Battery Status Detection System and Method

Abstract

This application relates to battery state detection systems and methods. A battery charger and method are disclosed for detecting when a battery has a low health state while charging or maintaining the battery. A battery charger includes a processor; a non-transitory memory device; a power management device for receiving input power and outputting a charging current; a pair of electrical conductors for electrically coupling to the battery; and a display electrically coupled to the processor. The display is configured to indicate a poor battery indicator when the battery has a low health state, and whether the battery is beneficial for startup.

Description

[0001] Information related to divisional application

[0002] This case is a divisional application. The parent application of this divisional application is the invention patent application filed on May 15, 2017, with application number 201780026057.0 and entitled "Battery State Detection System and Method".

[0003] Cross-reference of related applications

[0004] This application claims the benefits of Provisional Patent Application No. 62 / 336,118, filed May 13, 2016, and Provisional Patent Application No. 62 / 370,317, filed August 3, 2016, pursuant to 35 U.SC §119(e), the contents of which are incorporated herein by reference. Technical Field

[0005] This disclosure relates to a system and method for detecting the state of a battery. More specifically, this disclosure relates to a battery charger system, method, and apparatus for quickly determining and alerting a user about the health and / or charge state of a battery, for example, using a faulty battery indicator. Background Technology

[0006] It is typically desirable to know the battery's state of charge (SoC) and state of health (SOH). Rechargeable batteries (such as accumulators, secondary batteries, etc.) are used in many applications, including starting internal combustion engines in vehicles, cars, or other structures.

[0007] SoC indicates the state of charge of a battery (or an individual battery cell or battery pack). SoC is measured in percentage points, where 0% is empty and 100% is fully charged. An alternative form of the same measurement is the depth of discharge (DoD), which is the inverse of SoC (i.e., 0% is fully charged and 100% is empty). SoC is typically used when discussing the current state of a battery in use, while DoD is most commonly seen when discussing the lifespan of a battery after repeated use.

[0008] SoH (Solar Health) indicates the health of a battery (or an individual battery cell or battery pack). Over time, batteries age and degrade, resulting in a reduced ability to retain charge and deliver its rated current to a load. Ultimately, the battery will need to be replaced—once it has degraded to the point where it may no longer effectively retain charge. SoH represents the condition of a battery compared to its ideal conditions and / or design specifications. Similar to SoC (Solar System Design), SoH can be provided as a percentage. For example, a score of 100% indicates that the battery's condition is largely in line with the battery's original manufacturing specifications.

[0009] As is understood, when charging a battery, it is beneficial to determine whether the battery has a low SoH (Solar Hourly Hovering) in addition to the SoC (Solar Hourly Rate), which can indicate that the battery needs repair or replacement (i.e., a "bad battery"). Therefore, a system, method, and apparatus are needed to determine and display the SoH and SoC of a battery while it is being charged (e.g., during a charging cycle). It is also necessary to determine and display whether the battery has a SoC and / or SoH sufficient to start the engine. Summary of the Invention

[0010] In simple terms, this disclosure relates to a battery charging system, method, and apparatus for determining and alerting a user regarding the battery's SoC and / or SoH. More specifically, it relates to a system, method, and apparatus for determining and displaying the battery's SoH and SoC to a user, and for determining / displaying whether the battery has a SoC and / or SoH sufficient to start the engine.

[0011] According to a first aspect, a method for identifying faulty battery conditions via a battery charger having a display device during the charging process of a lead-acid battery includes: measuring a first battery voltage of a lead-acid battery connected to the battery charger across a pair of electrical conductors using a voltage sensor; comparing the first battery voltage with a first predetermined voltage value stored in the memory device using a processor operatively coupled to the memory device; if the first battery voltage is less than the first predetermined voltage value, measuring a second battery voltage of the lead-acid battery using the voltage sensor after a first time period; comparing the second battery voltage with a second predetermined voltage value stored in the memory device using the processor; and if the second battery voltage is greater than or equal to the second predetermined voltage value, then displaying a faulty battery indicator via the display device.

[0012] According to a second aspect, a battery charger for identifying faulty batteries includes: a processor operably coupled to a voltage sensor; a non-transitory memory device operably coupled to the processor; a power management device for receiving input power and outputting a charging current during a charging process; a display device electrically coupled to the processor, wherein the display device is configured to display a faulty battery indicator; and a pair of electrical conductors for electrically connecting to a lead-acid battery, wherein, in order to determine and display whether the lead-acid battery has a low health state, the battery charger is configured to: use the voltage sensor to measure a first battery voltage of the lead-acid battery connected across the pair of electrical conductors; use the processor to compare the first battery voltage with a first predetermined voltage value stored in the non-transitory memory device; if the first battery voltage is less than the first predetermined voltage value, after a first time period, use the voltage sensor to measure a second battery voltage of the lead-acid battery; compare the second battery voltage with a second predetermined voltage value stored in the non-transitory memory device; and if the second battery voltage is greater than or equal to the second predetermined voltage value, then instruct the display device to display a faulty battery indicator.

[0013] In some respects, the processor is further configured to abort the charging process if the second battery voltage is greater than or equal to a second predetermined voltage value.

[0014] In some respects, the processor is further configured to initiate the desulfurization process when the second battery voltage is greater than or equal to a second predetermined voltage value.

[0015] In some respects, the processor is further configured to measure the third battery voltage of the lead-acid battery connected across the electrical conductor after a second time period, provided that the second battery voltage is greater than or equal to a second predetermined voltage value.

[0016] In some respects, the processor is further configured to compare the third battery voltage with a second predetermined voltage value.

[0017] In some respects, the processor is further configured so that the instruction display device does not display a faulty battery indicator when the third battery voltage is less than or equal to a second predetermined voltage value.

[0018] In some respects, the processor is further configured to display a faulty battery indicator when the third battery voltage is less than a second predetermined voltage value and a lack of progress is detected.

[0019] In some respects, the processor is further configured to display a faulty battery indicator on the instruction display device when the third battery voltage is less than a second predetermined voltage value and thermal runaway conditions are detected.

[0020] In some aspects, the method further includes the step of terminating the charging process when the second battery voltage is greater than or equal to a second predetermined voltage value.

[0021] In some respects, the method further includes the step of initiating the desulfurization process when the second battery voltage is greater than or equal to a second predetermined voltage value.

[0022] In some aspects, the method further includes the step of measuring the voltage of a third battery connected across the lead-acid battery via the electrical conductor after a second time period, provided that the second battery voltage is greater than or equal to a second predetermined voltage value.

[0023] In some aspects, the method further includes the step of comparing a third battery voltage with a second predetermined voltage value.

[0024] In some aspects, the method further includes the step of not displaying a faulty battery indicator when the third battery voltage is less than or equal to a second predetermined voltage value.

[0025] In some aspects, the method further includes the step of displaying a faulty battery indicator when the third battery voltage is less than a second predetermined voltage value and a lack of progress is detected.

[0026] In some aspects, the method further includes the step of displaying a faulty battery indicator when the third battery voltage is less than a second predetermined voltage value and thermal runaway conditions are detected.

[0027] In some respects, the first predetermined voltage value may be between 12.0 volts and 12.4 volts, or about 12.2 volts. The second predetermined voltage value may be between 14.0 volts and 16.0 volts, or about 14.2 volts.

[0028] In some respects, the first time period may be between 1 minute and 10 minutes, or about 5 minutes. The second time period may be between 1 minute and 10 minutes, or about 5 minutes.

[0029] According to a third aspect, a method for identifying a faulty battery during the charging process of a lithium battery includes: using a voltage sensor to measure a first battery voltage of a lithium battery connected to a battery charger across a pair of electrical conductors; using a processor operatively coupled to a memory device to compare the first battery voltage with a first predetermined voltage value stored in the memory device; if the first battery voltage is less than the first predetermined voltage value, then supplying a first current from the battery charger to the lithium battery for a first time period; during the first time period, measuring a second battery voltage of the lithium battery; using the processor to compare the second battery voltage with a second predetermined voltage value stored in the memory device; and if the second battery voltage (1) is greater than the first predetermined voltage value and (2) is less than the second predetermined voltage value, then supplying a second current from the battery charger to the lithium battery.

[0030] According to a fourth aspect, a battery charger for identifying faulty batteries includes: a processor operably coupled to a voltage sensor; a non-transitory memory device operably coupled to the processor; a power management device for receiving input power and outputting current during a charging process; a display device electrically coupled to the processor, wherein the display device is configured to display a faulty battery indicator; and a pair of electrical conductors for electrically connecting to a lithium battery, wherein, in order to determine and display whether the lithium battery has a low health state, the battery charger is configured to: use the voltage sensor to measure a first battery voltage of the lithium battery connected to the battery charger across the pair of electrical conductors; and use the processor... The device compares a first battery voltage with a first predetermined voltage value stored in the memory device; if the first battery voltage is less than the first predetermined voltage value, the power management device supplies a first current from the battery charger to the lithium battery for a first time period; the voltage sensor measures a second battery voltage of the lithium battery during the first time period; the processor compares the second battery voltage with a second predetermined voltage value stored in the memory device; and if the second battery voltage (1) is greater than the first predetermined voltage value and (2) is less than the second predetermined voltage value, the power management device supplies a second current from the battery charger to the lithium battery.

[0031] In some respects, the battery charger is further configured to: after a second time period, use a voltage sensor to measure a third battery voltage of the lithium battery; use the processor to compare the third battery voltage with a second predetermined voltage value; if after the second time period the third battery voltage is less than the second predetermined voltage value, then stop the charging process; and if the third battery voltage (1) is greater than the second predetermined voltage value and (2) is less than the third predetermined voltage value, then supply a third current to the lithium battery.

[0032] In some respects, if the third battery voltage is greater than or equal to a third predetermined voltage value, then the battery charger is further configured to enter a maintenance mode.

[0033] In some respects, the maintenance mode includes periodically supplying a fourth current to the lithium battery.

[0034] In some respects, if the measured battery voltage drops below a fourth predetermined voltage value, the battery charger is further configured to supply a third current to the lithium battery.

