Battery protection circuit for multiple battery power supply and charging system

• US 8,749,193 B1
• Filed: 05/10/2013
• Issued: 06/10/2014
• Est. Priority Date: 05/10/2013
• Status: Active Grant

• Current Assignee: InPower LLC
• Original Assignee: InPower LLC
• Inventors: Sullivan, James D.
• Primary Examiner(s): Muralidar, Richard V
• Application Number:
  US13/891,453
• Time in Patent Office: 396 Days
• Field of Search: 320/104, 307/10.7
• US Class Current: 320/104
• CPC Class Codes: H02J 1/08 Three-wire systems; Systems having more than three wires
• CPC Class Codes: H02J 2310/46 for ICE-powered road vehicles
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/1492 by means of controlling devices between the generator output and the battery
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles

Abstract

A battery protection circuit for connection to a vehicle'"'"'s auxiliary battery, auxiliary battery load and chassis battery that is connected to the vehicle'"'"'s alternator. A switching control circuit, including a digital processor, has a voltage sensing circuit connected to the alternator, a voltage sensing circuit connected to the auxiliary battery, a ground terminal for connection to the vehicle'"'"'s common ground and outputs for controlling switches. An electrically controlled first switch is interconnected between the alternator and the auxiliary load. The first switch has a control input terminal connected to an output of the control circuit for being switched between a closed state and an open state. An electrically controlled second switch is interconnected between the auxiliary load and the auxiliary battery. The second switch has a control input terminal connected to an output of the control circuit for being switched between a closed state and an open state.

Claims

1. A protection circuit for controlling the charge and discharge of an auxiliary battery of a multi-battery power supply and charging system, the multi-battery power supply and charging system including a chassis storage battery for supplying electrical power to chassis loads, the auxiliary storage battery for supplying electrical power to auxiliary loads, and an electrical power generator for charging the batteries and supplying electrical power to the loads, the electrical power generator, the batteries and the loads each having an ungrounded terminal and each having a grounded terminal connected to a common ground, the ungrounded electrical power generator terminal being connected to the ungrounded chassis battery terminal, the protection circuit comprising:

(a) circuit node connection terminals including an electrical power generator node for connection to the ungrounded terminal of the electrical power generator, an auxiliary battery node for connection to the ungrounded terminal of the auxiliary storage battery, an auxiliary load node for connection to the ungrounded terminal of the auxiliary load and a ground node for connection to the common ground;

(b) a switching control circuit including a digital processor, the control circuit having a voltage sensing circuit connected to the power generator node, a voltage sensing circuit connected to the auxiliary battery node, a ground terminal for connection to the common ground and outputs for controlling switches;

(c) an electrically controlled first switch connected between the power generator node and the auxiliary load node, the first switch having a control input terminal connected to an output of the control circuit for being switched between a closed state and an open state by the control circuit;

(d) an electrically controlled second switch connected between the auxiliary load node and the auxiliary battery node, the second switch having a control input terminal connected to an output of the control circuit for being switched between a closed state and an open state by the control circuit.

2. A protection circuit in accordance with claim 1 and further comprising a current sensing circuit in series with the second switch and interposed between the auxiliary battery node and the auxiliary load node for sensing the auxiliary battery current, the current sensing circuit having an output connected to an input of the switching control circuit.

3. A protection circuit in accordance with claim 2 and further comprising a voltage sensing circuit connected to the auxiliary load node and having an output connected to an input of the switching control circuit.

4. A protection circuit in accordance with claim 1 and further comprising a voltage sensing circuit connected to the auxiliary load node and having an output connected to an input of the switching control circuit.

5. A protection circuit in accordance with claim 1 wherein the first switch has only one MOS/FET in series connection between the power generator node and the auxiliary load node and the second switch has one MOS/FET in series connection between the auxiliary load node and the auxiliary battery node.

6. A protection circuit in accordance with claim 5 wherein the MOS/FET of the second switch includes an inherent diode and is connected with the anode of the diode connected to the auxiliary load node and cathode of the diode connected to the auxiliary battery node.

7. A protection circuit in accordance with claim 6 and further comprising a current sensing circuit in series with the second switch and interposed between the auxiliary battery node and the auxiliary load node for sensing the auxiliary battery current, the current sensing circuit having an output connected to an input of the switching control circuit.

8. A protection circuit in accordance with claim 7 and further comprising a voltage sensing circuit connected to the auxiliary load node and having an output connected to an input of the switching control circuit.

9. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that

(a) close the first switch when the voltage at the power generator node is at least a designer selected voltage capable of charging the auxiliary battery;

(b) open the first switch when the voltage at the power generator node is less than the designer selected voltage capable of charging the auxiliary battery OR the auxiliary battery voltage exceeds a designer selected auxiliary battery maximum permissible charge state;

(c) close the second switch when the auxiliary battery has a state of charge that is at least a designer selected auxiliary battery minimum permissible charge state OR when the auxiliary battery is receiving a charging current; and

(d) open the second switch when the auxiliary battery has a state of charge that is NOT at least the designer selected minimum permissible state of charge AND the auxiliary battery is NOT receiving a charging current.

10. A protection circuit in accordance with claim 9 wherein

(a) the designer selected voltage capable of charging the auxiliary battery is a constant DC voltage;

(b) the designer selected auxiliary battery maximum permissible charge state is a constant auxiliary battery voltage; and

(c) the designer selected auxiliary battery minimum permissible charge state is a constant auxiliary battery voltage.

11. A protection circuit in accordance with claim 10 wherein

(a) the designer selected voltage capable of charging the auxiliary battery is substantially in the range of 12.8 to 12.9 volts;

(b) the designer selected auxiliary battery maximum permissible charge state is substantially 14.3 volts; and

(c) the designer selected auxiliary battery minimum permissible charge state is substantially 10.3 volts.

12. A protection circuit in accordance with claim 9 wherein the conditions for closing the first switch further require that the voltage across the auxiliary battery is less than the auxiliary battery'"'"'s maximum permissible charge state.

13. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that open the first switch when the auxiliary battery voltage exceeds a designer selected auxiliary battery maximum permissible voltage or charge state.

14. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that close the first switch when the voltage at the power generator node is at least a designer selected voltage capable of charging the auxiliary battery.

15. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that open the first switch when the voltage at the power generator node is less than a designer selected voltage capable of charging the auxiliary battery.

16. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that close the second switch when the auxiliary battery has a state of charge that is at least a designer selected auxiliary battery minimum permissible charge state.

17. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that close the second switch when the auxiliary battery is receiving a charging current.

18. A protection circuit in accordance with claim 1 wherein the switching control circuit has stored instructions that open the second switch when the auxiliary battery charge state is less than its minimum permissible charge state OR when the auxiliary battery charge state is more than its maximum permissible charge state.

19. A protection circuit in accordance with claim 18 wherein the switching control circuit has a stored ampere-hour capacity of the auxiliary battery and has stored instructions that compute the auxiliary battery'"'"'s present charge state by integrating the auxiliary battery'"'"'s current, including both charging and discharging current, beginning from a time that the auxiliary battery was in a fully charged state and has stored instructions for computing a fraction by dividing the present value of the battery'"'"'s stored charge state by the stored ampere-hour capacity to obtain a fraction that represents the present charge state of the battery.

20. A protection circuit in accordance with claim 19 wherein the stored ampere-hour capacity of the auxiliary battery is computed by the switching control circuit by integrating the auxiliary battery'"'"'s current, including both charging and discharging current, at a time during its operation when it was discharged from a fully charged state to a fully discharged state and storing that computed integral.