Systems and methods for self-contained automatic battery charging and battery-life-extension charging
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
H02J-007/00
H02M-007/04
H02J-007/02
출원번호
US-0258371
(2016-09-07)
등록번호
US-9948125
(2018-04-17)
발명자
/ 주소
Groat, Timothy
Miller, Kyle
Flavin, John
Kaewert, William
출원인 / 주소
Stored Energy Systems, a Limited Liability Company
대리인 / 주소
Sheridan, James A.
인용정보
피인용 횟수 :
0인용 특허 :
15
초록▼
The disclosure provides embodiments of a self-contained automatic battery charging system having a power printed circuit board (PCB) that enables inputting an alternating current (AC) power flow to the automatic battery charging system. A first switchmode converter converts an AC input power to a di
The disclosure provides embodiments of a self-contained automatic battery charging system having a power printed circuit board (PCB) that enables inputting an alternating current (AC) power flow to the automatic battery charging system. A first switchmode converter converts an AC input power to a direct current (DC) power, thereby providing an active power factor correction. The first switchmode converter comprises an isolation transformer, which provides an electrical isolation between a primary circuitry and a secondary circuitry of the automatic battery charging system. A second switch mode converter regulates a system output voltage and limits a system output current to an electrical load. A DC output is connected to a battery, another electrical storage device, and/or a parallel-connected DC load to be powered. An optional accessory PCB electrically connects to the power PCB and provides features including a liquid crystal display (LCD), alarm output relay(s), and/or a controller area network bus (CANbus) interface. The automatic battery charging system can implement a battery-life-extension charging regime. Other embodiments are disclosed.
대표청구항▼
1. A battery-life-extension charging system, comprising: a monitoring component configured to measure a direct current (DC) output current delivered by the charging system to a battery, wherein the DC output current is a function of an existing charge status of the battery;a timing component; anda c
1. A battery-life-extension charging system, comprising: a monitoring component configured to measure a direct current (DC) output current delivered by the charging system to a battery, wherein the DC output current is a function of an existing charge status of the battery;a timing component; anda charge control system in communication with the monitoring component and the timing component, the charge control system configured for: obtaining at least one of a time measurement from the timing component and a charge measurement from the monitoring component;based on the at least one of the time measurement and the charge measurement, determining at least one of a time to complete the charge mode cycle and a charge to complete a charge mode cycle, each tailored to achieve a desired charge status of the battery; andbased on at least one of the determined time and the determined charge to complete the charge mode cycle, transitioning to a select one of a number of DC output voltage settings until the determined time to complete the determined charge mode cycle has passed or the charge to complete the charge mode cycle has been provided, wherein the DC output voltage settings include at least an eco-float output voltage setting, a refresh output voltage setting, and a boost output voltage setting. 2. The battery-life-extension charging system of claim 1, wherein the charge control system is further configured for continually repeating the obtaining the at least one of a time measurement and a charge measurement, the determining at least one of a time to complete a charge mode cycle and a charge to complete the charge mode cycle, and the transitioning to a select one of a number of the DC output voltage settings. 3. The battery-life-extension charging system of claim 2, wherein the DC output voltage settings further include a float output voltage setting. 4. The battery-life-extension charging system of claim 3, wherein: the eco-float output voltage setting comprises an eco-float output voltage that is equal to or nominally higher than an open-circuit voltage of the battery;the float output voltage setting comprises a float output voltage that offsets at least a rate of self-discharge of the battery;the boost output voltage setting comprises a boost output voltage that is equal to a maximum voltage required to accelerate battery charging; andthe refresh output voltage setting comprises a refresh output voltage that is higher than the float output voltage and lower than the boost output voltage. 5. The battery-life-extension charging system of claim 3, wherein a first time to complete a first charge mode cycle in the refresh output voltage setting comprises between 1% and 10% of a second time to complete a second charge mode cycle in the eco-float output voltage setting. 6. The battery-life-extension charging system of claim 1, wherein: the monitoring component comprises a DC current sensor integrated within a monitoring and control circuitry of the charging system; andthe timing component is one or more of a timer, a clock, or a counter integrated within the monitoring and control circuitry of the charging system. 7. The battery-life-extension charging system of claim 1, wherein the battery is a flooded lead-acid starting, lighting, and ignition (SLI) battery. 