[0035] In some respects, if the processor aborts the charging process, the battery charger is further configured to display a faulty battery indicator via a display device on the battery charger.

[0036] In some respects, if the third battery voltage is less than a second predetermined voltage value after the second time period, the battery charger is further configured to display a faulty battery indicator via a display device on the battery charger.

[0037] In some aspects, the method further includes the following steps: after a second time period, using a voltage sensor to measure a third battery voltage of the lithium battery; using the processor to compare the third battery voltage with a second predetermined voltage value; if after the second time period, the third battery voltage is less than the second predetermined voltage value, then the charging process is stopped; and if the third battery voltage (1) is greater than the second predetermined voltage value and (2) is less than the third predetermined voltage value, then a third current is supplied to the lithium battery.

[0038] In some respects, if the voltage of the third battery is greater than or equal to a third predetermined voltage value, then the method further includes the step of entering a maintenance mode.

[0039] In some respects, the maintenance mode includes periodically supplying a fourth current to the lithium battery.

[0040] In some aspects, the method further includes the step of supplying a third current to the lithium battery when the measured battery voltage drops below a fourth predetermined voltage value.

[0041] In some aspects, the method further includes the step of displaying a faulty battery indicator via a display device on the battery charger when the processor aborts the charging process.

[0042] In some aspects, the method further includes the step of displaying a faulty battery indicator via a display device on the battery charger when the third battery voltage is less than a second predetermined voltage value after the second time period.

[0043] In some respects, the first predetermined voltage value may be between 5.0 volts and 12.4 volts, or approximately 8.0 volts. The second predetermined voltage value may be between 8.0 volts and 12.0 volts, or approximately 10.0 volts. The third predetermined voltage value may be between 14.0 volts and 15.0 volts, or approximately 14.2 volts. The third predetermined voltage value may be the full charge voltage of the lithium battery. The fourth predetermined voltage value may be between 12.5 volts and 13.5 volts, or approximately 13.1 volts.

[0044] In some respects, the first current may be between 0.01 amps and 0.5 amps, or about 0.1 amps. The second current may be between 0.25 amps and 1.0 amps, or about 0.5 amps. The third current may be between 1.0 amps and 3.0 amps, or about 2.0 amps. The fourth current may be between 0.1 amps and 0.3 amps, or about 0.2 amps.

[0045] In some respects, the second time period may be between 1 hour and 3 hours, or about 2 hours. The first time period may be shorter than the second time period.

[0046] According to a fifth aspect, a method for identifying a faulty battery condition via a battery charger having a display device during the charging process of a lead-acid battery includes: determining the state of charge of a lead-acid battery connected to the battery charger across a pair of electrical conductors; measuring a first battery voltage of the lead-acid battery using a voltage sensor; measuring a second battery voltage of the lead-acid battery using the voltage sensor after a first time period; calculating a first rate of change for the first time period using a processor; and displaying a faulty battery indicator via the display device if the first rate of change is greater than or equal to a first predetermined rate of change value.

[0047] According to a sixth aspect, a battery charger for identifying faulty batteries includes: a processor operably coupled to a voltage sensor; a non-transitory memory device operably coupled to the processor; a power management device that receives input power and outputs current during a charging process; a display device electrically coupled to the processor, wherein the display device is configured to display a faulty battery indicator; and a pair of electrical conductors for electrical coupling to a lithium battery, wherein, in order to determine and display whether the lithium battery has a low health state, the battery charger is configured to: determine the state of charge of a lead-acid battery connected across the pair of electrical conductors; measure a first battery voltage of the lead-acid battery using the voltage sensor; measure a second battery voltage of the lead-acid battery using the voltage sensor after a first time period; calculate a first rate of change for the first time period using the processor; and display a faulty battery indicator via the display device if the first rate of change is greater than or equal to a first predetermined rate of change value stored in the non-transitory memory device.

[0048] In some respects, the first predetermined rate of change can vary with the state of charge of the lead-acid battery.

[0049] In some respects, the method further includes the step of measuring the third battery voltage of the lead-acid battery after the second time period.

[0050] In some aspects, the method further includes the step of: if the second rate of change is greater than or equal to a second predetermined rate of change value, then displaying a faulty battery indicator via a display device.

[0051] In some respects, the battery charger is further configured to measure the third battery voltage of the lead-acid battery after the second time period.

[0052] In some aspects, the battery charger is further configured to display a faulty battery indicator via a display device if the second rate of change is greater than or equal to a second predetermined rate of change value. The second predetermined rate of change value may vary depending on the state of charge of the lead-acid battery. The second predetermined rate of change value may not be equal to the first predetermined rate of change value. For example, the second predetermined rate of change value may be less than the first predetermined rate of change value.

[0053] In some respects, the first and second time periods may be between 30 seconds and 5 minutes, or about 1 minute. Attached Figure Description

[0054] These and other advantages of this disclosure will be readily understood with reference to the following description and drawings, wherein:

[0055] Figure 1a A block diagram illustrating an exemplary battery charger.

[0056] Figure 1b Explanatory front perspective view of a model battery charger.

[0057] Figure 1c This illustrates the rear perspective view of an exemplary battery charger.

[0058] Figure 1d A diagram illustrating an exemplary network for a battery charger.

[0059] Figure 2 A flowchart illustrating a demonstrative battery charging cycle.

[0060] Figure 3 A flowchart illustrating the exemplary nominal voltage detection cycle.

[0061] Figure 4 A flowchart illustrating the exemplary battery type detection cycle.

[0062] Figure 5 A flowchart illustrating the exemplary desulfurization cycle.

[0063] Figure 6 This document describes a flowchart illustrating a demonstrative load detection loop.

[0064] Figure 7 This document describes a flowchart illustrating the exemplary battery engine startup detection cycle.

[0065] Figure 8 A circuit diagram illustrating an exemplary connection between the battery and the battery charger.

[0066] Figure 9 This section describes a circuit diagram illustrating a resistor-capacitor circuit model used in lead-acid batteries.

[0067] Figure 10a and 10b This section describes an example charge curve showing dv / dt relative to the AGM and the battery voltage curve of a fully charged lead-acid battery.

[0068] Figure 11 A flowchart illustrating a demonstrative lithium charging cycle. Detailed Implementation

[0069] Preferred embodiments of the invention will be described below with reference to the accompanying drawings. The components in the drawings are not necessarily drawn to scale, but rather the emphasis is on clearly illustrating the principles of the invention. For example, the size of elements may be enlarged for clarity and ease of description. Furthermore, where possible, the same reference numerals are used throughout the drawings to refer to the same or similar elements of the embodiments. In the following description, well-known functions or constructions are not described in detail so as not to obscure the invention with unnecessary detail. No language in this specification should be construed as indicating any non-claimed elements necessary for practical implementation.

[0070] Unless otherwise indicated herein, the description of ranges of values ​​herein is not intended to be limiting, but rather to individually refer to any and all values ​​falling within the range, and each individual value within this range is incorporated into this specification as individually described herein. The terms “about,” “approximately,” etc., when used with numerical values, are to be interpreted as indicating deviations that would be satisfactorily performed for the intended purpose, as would be understood by one of ordinary skill in the art. Ranges of values ​​and / or numerical values ​​are provided herein only as examples and do not constitute a limitation on the scope of the described embodiments. The use of any and all examples or exemplary language (“e.g.,” “such as,” etc.) provided herein is solely intended to better illustrate the embodiments and does not limit the scope of the embodiments. No language in this specification should be construed as indicating any non-claimed element necessary for practicing the embodiments.

[0071] In the following description, it should be understood that terms such as “first,” “second,” “top,” “bottom,” “side,” “front,” and “rear” are convenience terms and should not be construed as limiting terms. Various data values ​​(e.g., voltage, seconds, etc.) provided herein may be replaced by one or more other predetermined data values ​​and therefore should not be considered limiting but exemplary. For the purposes of this disclosure, the following terms and definitions will apply:

[0072] The term "and / or" refers to any one or more items in a list linked by "and / or". For example, "x and / or y" means any element in the three-element set {(x),(y),(x,y)}. In other words, "x and / or y" means "one or both of x and y". As another example, "x, y and / or z" means any element in the seven-element set {(x),(y),(z),(x,y),(x,z),(y,z),(x,y,z)}. In other words, "x, y and / or z" means "one or more of x, y and z".

[0073] The terms "circuit" and "circuit" refer to physical electronic components (e.g., hardware) and any software and / or firmware ("code") that are configurable to, executed by, and or otherwise associated with the hardware. As used herein, for example, a particular processor and memory may include a first "circuit" when executing one or more lines of code from a first set, and a second "circuit" may be included when executing one or more lines of code from a second set. As used herein, a circuit is "operable" to perform a function whenever it includes the necessary hardware and code (if either is necessary) to perform that function, regardless of whether the function's performance is disabled or not enabled (e.g., via user-configurable settings, factory adjustments, etc.).

[0074] As used herein, the term "communication" (communicate and communicating) includes both the transmission of data from a source to a destination and the delivery of data to a communication medium, system, channel, network, device, line, cable, fiber optic, circuit, and / or link for transmission to a destination. As used herein, the term "communication" refers to data thus transmitted or delivered. As used herein, the term "communication" includes one or more of a communication medium, system, channel, network, device, line, cable, fiber optic, circuit, and / or link.

[0075] As used herein, the terms “coupled,” “coupled to,” and “coupled with” each refer to a relationship between two or more pieces of equipment, devices, documents, circuits, components, functions, operations, processes, procedures, media, components, networks, systems, subsystems, and / or apparatuses that constitute one or more of the following: (i) a connection, whether direct or through one or more other pieces of equipment, devices, documents, circuits, components, functions, operations, processes, procedures, media, components, networks, systems, subsystems, or apparatuses; (ii) a communication relationship, whether direct or through one or more other apparatuses, devices, documents, circuits, components, functions, operations, processes, procedures, media, components, networks, systems, subsystems, or apparatuses; and / or (iii) a functional relationship in which the operation of any one or more pieces of equipment, devices, documents, circuits, components, functions, operations, processes, procedures, media, components, networks, systems, subsystems, or apparatuses depends wholly or partially on the operation of any one or more of the other.

