the target battery based on at least one of the measured voltage or current, wherein the means for receiving and calculating provide a test current that is lower than a charging current from the battery charger to the target battery;

detect if the test current is present at the target battery;

indicate a fault if the test current is not detected at the target battery; and

increase the test current a predetermined amount and return to the detecting step if the test current is detected at the target battery.

15. The charger of claim 14, further comprising connecting means adapted to be connected to the target battery for providing the DC voltage signal to the target battery, the means for measuring being coupled to the connecting means to measure at least one of the voltage or the current.

16. The charger of claim 14, wherein the diagnostics include at least one of an overtime fault, a shorted cell fault, a bad battery fault, or an open cell fault.

17. The charger of claim 14, wherein the means for receiving and calculating determines a charging time of the target battery.

18. The charger of claim 17, wherein the means for receiving and calculating detects the overtime fault in dependence on the charging current being greater than a predetermined current, the charging time being longer than a predetermined time, and the voltage of the battery being less than or equal to a predetermined voltage after the predetermined time.