8. The battery-life-extension charging system of claim 1, wherein the DC output current delivered by the charging system also powers an accessory DC load. 9. A battery-life-extension charging method of a charging system, the method comprising: obtaining a charge measurement associated with a battery via a monitoring component of a battery charger, the charge measurement reflecting a direct current (DC) output current delivered by the battery charger to the battery;obtaining a time measurement associated with the battery via a timing component of the battery charger;transmitting at least one of the charge measurement and the time measurement to a battery charge control system of the battery charger;determining, by the battery charge control system and based on at least one of the charge measurement and the time measurement, at least one of a charge to complete a charge mode cycle and a time to complete the charge mode cycle, the charge mode cycle is tailored to achieve a desired charge status of the battery; andselectively regulating, by a voltage regulator in communication with the battery charge control system, a DC output voltage of the battery charger to one of a number of pre-set DC output voltages until the time to complete the charge mode cycle has passed or the charge to complete the charge mode cycle has been provided, the pre-set DC output voltages comprising an eco-float output voltage, a refresh output voltage, and a boost output voltage. 10. The battery-life-extension charging method of claim 9, wherein the pre-set DC output voltages further comprise a float output voltage. 11. The battery-life-extension charging method of claim 10, wherein: the eco-float output voltage comprises a voltage equal to or nominally higher than an open-circuit voltage of the battery;the float output voltage comprises a voltage that offsets at least a rate of self-discharge of the battery;the boost output voltage comprises a voltage equal to a maximum voltage required to accelerate battery charging; andthe refresh output voltage comprises a voltage higher than the float output voltage and lower than the boost output voltage. 12. The battery-life-extension charging method of claim 9, wherein: the monitoring component comprises a DC current sensor integrated within a monitoring and control circuitry of the charging system; andthe timing component comprises one of a timer, a clock, or a counter integrated within the monitoring and control circuitry of the charging system. 13. An automatic, self-contained, battery-life-extension charging system, comprising: a power printed circuit board (PCB) comprising: input connections to allow an input alternating current (AC) to flow into the charging system;two series-connected switchmode converters that together are configured to convert the input AC into an output direct current (DC) for delivery to a DC load, to limit the output DC to the DC load, and to regulate a DC output voltage; andmonitoring and control circuitry in communication with the two series-connected switchmode converters, the monitoring and control circuitry comprising: a monitoring component configured to measure a charge measurement associated with the DC load;a timing component configured to measure a time measurement associated with a charge mode cycle of the DC load; anda charge control system in communication with the monitoring component and the timing component, the charge control system configured to transition the two series-connected switchmode converters between a number of DC output voltage charge modes based upon at least one of the charge measurement and the time measurement. 14. The automatic, self-contained, battery-life-extension charging system of claim 13, wherein the charge measurement reflects the output DC delivered by the two series-connected switchmode converters to the DC load, and wherein the output DC is a function of an existing charge status of the DC load. 15. The automatic, self-contained, battery-life-extension charging system of claim 13, wherein of the DC output voltage charge modes include: an eco-float charge mode in which the DC output voltage comprises a voltage equal to or nominally higher than an open-circuit voltage of the DC load;a float charge mode in which the DC output voltage comprises a voltage that offsets at least a rate of self-discharge of the DC load;a boost charge mode in which the DC output voltage comprises a float output voltage equal to a maximum voltage required to accelerate charging of the DC load; anda refresh charge mode in which the DC output voltage comprises a boost output voltage higher than the float output voltage and lower than the boost output voltage. 16. The automatic, self-contained, battery-life-extension charging system of claim 15, wherein the timing component causes the charge control system to maintain a charge-mode ratio of the eco-float charge mode to the refresh charge mode that is between 90:10 and 99:1. 17. The automatic, self-contained, battery-life-extension charging system of claim 13, wherein the two series-connected switchmode converters are further configured to provide an active power factor correction so as to provide an improved power factor, provide an electrical isolation between a primary circuitry and a secondary circuitry, and provide output connections configured for wiring the output DC to the DC load. 18. The automatic, self-contained, battery-life-extension charging system of claim 17, wherein the two series-connected switchmode converters combine to form a two-stage switchmode converter, the two-stage switchmode converter comprising an active circuitry for controlling an amount of the input AC to maintain a sinusoidal waveform in phase with an input voltage waveform to provide the active power factor correction. 19. The automatic, self-contained, battery-life-extension charging system of claim 13, further comprising an accessory PCB electrically connected to the power PCB, the accessory PCB and the power PCB housed in a common enclosure, the accessory PCB further comprising a liquid crystal diode (LCD) display, one or more alarm output relays, and/or a controller area network bus (CANbus) interface. 20. The automatic, self-contained, battery-life-extension charging system of claim 13, wherein the DC load comprises at least one of a flooded lead-acid starting-lighting-ignition (SLI) battery to be charged, another electrical storage device to be charged, and an accessory DC load to be powered.
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