[0076] As used herein, the term "data" means any mark, signal, sign, symbol, field, group of symbols, representation, and any other physical form representing information, whether permanent or temporary, whether visible, audible, acoustic, electrical, magnetic, electromagnetic, or otherwise embodied. The term "data" is used to represent a predetermined piece of information in a physical form, including any and all representations of corresponding information in different physical forms.

[0077] As used herein, the term "database" refers to an organized body of related data, regardless of how the data or its organized body is represented. For example, an organized body of related data may be in the form of one or more of the following: a table, map, grid, packet, datagram, frame, file, email, message, document, report, list, or any other form.

[0078] The term "exemplary" means "serving as an example, illustration, or description." The embodiments described herein are not limiting but merely exemplary. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, the terms "embodiments of the invention," "embodiments," or "the invention" do not require that all embodiments of the invention encompass the discussed features, advantages, or modes of operation.

[0079] As used herein, the term “network” encompasses all kinds of networks and interconnected networks, including the Internet, but not limited to any particular network or interconnected network.

[0080] As used herein, the term "processor" means a processing device, apparatus, program, circuit, component, system, or subsystem, whether implemented in hardware, in tangibly manifested software, or both, and whether or not it is programmable. As used herein, the term "processor" includes (but is not limited to) one or more computing devices, hardwired circuits, signal modification devices and systems, devices and machines for controlling systems, central processing units, programmable devices and systems, field-programmable gate arrays, application-specific integrated circuits, systems-on-a-chip, systems comprising discrete elements and / or circuits, state machines, virtual machines, data processors, processing facilities, and combinations of any of the foregoing.

[0081] Several methods can be used to determine the SoH of a battery. For example, a first method calculates the SoH by measuring the battery's internal resistance. Specifically, high internal resistance is an indicator of a lower SoH. U.S. Patent Publication No. 2011 / 0172939A1 by Santip Uppretty discloses example systems and methods for determining the internal resistance, SoC, SoH, and / or energy level of a rechargeable battery. However, the wide range of different battery types presents problems when attempting to determine the SoH of a battery solely based on internal resistance. Examples of different battery types (i.e., chemistry) include, for example, lithium, lithium-ion, lithium-nickel, lead-acid, nickel-cadmium, nickel metal hydride, etc.

[0082] Simply measuring a battery's internal resistance to determine its SoH (Solar Hour) leads to inconsistencies across different battery chemistry. However, systems that can detect the battery type and then measure the internal resistance mitigate these inconsistencies. Furthermore, SoH can vary with temperature because internal resistance fluctuates as a function of temperature. Therefore, temperature sensors can be used to monitor the battery's temperature to further reduce inconsistencies. Another factor that can affect a battery's internal resistance is the battery charging process itself.

[0083] Battery chargers can be configured to perform one or more tests to detect and monitor additional dynamic indications of the battery. For example, a battery charger can perform a full / partial discharge test, in which the battery is fully or partially discharged by subjecting it to a known constant load. During the discharge time, the battery voltage is monitored, and the duration required for the battery to drop to a predetermined (e.g., pre-established, set, or otherwise determined) voltage is compared to a known time for a healthy battery (which may be a standard value or based on test data from initial testing of the battery, such as testing immediately after installation). This comparison enables the calculation of the battery's SoH (Solar Hours). However, disadvantages associated with this method include its relative cost, time requirement (i.e., discharging the battery is time-consuming), and the requirement that the battery be offline during the test.

[0084] Historical battery data can be used to determine the SoH of a battery (e.g., via a standalone battery monitoring system). During battery aging, the system dynamically (i.e., continuously, in real-time or near real-time) measures and monitors the values ​​of one or more electrochemical parameters of the battery over time to generate a dataset of historical battery data. The battery's SoH is then determined based on how these parameters change over time. However, because historical battery data must accumulate before degradation of these parameters can be determined, such systems cannot determine the battery's SoH without first acquiring the battery's historical dataset. It is anticipated that a dataset of historical battery data for comparable batteries (e.g., batteries of the same model, chemistry, etc.) can be loaded into a battery charger (e.g., via an input / output interface). Battery capacity can also be monitored to determine the battery's SoH. An example method involves charging the battery to its maximum charge potential and then waiting a predetermined time frame to measure the open-circuit voltage (V). OC ). It can be achieved by using V OC With Ideal V OC The comparison is used to determine the SoH. An example of this method is described in U.S. Patent No. 9,244,132, filed August 17, 2012.

[0085] It would be advantageous to provide a battery charger that uses multiple processes to determine the battery's SoH (Solar Hourly Hazard) depending on the current state of the charging process, thereby producing a battery charger that can more efficiently and quickly identify batteries with low SoH and more quickly warn the user of "bad battery" conditions via a bad battery indicator without requiring the battery to be connected to the charger for an extended period. To this end, this disclosure relates to a battery charger system, method, and apparatus for determining and warning a user about the battery's SoC and / or SoH. In some aspects, the battery charger system, method, and apparatus may be further configured to determine whether the battery's SoC and / or SoH is sufficiently high, such that it can initiate vehicle operation to warn the user of a "battery engine start" condition. Furthermore, the disclosed battery charger system, method, and apparatus may be configured to warn a remote user about the battery's SoC and / or SoH via a network.

[0086] Many disclosures will be described in conjunction with a six-cell nominal 12-volt battery, but the various techniques disclosed herein can be applied to virtually any battery by scaling (enlarging or reducing) a threshold (e.g., a voltage threshold) according to the number of cells / nominal voltage of the battery. Therefore, while various exemplary predetermined voltage values ​​(e.g., voltage thresholds) are described in conjunction with a six-cell nominal 12-volt battery, it should be understood that these exemplary predetermined voltage values ​​are not intended to apply only to a six-cell nominal 12-volt battery. In practice, predetermined voltage values ​​and ranges can be scaled up or down for a particular battery as a generally linear function of the number of cells / nominal voltage of said particular battery. For example, if a 10-volt threshold is described in conjunction with a six-cell nominal 12-volt battery, those skilled in the art will understand that a 10-volt threshold can be scaled up for a three-cell 6-volt battery by dividing the 10-volt threshold by two, since the ratio of a six-cell nominal 12-volt battery to a three-cell 6-volt battery is 2:1. Therefore, unless otherwise stated herein, each predetermined voltage value and range disclosed herein should be understood as a value or range disclosed on a "per cell" basis, and each "per cell" voltage value or range (expressed herein as volts per cell (V)) CELL This is hereby incorporated into this specification, as it is stated individually herein.

[0087] Referring to the diagrams disclosed herein, the battery charger 100 facilitates both charging and maintenance functions of the battery 104 (e.g., a vehicle battery). The battery charger 100 may further provide a floating mode to maintain the battery 104 in a fully charged state. The battery charger 100 may also be configured to initiate (i.e., “boost,” “jump,” or “jump start”) an engine (e.g., an internal combustion engine) coupled to the battery 104.

[0088] Battery 104 can be a starting battery, a storage battery, a marine battery (such as a deep-cycle battery, which is designed to use most of its capacity for periodic deep discharge), a storage battery, or another rechargeable battery. Example motor vehicle batteries include (but are not limited to) lead-acid battery packs (such as wet / immersion batteries, calcium-calcium batteries, valve-regulated lead-acid (VRLA) batteries, gel cells, and absorbent glass wool (AGM)), as well as other rechargeable batteries, such as lithium batteries. Battery charger 100 can be configured to automatically determine the battery type / chemical—AGM, gel, lithium-ion, etc.

[0089] Depending on the application, battery 104 can be one of several nominal voltages (e.g., 6V / 12V / 24V / 36V / 48V, etc.) and can use various cell counts and arrangements. Typically, each cell in battery 104 provides a nominal 2 volts. Therefore, a 6-volt battery will use three cells, a 12-volt battery will use six cells, a 24-volt battery will use 12 cells, and so on. Thus, the desired nominal voltage can be achieved by adjusting the number of cells in the battery pack, array, etc. For example, a commonly used battery in the automotive industry is a six-cell nominal 12-volt battery. In addition to the nominal voltage, battery 104 can use several different battery types (i.e., chemistry), such as lithium, lithium-ion, lithium-nickel, lead-acid, nickel-cadmium, nickel-metal hydride, etc. Commonly used battery types in the automotive industry include lead-acid and lithium.

[0090] In operation, the battery charger 100 may indicate to the user the number of ampere-hours placed in the battery 104, and / or the SoC and / or SoH of the battery 104. The battery charger 100 may be further configured to receive input from the user to identify the specific characteristics of the battery 104. For example, if the user inputs the battery size and / or model, then the battery charger 100 will know the battery manufacturer's specifications (e.g., raw / target values, including full charge voltage) and can therefore determine and provide the SoH, or at least in part determine other characteristics of the battery 104 based on dynamically measured parameters of the battery 104.

[0091] Figures 1a to 1c This describes an example battery charger 100 having a processor 128 (e.g., a central processing unit (CPU)). The processor 128 is operatively coupled to one or more memory devices, such as a read-only memory (ROM) 118 for receiving one or more instruction sets, a random access memory (RAM) 120 having multiple buffers for temporary storage and retrieval of information, and / or an internal data storage device 122. The internal data storage device 122 may be, for example, a hard disk drive (e.g., a solid-state drive or other non-volatile data storage device) or another non-volatile data storage device (e.g., flash memory, including removable memory cards). A clock 130 for providing clock / timing signals or pulses may be coupled to the processor 128.

