Method and apparatus for using an external resistor for charging applications

• US 7,656,127 B1
• Filed: 02/27/2007
• Issued: 02/02/2010
• Est. Priority Date: 02/27/2006
• Status: Active Grant

• Current Assignee: Monterey Research, LLC (Vector Capital Corporation)
• Original Assignee: Cypress Semiconductor Corporation (Infineon Technologies AG)
• Inventors: Snyder, Warren S., Shutt, James H.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US11/711,966
• Time in Patent Office: 1,071 Days
• Field of Search: 320/107, 320/128, 320/132, 320/134, 320/136
• US Class Current: 320/134
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 50/569 Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A device using a single external resistor for battery charging applications and a software current feedback control loop for use with the external resistor is described. For instance, a single resistor can be used to determine the charge electrical current level being used to charge a battery. The determined level from the single resistor can be used in a feedback loop to set the charge electrical current level and to determine if there is an over current condition requiring the charge current be shut down.

Claims

1. An apparatus comprising:

a battery charger control loop comprising a single external resistor, the loop configured to set a battery charge current of a battery and monitor an over-current condition of the battery.

2. The apparatus of claim 1, wherein the control loop comprises:

a current sensor to determine the battery charge current flowing through the single external resistor; and

a controller sub-system coupled to the current sensor, the controller sub-system to set the battery charge current based on the determined battery charge current and to monitor the over-current condition based on the determined battery charge current.

3. The apparatus of claim 2, wherein the control loop further comprises:

a current source coupled to the controller sub-system, the current source to generate the battery charge current; and

a transistor coupled to the current source, the transistor to shut down the battery charge current.

4. The apparatus of claim 3, wherein the current sensor comprises an analog-to-digital converter (ADC) to measure the voltage across the single external resistor, wherein the determined battery charge current is based on the measured voltage and the resistive value of the external single resistor, and wherein the controller sub-system comprises an digital-to-analog converter (DAC), the DAC to send a control signal to the current source based on the measured voltage.

5. The apparatus of claim 4, wherein the battery charger control loop is under software control to set the battery charge current and monitor the over-current condition based on a current level flowing through the single external resistor by measuring a voltage level across the single external resistor using an analog-to-digital converter (ADC), and by setting the control signal in the DAC.

6. The apparatus of claim 2, wherein the single external resistor and the current sensor are coupled between a battery and ground to an external contact pin of a chip, and the current sensor is configured to measure a voltage across the single external resistor to determine the battery charge current flowing through the battery.

7. The apparatus of claim 6, further comprising:

a first comparator to compare the measured voltage to a predetermined battery charge current threshold range; and

a second comparator to comparator the measured voltage to a predetermined over-current threshold value,

wherein if the measured voltage is not within the battery charge current threshold range, the controller sub-system adjusts the battery charge voltage, and wherein if the measured voltage exceeds the over-current threshold value, the controller sub-system shuts down the battery charge current.

8. A battery charging system comprising:

a current source to generate current through a battery;

a resistor to receive the current from the battery;

a current sensor coupled to the resistor to determine the current from the battery using the resistor and to output a determined current level; and

a controller sub-system to receive the output and to set the current through the battery based on the determined current level, and to shut down the current through the battery based on the determined current level.

9. The system of claim 8, wherein the current source, resistor, current sensor and controller sub-system form a feedback loop to control the current generated by the current source based on the determined current flowing through the resistor.

10. The system of claim 9, wherein the feedback loop comprises a controller sub-system of a microcontroller unit (MCU) coupled between the current sensor and the current source to control the current source based on the determined current level.

11. The system of claim 10, wherein the controller sub-system comprises a software controlled controller sub-system coupled between the current sensor and the current source configured to:

measure a voltage across the resistor using an analog-to-digital converter (ADC), and

set a digital-to-analog converter (DAC) reference voltage based on the measured voltage to set the current level or to shut down the current level.

12. The system of claim 11, wherein the current source comprises a transistor to shut down, increase, decrease, or maintain the current level, the transistor having a source coupled to a voltage source, a drain coupled to a first terminal of a battery, and a gate coupled to receive a signal based on the reference voltage.

13. The system of claim 12, wherein the resistor is coupled between a second terminal of the battery and ground, wherein the current sensor is coupled between the second terminal, the resistor, and the controller sub-system, and wherein the system further comprises a voltage sensor coupled between the source of the transistor, the first terminal, and the controller sub-system.

14. The system of claim 8, wherein the system is a linear system and wherein the current source comprises a P-type field effect transistor (PFET) having a source coupled to a voltage source, a drain coupled to a first terminal of a battery, wherein the resistor is coupled between a second terminal of the battery and ground, wherein the current sensor comprises an analog-to-digital converter (ADC) coupled between the second terminal and the resistor;

and wherein the system further comprises;

a controller sub-system of a MCU coupled between the current sensor and a DAC;

a voltage sensor coupled between the first terminal and the controller sub-system; and

an error amplifier having an inverting input coupled to the DAC, and output coupled to a gate of the PFET, and a non-inverting input coupled to the first terminal.

15. The system of claim 8, wherein the system is a switching system and herein the current source comprises a P-type field effect transistor (PFET) coupled between a voltage source and first terminal of an inductor, and a second terminal of the inductor coupled to a first terminal of a battery, wherein the resistor is coupled between a second terminal of the battery and ground, wherein the current sensor comprises an ADC coupled to the second terminal, and wherein the system further comprises:

a controller sub-system of a MCU coupled between the current sensor and a DAC;

a voltage sensor coupled between the first terminal and the controller sub-system;

a DAC coupled between an output of the controller sub-system and an input of a pulse width modulator (PWM); and

a high-side driver (HSDRV) coupled between an output of the PWM and a gate of the PFET.

16. A method comprising:

receiving a charge current determination of a current flowing through a single resistor;

setting a battery charge current based on the determination; and

monitoring an over-current condition based on the determination.

17. The method of claim 16, wherein setting comprises maintaining the charge current within a predetermined current range and wherein monitoring comprises determining whether to shut down the charge current.

18. The method of claim 17, wherein maintaining comprises:

increasing the charge current from a level below the range to a level within the range; and

decreasing the charge current within the range,

and wherein determining whether to shut down the charge current comprises determining whether to maintain the charge current below a predetermined over-current threshold or to shut down the charge current.

19. The method of 17, wherein setting comprises:

comparing the determination with a predetermined charge current threshold;

increasing the charge current if the determination is below the predetermined charge current threshold; and

decreasing the charge current if the determination is above the predetermined charge current threshold.

20. The method of 19, wherein monitoring comprises:

comparing the determination with a predetermined over-current threshold; and

shutting down the charge current if the determination is above the predetermined over-current threshold.