[0092] The processor 128 is also operatively coupled to the power management device 132, the input / output interface 126, and a plurality of sensors 112 to provide measurement data describing the surrounding environment, the battery charger 100, and / or the battery 104. Those skilled in the art will understand that the battery charger 100 includes one or more bus structures for interconnecting its various components. Additionally, to increase ease of use in mobile applications (i.e., to increase portability), the various components of the battery charger 100 may be housed in a single housing. The plurality of sensors 112 may be internal to the battery charger 100 or located externally to the battery charger 100. The plurality of sensors 112 may include one or more of a voltmeter (i.e., a voltage sensor) for measuring voltage, an ammeter for measuring current, and / or a temperature sensor for measuring temperature (e.g., the temperature of the environment, the battery 104, the battery charger 100, and / or the auxiliary power supply 108). In some respects, the processor 128 may receive sensor data from remote sensors 112 via a wired link 142 or a wireless device 144.

[0093] As will be discussed, processor 128 is configured to perform calculations and comparisons to determine whether battery 104 is considered to have a low SoH, based at least in part on one or more measured battery parameters from multiple sensors 112. For example, battery charger 100 may be configured to send one or more small AC test signals to battery 104 and record the response to calculate the impedance of battery 104. In another example, battery charger 100 may be configured to automatically detect the battery type and / or nominal voltage of battery 104. Battery charger 100 may further include start / stop technology. In other aspects, processor may be configured to calculate the temperature of battery 104 based at least in part on measured or calculated impedance, which can indicate heat dissipation through resistive loss.

[0094] Power management device 132. Power management device 132 can be used to manage the power required to operate battery charger 100 (and its components) and charge (or boost) battery 104. That is, AC power can be drawn from alternating current (AC) power supply 102 via AC input device 134, converted to direct current (DC) power using an AC-to-DC converter, and charged battery 104 using one or more transformers depending on one or more selectable charging modes. For example, battery charger 100 can be detachably coupled to AC power supply 102 (e.g., 110-120VAC line current from a wall socket) located in the housing via AC input device 134 (e.g., a plug). In addition to, or instead of, AC input device 134, battery charger 100 can be coupled (e.g., detachably) to solar power supply 170 (or other external DC power supply) via DC input device 168. One or more transformers may include linear transformers, switching mode transformers, or combinations thereof. For example, battery charger 100 may use a hybrid of linear and switching mode transformers. An exemplary hybrid battery charger is disclosed in U.S. Patent No. 9,368,269, jointly owned by Xiao Ping Chen et al., entitled "Hybrid Battery Charger," issued on June 14, 2016.

[0095] The battery charger 100 can be detachably coupled to the battery 104 (e.g., at its battery posts / terminals) via a pair of electrical conductors 172a, 172b, which are electrically coupled to the battery charger 100 via a DC output 136. Each of the electrical conductors 172a, 172b can be, for example, a battery cable with terminal connections (e.g., battery clamps 152, ring connectors, etc.) at its distal end. The proximal ends of the electrical conductors 172a, 172b can be detachably coupled to the battery charger 100 at the DC output 136 via, for example, one or more detachable electrical ports / connectors 154 (e.g., EC5 connectors, barrel connectors, pin connectors, etc.). In another embodiment, the proximal ends of the electrical conductors 172a, 172b can be fixedly coupled to the battery charger 100. The housing 156 of the battery charger 100 may further include one or more cable winding posts 164 and / or cable reels around which various types of electrical cords can be wound.

[0096] In addition to transmitting charging current and / or boost current to battery 104, battery charger 100 can also measure, in particular, the battery voltage of battery 104 and / or the current through battery 104 via electrical conductors 172a and 172b. Electrical conductors 172a and 172b can, for example, use battery clamps 152 capable of Kelvin sensing (four-terminal sensing). Kelvin sensing is an impedance measurement technique that uses two separate pairs of current-carrying and voltage-sensing electrodes per conductor 172a and 172b to provide more accurate measurements than two-terminal (2T) sensing. For this purpose, each of electrical conductors 172a and 172b can use multiple electrically isolating electrodes (i.e., cables, conductors, lines, etc.), regardless of whether they share an isolating outer housing or are otherwise bundled. By way of illustration, each of electrical conductors 172a and 172b can use two electrodes and provide two battery contacts (e.g., via battery clamps 152 capable of Kelvin sensing), as shown in the diagram. Figure 8 As explained. Specifically, Figure 8 A circuit diagram 800 illustrates an exemplary connection between a battery charger 100 and a battery 104, wherein electrodes 806 and 812 are configured to apply and sense current using an ammeter 802, and electrodes 810 and 808 are configured to sense voltage using a voltmeter 804. As illustrated, electrodes 806 and 808 are provided via a first conductor 172a, and electrodes 810 and 812 are provided via a second conductor 172b.

[0097] In some respects, three electrodes can be used to simulate Kelvin sensing. For example, one battery terminal has a separate load and sensing electrode, and another terminal has a single (shared) electrode. The voltage drop in the shared electrode is compensated by assuming it is the same as that in the load electrode, having the same wire diameter and length. Although this disclosure primarily discusses the measurement of battery 104 parameters by the battery charger 100 via electrical conductors 172a, 172b, the battery charger 100 may receive dynamically monitored battery parameters via a wired link 142 or a wireless device 144.

[0098] The DC power from the power management device 132 can be further used to charge the internal auxiliary power supply 108 (e.g., a supercapacitor, rechargeable lithium-ion battery, or lead-acid battery) via the AC input device 134. During operation, when external power (e.g., AC power supply 102) is unavailable (e.g., disconnected or out of service), the battery charger 100 can draw power from the battery 104 and / or the auxiliary power supply 108 required to operate its components, allowing the user to determine the status of the battery charger 100 (including the battery 104's SoH, SoC, or other parameters) even when the AC power supply 102 is unavailable (e.g., when a circuit breaker blows). For this purpose, the battery charger 100 can report AC power supply 102 malfunctions (e.g., as an alarm) to one or more interface devices (e.g., portable electronic device 110) via the communication network 106.

[0099] In some respects, besides the car battery, the power management device 132 can be configured to charge and monitor one or more portable user devices (e.g., cell phones, computers, etc.) or AC-powered devices coupled to the battery charger 100. For this purpose, one or more DC output ports (e.g., USB port 158 ​​or other DC socket 166, such as a 12-volt DC cigarette lighter port) can be provided on the housing 156 of the battery charger 100. For example, the USB port 158 ​​can output a charging current of 3.0 to 5.0 A at 5VDC. Further different currents can be provided, such that one USB port can provide a charging current of 1.0 A at 5VDC, while a second USB port can provide a charging current of 2.1 A / 2.4 A / 3.0 A / etc. at 5VDC, to achieve faster charging (e.g., for larger devices). To activate the DC output port, one or more DC power buttons (or other user-optional elements, such as digital soft buttons) may be provided on the housing 156 via user interface 138 or remotely via a network (e.g., for portable electronic device 110 via communication network 106). The DC output port can be activated by pressing the DC power button and deactivated by, for example, pressing the DC power button a second time, two or more times in quick succession, or holding it for a predetermined time frame. Similarly, an AC output port 162 is provided to output AC current to an AC-powered device. The AC output port 162 can use AC power transmitted from the AC input device 134, which can bypass the power management device 132. On the other hand, the power management device 132 may include an inverter to convert the DC power stored in the internal auxiliary power supply 108 into the desired AC power signal (e.g., 110 to 120 volts AC at 60 Hz).

[0100] The battery charger 100 can use one or more charging technologies, including conventional and fast charging. The power management device 132 and processor 128 can provide one or more features, such as reverse temporary connection protection, automatic battery voltage detection, and battery type detection. Commonly owned U.S. Patent No. 7,808,211 discloses an example of a switch-mode battery charger for automotive and marine battery applications. Additionally, commonly owned U.S. Patent No. 8,947,054 discloses a battery charger and method utilizing alternating DC charging currents, while commonly owned U.S. Patent No. 8,575,899 discloses a battery charger with automatic voltage detection.

[0101] The battery charger 100 can be further configured to automatically determine different battery chemistry (e.g., AGM, gel, lithium-ion, etc.) and the nominal voltage of the battery 104. The charging characteristics of the battery charger can be configured to match the battery chemistry of the battery 104 to be charged. For example, a constant power, constant current, constant voltage, or a combination thereof can be used to charge a lead-acid battery. Both linear and / or switching-mode (high-frequency) transformers can be used to charge such batteries. In addition to charging and / or maintaining the battery 104, the power management device 132 and the processor 128 can provide jump-start functionality. For example, the battery charger 100 can use one or more of an auxiliary power supply 108, a linear transformer, and / or a switching-mode transformer to provide jump-start functionality for switching vehicles. Brian F. Butler et al. jointly own U.S. Patent No. 9,397,513, published on February 18, 2016, entitled “Compact Multifunctional Battery Booster,” which discloses an exemplary battery boosting functionality that can be incorporated into the patent.

[0102] Although the power management device 132 and the processor 128 are shown as separate components, those skilled in the art will understand that power management functionality (such as battery charging, battery maintenance, etc.) can be provided as a single component combining the functionality of the power management device 132 and the processor 128.

[0103] Input / output interface 126. The battery charger 100 may further include an input / output interface 126 to interface the processor 128 with one or more peripheral and / or communication devices, such as a user interface 138, a Global Positioning System (GPS) transmitter 140, a wired link 142, a wireless device 144, and a speaker 124, which can be used to signal alarms (e.g., SoH, SoC, charging complete, error, etc.) or other status information.

[0104] A wired link 142 and a wireless device 144 may be provided to manage communication and / or transmission of signals or data between the processor 128 and another device. The wired link 142 may be a port (and / or cable) for wired coupling to another data port 146 located external to the battery charger 100, such as an on-board diagnostic (OBD) data port and other data ports (e.g., RS-232, Universal Serial Bus (USB), and / or Ethernet ports). The wireless device 144 may be a wireless transceiver configured to communicate via one or more wireless standards, such as Bluetooth (e.g., short-wavelength, Industrial, Scientific, and Medical (ISM) band UHF radio waves from 2.4 to 2.485 GHz), Near Field Communication (NFC), Wi-Fi (e.g., the Institute of Electrical and Electronics Engineers (IEEE) 802.11 standard), etc. The user interface 138 may further provide one or more connection status icons to indicate the connection status of the wired link 142 and / or the wireless device 144.

[0105] Processor 128 may be operatively coupled to display device 114 via display driver 116. Display device 114 may include one or more light-emitting diodes (LEDs) 114a, liquid crystal display (LCD) screens 114b, and / or segmented display devices 114c. For example, display device 114 may be an alphanumeric segmented LED / LCD display or a matrix LCD display. In some embodiments, display device 114 may further provide touchscreen functionality via a thin layer of sensing circuitry beneath a visible portion of the surface of display device 114 or as part of a thin, transparent film overlaid on display device 114 that is sensitive to the position of a pen or finger on its surface, to facilitate user input.

[0106] Display device 114 can be used to provide an indication of the battery's poor SoH, indicating a "battery bad" or "battery good for starting" indicator, and is compatible with a variety of nominal battery voltages, chemicals, and constructions, including, for example, 6V, 8V, 12V, 16V, 24V lead-acid, AGM, gel, lithium-ion, etc.

[0107] The "battery faulty" or "battery good for startup" indicator can be a text or graphic display (e.g., an icon on an LCD display) or a backlit display (e.g., a backlit LED translite). The display device 114 can also be used to indicate the operating mode of the battery charger 100. For example, the display device 114 can show that the battery 104 is in desulfurization mode, and / or indicate when the battery 104 is charging, fully charged, etc. In operation, the display driver 116 can receive display data from the processor 128 via the input / output interface 126 and display the display data via the display device 114. For example, an interactive LED and / or an easy-to-read digital LCD display can be provided on the housing to provide the user with status information and / or input capabilities (e.g., via a touchscreen).

[0108] Once the AC power supply 102 is connected, for example, the first LED can be illuminated to indicate that the battery charger 100 is ready for use. When the AC power supply 102 is connected and the battery charger 100 is successfully connected to the communication network 106 or the wireless transceiver 148, the second LED on the unit can be illuminated. Finally, when the DC output 136 is successfully coupled (e.g., clamped, or otherwise electrically coupled) to the battery 104, the third LED can be illuminated. Instead of using a single LED, a single multi-color LED (e.g., a tri-color LED (RGB)) can be used, which changes color depending on the state of the battery charger 100.

[0109] User interface 138 may include user-actuated input device 160 to enable a user to input commands to switch charging modes, battery types, amperage (e.g., 1A, 10A, 50A, etc.), or other settings. Examples of user-actuated input device 160 include physical buttons, physical switches, digitizers (whether touchpads or a transparent layer covering display device 114), and other input devices. For example, using a digitizer, a user can control or interact with the battery charger 100 by writing or tapping on display device 114 with a pen, stylus, or finger. Battery charger 100 may be configured to modify the charging cycle algorithm based on input from the user (via input / output interface 126 or portable electronics device 110) (e.g., battery type, battery size, geographical location of battery 104 / battery charger 100, and charging history). In practice, as battery 104 ages, battery charger 100 may charge battery 104 in different ways to compensate for battery aging. In some respects, if (for example, a user) enters an incorrect setting, the battery charger 100 can update the setting to a new setting for the next charging cycle.

[0110] Remote monitoring / control. Figure 1dThis describes a battery charging system and network configured to facilitate remote monitoring and control of a remote battery (e.g., battery 104) and / or a remote battery charger (e.g., battery charger 100). As described, the battery charging system may include a communication network 106 (e.g., the Internet) communicatively coupled to, for example, a battery management server 150, one or more battery chargers 100, and one or more portable electronic devices 110 via one or more data transmitting devices.

[0111] In operation, the battery charger 100 can be configured to communicate via a communication network 106 with one or more portable electronic devices 110 (e.g., telephones, tablets, laptops, or other handheld user terminals) within the battery monitoring system. For example, the battery charger 100 can wirelessly communicate with a wireless transceiver 148 (e.g., a Wi-Fi router and / or modem), which can be wired to the network 106. In other aspects, the battery charger 100 can directly communicate wirelessly with one or more portable electronic devices 110 (e.g., via Bluetooth, Wi-Fi, NFC, etc.).

[0112] The battery management server 150 can be configured to receive data and, therefore, can be communicatively coupled to one or more non-transitory data storage devices 150b. In some aspects, a portable electronic device 110 can be used to monitor and remotely control the battery charger 100. Suitable example battery monitoring systems are disclosed in more detail in U.S. Patent No. 9,579,990, issued February 28, 2017, entitled "Battery Charger Status Control System and Method".

[0113] Battery charging protocol. Figure 2 The flowchart illustrates an example battery charging cycle 200. As illustrated, after startup (startup mode) at step 202 and before termination at step 220, the battery charger 100 can be configured to cycle through multiple modes via the processor 128, including, for example, diagnostic mode 204 (which may include nominal voltage detection, battery type detection, etc.), soft-start mode 208, batch mode 210, absorption mode 212, di / dt charging mode 214, and maintenance mode 216.

[0114] Although the example battery charging cycle 200 is described as having seven different modes, those skilled in the art will understand that fewer or additional modes can be implemented. For example, one or more modes may be omitted from the battery charging cycle 200, or performed independently and / or upon request from the user. Furthermore, the order of the mode cycles can be rearranged according to the user's needs. Additionally, at one or more points in the battery charging cycle 200, the processor 128 may perform one or more battery engine start checks 218 to indicate to the user whether the battery 104 is adequately charged and / or at a sufficient SOH to start the vehicle. If the battery 104 is deemed adequately charged and / or at a sufficient SOH to start the vehicle by the battery charger 100 (via the processor 128), then the display device 114 may display "Battery Good for Starting" or an equivalent icon. The following is combined with... Figure 7 Example description: Battery engine startup detection loop 700.

[0115] In startup mode 202, battery charger 100 initializes its various hardware and software systems. For example, the input / output ports on processor 128 are initialized along with clock 130. Display device 114 can also be tested and set to its initial state. Various system variables (e.g., default states / values ​​or initial measured values) can be initialized. In one embodiment, upon power-on (e.g., when plugged into AC power supply 102) or upon receiving a start signal, battery charger 100 automatically enters startup mode 202 immediately, which can be triggered by a user-actuated input device 160 on battery charger 100 (e.g., a power button or "start charging" button) or via a remote portable device on a communication network.

[0116] In diagnostic mode 204, battery charger 100 can specifically determine one or more characteristics of battery 104, the vehicle coupled to battery 104, or battery charger 100 itself. For example, battery charger 100 can determine the nominal voltage of battery 104 and / or the type of battery 104, which can be used to specify a charging protocol for charging battery 104. (See also...) Figure 3 and 4 The description determines the nominal voltage and / or type of battery 104. Battery charger 100 can also determine whether battery 104 is properly connected to DC output 136 by checking predetermined measurements on DC output 136 (e.g., by acquiring voltage measurements, resistance measurements, capacitance measurements, impedance measurements, etc.). For example, battery charger 100 may require the voltage measured on DC output 136 to meet a predetermined voltage value (e.g., a voltage threshold), such as 0.1 volts.

[0117] If battery 104 is not properly connected to DC output 136, display device 114 may indicate accordingly (e.g., LCD may display "Battery not connected" or an LED may be illuminated). During diagnostic mode 404, battery charger 100 may measure and record one or more parameters of battery 104, such as the maximum voltage of battery 104 (V). MAX ) and minimum voltage (V MIN In some respects, processor 128 may be further configured to perform a battery engine start check 218 during diagnostic mode 404 to determine and / or display whether battery 104 is adequately charged and / or at a sufficient SoH to start the vehicle. Alternatively, the battery engine start check 218 may be triggered via actuation of user actuation input device 160 or via remote portable electronics device 110 on communication network 106.

[0118] In soft-start mode 208, battery charger 100 may output a reduced charging current. For example, soft-start mode 208 may run for a shortened time frame (e.g., 1 to 10 minutes, more preferably about 2 minutes). During soft-start mode 208, battery charger 100 uses a reduced charging current to charge battery 104 (e.g., about half the maximum charging current for a given battery type, until the battery reaches a predetermined state of charge). Assuming the use and / or detection of lead-acid batteries, battery charger 100 may determine whether battery 104 is sulfated during soft-start mode 208.

[0119] Soft-start mode 208 can also be used to determine the battery's capacity. The rate of change of the battery voltage during charging (which varies with the battery's SoC) is used to determine the battery's actual capacity. As the battery ages, the actual capacity decreases below the rated capacity (as specified by the battery manufacturer). Manually setting the charging current based on a percentage of the rated battery capacity can damage the battery. For example, charging a six-cell 12-volt battery at 20% capacity (i.e., 0.2C) will produce a voltage change rate of approximately 0.0175 V / min. However, at 10% capacity (i.e., 0.1C), the change rate will be approximately 0.00875 V / min. Therefore, the SoC of battery 104 can be determined first to identify the expected rate of voltage change. For example, if the SoC is calculated to be between 10% and 20%, the battery charger 100 can vary the charging current during soft-start mode 208 until the rate of voltage change is 0.00875V / min and 0.0175V / min (which is expected for the rate of change of battery voltage in the range of 0.1 to 0.2C) to determine the correct charging current.

[0120] Battery charger 100 also dynamically monitors sulfation conditions, which are conditions that occur in lead-acid batteries where the battery is unable to retain charge due to the crystallization of lead sulfate. Desulfation mode 206 can be achieved by repeatedly sending short current surges through the sulfated / damaged battery. The current pulses tend to break up and dissolve sulfate crystals, restoring some of the capacity of battery 104 over time. To identify sulfation conditions, battery charger 100 can dynamically monitor the battery voltage for a rapid increase in battery voltage. If battery 104 is not sulfated, or if battery 104 is not a lead-acid battery, then battery charging cycle 200 can continue to batch mode 210. For example, if the peak voltage in a nominal six-cell 12-volt battery exceeds a first predetermined value (e.g., 11 volts, which is 1.834V),... CELL However, the initial voltage is less than the second predetermined voltage (e.g., 3 volts, 0.5V). CELL If the processor 128 assumes that sulfation conditions exist, and the desulfurization process is initiated at step 206.

[0121] During desulfurization mode 206, display device 114 may indicate that battery charger 100 is in desulfurization mode (e.g., displaying "battery sulfation" or an equivalent icon), or may transmit this status to portable electronic device 110. If the desulfurization process is successful (i.e., battery 104 is restored / usable), then the charging cycle proceeds to step 210; otherwise, the process continues to step 220, and a faulty battery indication (e.g., "battery sulfation" or a representative icon) is provided via display device 114. The following is in conjunction with... Figure 5 Describe the exemplary desulfurization process 500.

[0122] In batch mode 210, the battery charger 100 can output the maximum charging current as the voltage increases. Batch mode 210 can run for a second time frame or until the battery 104 receives a predetermined SoC (e.g., 80% to 90% of the battery's rated capacity) and begins after soft-start mode 208. For example, in batch mode 210, charging a 100AH ​​battery with a 10A charger would take approximately 8 hours to reach 80AH (80% capacity or 0.8C), without considering any losses during the charging process. During batch mode 210, the battery charger 100 uses a constant maximum current to charge the battery 104 until the battery 104 rises to the absorption mode 212 level. In other words, the battery charger 100 can provide the maximum amount of current that the battery 104 will accept (up to the charger capacity, e.g., 25% of the battery capacity in ampere-hours). The temperature of battery 104 can also be monitored (e.g., directly via sensor 112, such as a thermometer, or indirectly as a function of the current supplied to the battery and measured battery parameters) to ensure that it does not exceed a predetermined temperature (e.g., 125℉ for wet batteries, 100℉ for AGM or GEL, etc.).

[0123] In absorption mode 212, battery charger 100 may output a predetermined charging current until the battery's SoC achieves a predetermined charge percentage (e.g., 80-90%). For example, if the battery 104's SoC fails to achieve the predetermined charge percentage within a predetermined time period (e.g., a predetermined time period value stored in a memory device), display device 114 may indicate that the battery is faulty (e.g., display "Faulty Battery" or an equivalent icon).

[0124] Absorption mode 212 begins at the start of di / dt, which is the rate of change of the charging current (i) with time (t). In di / dt charging mode 214, for example, the battery charger 100 can keep the battery voltage constant and wait for the charging current, or at least stop decreasing, which is preferable to setting a current limit (e.g., 0.5 amps), because even at full charge, some batteries can draw a large number of amps (e.g., 2.0 amps or more). Di / dt charging mode 214 utilizes the fact that when the battery 104 is charged at a constant voltage, the current rise slows down and eventually stops. In other words, at a constant voltage, the current decrease slows down and eventually flattens out. Furthermore, if the battery charger 100 detects an increase in current, then the battery charger 100 can conclude that the battery 104 is under thermal runaway conditions.

[0125] The di / dt charging mode 214 can be initiated when the measured battery voltage suddenly drops below a predetermined voltage after charging has exceeded a predetermined time frame (e.g., within 48 hours, more preferably within about 36 hours, most preferably within about 24 hours), or when the predetermined time frame has elapsed since the end of the process (voltage increase), or when the battery voltage is greater than the maximum voltage. If the voltage is greater than the predetermined voltage (e.g., 14.2 volts, 2.367V for a 12-volt battery), the mode can be initiated when the measured battery voltage suddenly drops below a predetermined voltage. CELL If the current battery voltage does not increase in the previous time frame (e.g., the previous 5 to 60 minutes, more preferably the previous 30 minutes), then this maximum voltage can be the maximum voltage of the battery type or the current battery voltage.

[0126] The di / dt charging mode 214 can also terminate when the charging current decreases below a predetermined current (e.g., 100-500mA, more preferably about 200-300mA) and / or the percentage charge reaches 100% (or another value close to the capacity). Two other conditions that may terminate the di / dt charging mode 214 include, for example, the current increasing beyond a predetermined current (e.g., about 250mA) for more than one minute, and the current not decreasing within a predetermined period (e.g., about 30 minutes). The charging current is monitored repeatedly during the operating cycle. Generally, the voltage is kept constant at V by continuously reducing the current through decreasing the operating cycle. MAX Once the current levels off and the voltage is maintained, the system assumes that battery 104 is fully charged. Once battery 104 is fully charged, the system enters maintenance mode 216.

[0127] In maintenance mode 216, the battery charger 100 dynamically monitors the current drawn by the battery 104 to maintain it at a fully charged state. During maintenance mode 216, the charging voltage can be reduced and kept constant at a predetermined voltage (e.g., between 13.0VDC and 13.8VDC for a 12-volt lead-acid battery, i.e., 2.167 to 2.3V). CELL The current decreases to less than 1% of the battery capacity. If, within a predetermined time value, the current drawn by battery 104 exceeds a predetermined value, then display device 114 will indicate that battery 104 has a low SoH. For example, in one embodiment, if battery 104 is drawing more than 1.0A for more than 12 hours, then display device 114 will indicate that battery 104 is faulty.

[0128] Faulty battery detection. While in various charging modes, the battery charger 100 dynamically monitors the battery charging process and various battery parameters via one or more sensors 112 to identify faulty batteries. The process for detecting faulty batteries can be adjusted depending on the battery type, nominal voltage, and / or the current pattern of the charging process.

[0129] In one aspect, the processor 128 can dynamically monitor the V of the battery 104 connected across the DC output 136. MIN and V MAX Is it greater than or equal to the stored V? MAX The V stored therein MAX This indicates the highest previously measured voltage of battery 104. If the voltage of battery 104 connected to DC output 136 is greater than or equal to V... MAX Then V MAX The voltage of the battery 104 connected to the DC output 136 is set to the current value. During the charging cycle, the system also continuously checks whether the voltage of the battery 104 connected to its DC output 136 is less than or equal to V. MIN V MIN This indicates the lowest previously measured voltage of battery 104. If the voltage of battery 104 connected to DC output 136 is less than or equal to V... MIN Then V MIN The current value of the voltage of the battery 104 connected across the DC output 136 is set. During the charging cycle, the processor 128 continuously monitors V. MAX With V MIN The difference between them. If V MAX With V MIN If the difference between the values ​​(i.e., the rate of change) exceeds a predetermined value, then battery 104 is considered to have low SoH, and display device 114 will accordingly indicate that battery 104 is defective. MAX With V MIN The difference should be less than a predetermined value, which can be a function of the SoC (e.g., changing the rate at 10% of the battery's rated value, such as 0.00875V / min or 0.525V / hour).

[0130] On the other hand, the processor 128 can dynamically monitor the voltage of the battery 104 connected across the output terminals to detect faulty batteries. For example, if the voltage of battery 104 does not exceed a predetermined threshold voltage after a predetermined amount of time, then battery 104 is considered to have low SoH. The display device 114 will accordingly indicate that battery 104 is faulty. For example, if the battery voltage 104 is less than or equal to 10 volts (1.667V) for a nominal 12-volt battery, CELL If charging continues for more than two hours, charging will stop, and display device 114 will indicate that battery 104 is faulty. Another low SoH indication for battery 104 is lack of progress. For example, if the voltage of battery 104 does not increase by a predetermined amount during a predetermined time frame, then lack of progress can be identified. For example, in a six-cell nominal 12-volt battery, if the voltage is lower than a predetermined voltage (e.g., full charge voltage, e.g., 14.2 volts, 2.367V), then the charging will stop, and display device 114 will indicate that battery 104 is faulty. CELLAnd the voltage does not increase by at least 0.05 volts (0.008333V) within a predetermined time period (e.g., 5 to 60 minutes, or approximately a 20-minute period). CELL If this happens, charging will stop, and the display device 114 will indicate that the battery 104 is faulty.

[0131] As an illustration, an example of a faulty battery process for identifying faulty battery conditions via a battery charger 100 having a display device 114 during the charging process of a six-cell nominal 12-volt lead-acid battery 104 will be described according to one embodiment. Upon startup, the battery charger 100 immediately determines the state of charge of the lead-acid battery 104 connected to the battery charger 100 across a pair of electrical conductors 172a, 172b via a processor 128 and a sensor 112 (e.g., a voltage sensor). The battery charger 100 then uses the voltage sensor to measure a first battery voltage of the lead-acid battery 104. After a first predetermined time period (e.g., a first predetermined time period value stored in a memory device), the battery charger 100 then uses the voltage sensor to measure a second battery voltage of the lead-acid battery 104. Using the first and second battery voltages as a function of the first time period, the battery charger 100 can (via the processor 128) calculate a first rate of change within the first time period. If the first rate of change is greater than or equal to a first predetermined rate of change value (e.g., a predetermined rate of change value stored in a memory device), then the battery charger 100 may display a faulty battery indicator via the display device 114. It will be understood that the first predetermined rate of change value may vary depending on the state of charge of the lead-acid battery 104. For example, a higher rate of change is expected in the battery at a higher state of charge.

[0132] Therefore, after a second time period (e.g., a second predetermined time period value stored in the memory device), the battery charger 100 can measure the third battery voltage of the lead-acid battery 104. If the second rate of change is greater than or equal to the second predetermined rate of change value, then the battery charger 100 can display a faulty battery indicator via the display device 114. The expected rate of change is higher (e.g., a spike) at the beginning of the charging cycle. Therefore, different rate of change values ​​can be used throughout the charging cycle as a function of charging time (i.e., depending on the elapsed time). Therefore, the second predetermined rate of change value may not be equal to the first predetermined rate of change value. For example, the second predetermined rate of change value may be less than the first predetermined rate of change value. The first and second time periods may be the same, for example, between 30 seconds and 5 minutes, or about 1 minute.

[0133] Thermal runaway detection. During various charging modes, the battery charger 100 can also check for thermal runaway conditions. Thermal runaway conditions exist when the temperature of the electrical conductors and / or electrolyte in the battery 104 increases during charging cycles. Since the resistance of an electrical conductor is inversely proportional to its temperature, the resistance decreases as temperature increases. Therefore, if the battery charger 100 is supplying a constant voltage to the battery 104 under undercharging conditions, the current will increase proportionally to the decrease in resistance. During this condition, even if the charging current increases, the voltage of the battery 104 will not increase, rather than remain the same or decrease.

[0134] During the initial phase of a normal charging cycle, the voltage of battery 104 will gradually ramp up to a predetermined value or a point where dv / dt: 0. Additionally, a reduction in the charging current is typically required to maintain a constant battery voltage. Given these trends, several techniques can be used to detect thermal runaway conditions during the initial phase by monitoring the voltage and charging current of battery 104. For example, processor 128 can identify thermal runaway conditions when it detects an increase in charging current or an increase relative to time (i.e., di / dt).

[0135] Therefore, processor 128 can monitor the charging current during the operating cycle and track trends throughout the entire charging cycle. When the trend in the operating cycle indicates an anomaly, a thermal runaway condition is indicated. Whenever a thermal runaway condition is indicated, battery charger 100 will stop charging, and display device 114 will indicate a faulty battery. Commonly owned U.S. Patent No. 7,834,593 describes additional suitable methods for detecting thermal runaway conditions. For example, processor 128 can also identify a thermal runaway condition when the voltage of battery 104 fails to ramp up continuously, or when additional charging current (beyond nominal) is required to achieve dv / dt:0. Similarly, processor 128 can identify a thermal runaway condition when the voltage of battery 104 fails to reach a predetermined voltage within a predetermined time.

[0136] Internal Impedance / Conductivity Calculation. The battery charger 100 can also dynamically calculate and monitor the internal impedance and / or conductivity of the battery 104 by measuring its internal resistance to determine whether the battery has a low SoH. As you may understand, the conductivity of the battery 104 is simply the reciprocal of its impedance.

[0137] If the internal resistance of a battery is too high, excessive energy will be dissipated internally (e.g., as heat), and the battery may have insufficient power to achieve its intended purpose, such as starting a vehicle. Therefore, a battery with high internal resistance (i.e., greater than a predetermined resistance value) is considered to have a low SoH, and the display device 114 will accordingly indicate that the battery is defective. The internal resistance of a battery typically increases with battery aging. A battery with a measured (or calculated) internal resistance less than 60% of its rated internal resistance will have insufficient power to start an engine under all conditions and should therefore be replaced. Therefore, a battery with an internal resistance less than 60% of its rated internal resistance can be marked as a defective battery.

[0138] To determine the internal resistance of battery 104, the battery charger 100 can measure the open-circuit voltage (V) of battery 104 when a current is applied. OC The voltage of battery 104 is dynamically compared with that of battery 104. Equation 1 provides a formula for calculating the internal resistance (R) of a given battery 104, where V is the voltage measured at the terminals of battery 104 when a predetermined current (I) is applied to battery 104.

[0139] V = V OC -(I*R)

[0140] Equation 1

[0141] In some respects, the battery 104 can be modeled as a resistor-capacitor (RC) circuit 900 to determine, in particular, impedance and conductivity. For example, a lead-acid battery can be modeled as a Landles equivalent circuit. Figure 3 This describes an example RC circuit 900 having a first resistor 902 connected in series with a combination of two parallel resistor-capacitors, the combination comprising a first capacitor 906 connected in parallel with a second resistor 904 and a second capacitor 908 connected in parallel with a third resistor 910. The first resistor 902 models the resistance of the terminals and inter-cell connections of the battery 104 (e.g., between about 5 and 100 mΩ), while the second resistor 904 (10-500 mΩ) and the first capacitor 906 (e.g., between about 1,000 and 20,000 farads (F)) represent transient effects due to displaced ion concentration and plate current density. The third resistor 910 represents the self-discharge resistance of the battery 104 (approximately 5 kΩ), and the second capacitor 908 represents the main charge storage (i.e., capacity) of the battery 104, equivalent to ~1 × 10⁻⁶ for a fully charged, healthy nominal 12-volt battery. 5The voltage across the second capacitor 908 is a suitable indicator of the State of Health (SoC), while the SoH (Solar Hysteresis) is inferred by observing significant changes in the second capacitor 908 over time attributable to aging effects of the battery 104 (e.g., degradation of effective mass and crystallization of effective mass). While the RC circuit 900 is a suitable technique for determining the SoH and / or SoC of the battery 104, other modeling circuits are anticipated. For example, Gould discloses an adaptive battery model based on a variation of Landels' lead-acid model. See Gould, CR, et al., “New Battery Model and State-of-Health Determination Through Subspace Parameter Estimation and State-Observer Techniques,” IEEE Transactions on Vehicle Technology (Vol. 58, Issued: October 8, 2009). In another example, Kelvin four-line sensing can be used to calculate the internal resistance.

[0142] In operation, the battery charger 100 can be configured to output a known input signal (e.g., a test signal, such as a predetermined AC signal) to the battery 104 via the DC output 136, and dynamically monitor and record the response of the battery 104 to the known input signal (e.g., voltage waveform). The processor 128 can then compare the response of the battery 104 with the known input signal (e.g., using Ohm's law) to calculate the impedance and / or conductivity of the battery 104.

[0143] Capacity Calculation. The battery charger 100 can also dynamically calculate and monitor the capacity of the battery 104 to determine whether the battery has a low SoH (Solar Hours). In the context of a secondary battery, capacity typically refers to the number of ampere-hours that the battery 104 can discharge to a load. If the capacity of the battery 104 is lower than a predetermined capacity value, the battery charger 100 will determine that the battery 104 has a low SoH, and the display device 114 will accordingly indicate that the battery 104 is faulty. For example, if the battery 104 does not reach the predetermined capacity (e.g., 225A within 3 seconds) after charging for a predetermined time value, then the battery 104 is considered to have a low SoH, and the display device 114 will indicate a faulty battery condition.

[0144] In some respects, the capacity can be derived from the battery's conductivity. For example, the phase shift of the response to a known input signal can be used to determine the ratio of reactive to resistive impedance, where the reactive component represents the capacity of battery 104 and the resistive component represents the internal resistance of battery 104. Processor 128 can compare the conductivity with values ​​stored in read-only memory 118 or data storage 122 to estimate the current capacity of battery 104.

[0145] In another embodiment, after a predetermined time value (e.g., 4 to 16 hours, more preferably 6 to 12 hours, and most preferably about 8 hours) in sustain mode, the battery charger 100 will measure the V of the battery 104. OC This corresponds to the capacity in a high-energy battery. The processor 128 can then process the measured V... OC The current capacity of battery 104 is determined by comparing it with a value stored in read-only memory 118 or data storage 122. The processor may also consider the battery's temperature in its calculations. If the processor 128 determines that the capacity is below a predetermined value, then battery 104 is considered to have a low SoH (energy sonic acid). A typical lead-acid battery has a nominal V0 of 12.8 volts. OC If V OC If the value drops by more than 3% within an 8-hour cycle and the battery's SOH is below 60%, then the lead-acid battery should be replaced. The display device 114 will indicate that the battery is faulty accordingly.

[0146] Example of a 12-volt lead-acid battery. As an illustration, an example of a faulty battery process will be described according to one embodiment for identifying faulty battery conditions via a battery charger 100 having a display device 114 during the charging process of a six-cell nominal 12-volt lead-acid battery 104. The example faulty battery process may be performed once per charging cycle, periodically, or upon instruction from a user. Upon startup, the battery charger 100 may, for example, use a voltage sensor to measure a first battery voltage across a pair of electrical conductors 172a, 172b connected to the battery charger 100. The battery charger 100 may then use a processor 128, for example operatively coupled to a memory device (e.g., ROM 118, RAM 120, and / or other data storage 122), to compare the first battery voltage with a first predetermined voltage value (e.g., approximately 12.0 to 12.4 volts, 2.0 to 2.067V) stored in the memory device. CELL Or approximately 12.2 volts, 2.034V CELL The voltage of the first battery is compared with that of the second battery. If the voltage of the first battery is less than a first predetermined voltage value, the battery charger 100 may then use a voltage sensor to measure the voltage of the second battery of the lead-acid battery 104 after a first time period (e.g., 1 minute to 10 minutes, or about 5 minutes). The battery charger 100 may then use a processor 128 to compare the voltage of the second battery with a second predetermined voltage value (e.g., about 14.0 to 16.0 volts, 2.334 to 2.667 V) stored in a memory device. CELL Or approximately 14.2 volts, 2.367V CELLThe two batteries are compared. If the second battery voltage is greater than or equal to a second predetermined voltage value, the battery charger 100 may display a faulty battery indicator via the display device 114. If the second battery voltage is greater than or equal to the second predetermined voltage value, the battery charger 100 may further abort the charging process in addition to displaying the faulty battery indicator. Alternatively, if the second battery voltage is greater than or equal to the second predetermined voltage value, the battery charger 100 may initiate a desulfurization process 500 (or a portion thereof) to repair the lead-acid battery 104.

[0147] The battery charger 100 can periodically check the lead-acid battery 104 to determine whether the lead-acid battery 104 has been activated to accept charge, for example, after or during the desulfurization process 500. For example, if the second battery voltage is greater than or equal to a second predetermined voltage value, then the battery charger 100 can measure the third battery voltage of the lead-acid battery 104 connected across the pair of electrical conductors 172a, 172b after a second time period (e.g., 1 minute to 10 minutes, or about 5 minutes). The battery charger 100 can use the processor 128 to compare the third battery voltage with the second predetermined voltage value stored in the memory device. If the third battery voltage is less than or equal to the second predetermined voltage value, then the battery charger 100 can instruct the display device 114 not to display (e.g., disable) the bad battery indicator. However, if the third battery voltage is less than the second predetermined voltage value, then after detecting a lack of progress (i.e., the third battery voltage is within a predetermined deviation of the second battery voltage, which may be a function of the second time period), and / or after detecting a thermal runaway condition, the battery charger 100 may instruct the display device 114 to continue displaying (e.g., enabling) the bad battery indicator, after which the battery charger 100 may further terminate the charging process.

[0148] Lithium SoH Monitoring. The battery charger 100 can also determine whether the lithium battery has a low SoH based on its charging characteristics. During the charging phase, the battery charger 100 dynamically records the voltage of the battery 104 and the current flowing through the battery 104. The processor 128 continuously compares the voltage and current of the battery 104 to determine whether the current drawn is too low for the measured voltage. For example, if the voltage of the battery 104 is between 2 volts (0.333V)... CELL ) and 8 volts (1.334V) CELL If the current received is less than 800mA, and the current is between 800mA and 800mA, then the processor will determine that the lithium battery has a low OH rating. The display device 114 can then indicate that the battery 104 is faulty.

[0149] Figure 11This describes an example lithium charging cycle 1100 for identifying adverse battery conditions during the charging process of lithium battery 104. Lithium charging cycle 1100 begins at step 1102. At step 1102, battery charger 100 measures (e.g., via a voltage sensor that can dynamically measure) the battery voltage (measured battery voltage) of lithium battery 104 connected to battery charger 100 (e.g., across a pair of terminals or clamps).

[0150] At step 1104, processor 128 determines the voltage of lithium battery 104 via a voltage sensor. Processor 128 may be configured to determine the voltage dynamically, periodically (e.g., at regular intervals), or immediately after a trigger event.

[0151] At step 1106, processor 128 determines whether the timer has expired. If the timer has expired, lithium charging cycle 1100 may be aborted / terminated at step 1124 until reset or restarted. If lithium charging cycle 1100 is aborted at step 1124, battery charger 100 may display a faulty battery indicator via display device 114. Otherwise, lithium charging cycle 1100 proceeds to step 1108.

[0152] The timer can be a function of time alone, or a function of both time and the battery voltage measured during the lithium charging cycle 1100 (e.g., at step 1104). For example, the lithium charging cycle 1100 can be configured to charge the lithium-ion battery only within a predetermined total time period (e.g., 5 to 15 hours, more preferably about 10 hours), whereby the lithium charging cycle 1100 can be stopped / terminated until reset and restarted, or stopped / terminated after a predetermined resting time period allowing the battery to rest or cool down. In another example, if, after a certain time period (e.g., about 1 to 3 hours, more preferably about 2 hours), the measured battery voltage is less than a predetermined voltage value (e.g., about 8.0 to 12.0 volts, 1.333 to 2.0 V). CELL More preferably about 10.0 volts, 1.667V CELL If the processor 128 determines that the lithium-ion battery is no longer accepting charge (and also indicates a faulty battery condition, which can be triggered via the display device 114 to indicate a faulty battery indicator), then the lithium charging cycle 1100 should terminate.

[0153] At step 1108, the processor 128 compares the measured battery voltage with a first predetermined voltage value (e.g., approximately 5.0 to 10.0 volts, 0.834 to 1.667 V). CELL More preferably about 8.0 volts, 1.334V CELLThe battery voltage is compared. If the measured battery voltage is less than a first predetermined voltage value, then at step 1122, the battery charger 100 supplies a first current (e.g., about 0.01 to 0.5 A, more preferably about 0.1 A) to the lithium battery 104 for a first time period.

[0154] At step 1110, the processor 128 compares the measured battery voltage with a second predetermined voltage value (e.g., approximately 8.0 to 12.0 volts, 1.334 to 2.0 V). CELL More preferably about 10.0, 1.667V CELL The battery voltage is compared. If the measured battery voltage is less than the second predetermined voltage value (but greater than the first predetermined voltage value), then at step 1120, the battery charger 100 supplies a second current (e.g., about 0.25 to 1.0 A, more preferably about 0.5 A) to the lithium battery 104 for a first time period.

[0155] At step 1110, the processor 128 compares the measured battery voltage with a second predetermined voltage value (e.g., about 8.0 to 12.0 volts, more preferably about 10.0 volts). If the measured battery voltage is less than the second predetermined voltage value (but greater than the first predetermined voltage value), then at step 1120, the battery charger 100 supplies a second current (e.g., about 0.25 to 1.0 A, more preferably about 0.5 A) to the lithium battery 104 for a second time period.

[0156] At step 1112, the processor 128 compares the measured battery voltage with a third predetermined voltage value (e.g., about 14 to 15.0 volts, more preferably about 14.2 volts). The third predetermined voltage value may be the battery's full-charge voltage. The full-charge voltage may be specified by the manufacturer's rating for the battery (i.e., according to the battery manufacturer's specifications) or a predetermined voltage value associated with a fully charged battery for a specific application. For example, the full-charge voltage of a six-cell nominal 12-volt battery may be set to 14.2 volts, which is equal to 2.367V. CELL .

[0157] If the measured battery voltage is less than a third predetermined voltage value (but greater than a second predetermined voltage value), then at step 1118, the battery charger 100 supplies a third current (e.g., about 1.0 to 3.0 A, more preferably about 2.0 A) to the lithium battery 104 for a third time period. If, at step 1112, the measured battery voltage third predetermined voltage value is greater than or equal to the third predetermined voltage value, then the battery charger 100 enters a maintenance mode at step 1114. During the maintenance mode, the battery charger 100 may periodically supply a maintenance current (e.g., about 0.1 to 0.4 A, more preferably about 0.2 A) to the lithium battery 104.

[0158] The battery charger 100 can also periodically measure the voltage of the lithium battery 104, and if the measured voltage drops below a fourth predetermined voltage value (e.g., approximately 12.5 to 13.5 volts, 2.083 to 2.25V), it will notify the battery charger. CELL More preferably about 13.1, 2.183V CELL If so, the battery charger 100 can return to step 1102 to restart the lithium charging cycle 1100, or simply supply a third current at step 1118.

[0159] Automatic nominal voltage detection 300. The battery charger 100 can be configured to have an automatic nominal voltage detection function, whereby the battery charger 100 can determine the nominal voltage of the battery 104. When presented as a nominal 6-volt and 12-volt battery, if the initial voltage of the battery 104 after being connected to the battery charger 100 is greater than a first predetermined voltage (e.g., about 7-10 volts, more preferably about 8 volts), then the battery charger 100 can determine that the battery 104 is a nominal 12-volt battery (relative to a nominal 6-volt battery); otherwise, no decision on the battery type may be made until one of a plurality of conditions is met. As a first example, if the voltage of the battery 104 exceeds a second predetermined voltage (e.g., about 9 to 12 volts, more preferably about 10 volts) within a predetermined time frame (e.g., within 48 hours, more preferably within about 36 hours, most preferably within about 24 hours), the battery charger 100 can determine that the battery 104 is a 12-volt battery. As a second example, if the voltage of battery 104 decreases by a third predetermined voltage (e.g., 0.1 or more volts), then battery charger 100 can determine that battery 104 is a 6-volt battery (e.g., a three-cell 6-volt battery).

[0160] Figure 3An exemplary automatic voltage detection process 300 is illustrated. As described, the battery charger 100 may, for example, determine whether the battery is a nominal 12-volt battery (six-cell) or a nominal 6-volt battery (three-cell). The process begins at step 302, where the battery charger 100 proceeds to step 304 to dynamically measure the voltage of battery 104. If, at step 306, the measured voltage is greater than a first predetermined value, then at step 312, the battery charger 100 marks the battery as a nominal 12-volt battery. Otherwise, the process proceeds to the next step. At step 308, the battery charger 100 determines whether, within a first predetermined time frame, the measured voltage exceeds a second predetermined value. If, at step 308, within the first predetermined time frame, the measured voltage exceeds the second predetermined value, then at step 314, the battery charger 100 marks battery 104 as a nominal 12-volt battery. Otherwise, the process proceeds to the next step. At step 316, the battery charger 100 charges the battery according to a charging protocol for nominal 12-volt batteries. At step 310, the battery charger 100 determines whether the voltage has decreased by a predetermined value within a second predetermined time frame. If the voltage has decreased by a predetermined value within the second predetermined time frame, then at step 318, the battery charger 100 marks the battery as a 6-volt battery. Otherwise, the process proceeds to the next step. At step 320, the battery charger 100 charges the battery according to a charging protocol for 6-volt batteries. At step 306, the battery charger 100 charges the battery according to a default charging protocol, which may be, for example, a protocol for 6-volt batteries.

[0161] While the aforementioned automatic nominal voltage detection 300 technology is discussed in conjunction with nominal 6-volt and 12-volt batteries, the principle can be similarly applied to and adapted to other nominal battery voltages, such as 24-volt, 36-volt, and 48-volt batteries (e.g., typically ~2.0 nominal volts per cell), by scaling a predetermined threshold value proportionally. For example, to automatically distinguish between nominal 12-volt and 24-volt batteries, the predetermined threshold value can be multiplied by two.

[0162] Automatic battery type detection 400. The battery charger 100 can be configured to have automatic battery type detection (e.g., AGM, gel, lithium-ion, etc.). Figure 4An exemplary battery type detection process 400 for determining battery type is illustrated. For example, after determining the nominal battery voltage, the battery charger 100 may send a test signal to the battery 104 at step 402. The battery charger 100 will then dynamically monitor the voltage response of the battery 104 at step 404 and record it in random access memory 120. The processor 128 may then, at step 406, use, for example, a lookup table to compare the voltage response with a predetermined voltage response stored in data storage 122 or read-only memory 118. The lookup table may contain multiple known battery types (e.g., lead-acid, lithium, etc.) and associated voltage response characteristics or ranges. As the battery charge, for example, ranges from 70% to 80% SoC, the battery type can be determined by applying constant current charging and measuring the rate of change of voltage (dv / dt).

[0163] As an explanation, Figure 10a The charging curve at point 1000a illustrates the dv / dt curve 1002a versus the battery voltage curve 1004a for a 22AH AGM battery being charged at a constant current of 2.0A. For illustrative purposes, the voltage range is from 14.0 to 14.7 volts (2.334 to 2.450 V). CELL dv / dt was measured at 60-second intervals. The maximum dv / dt was below 0.04V, which is characteristic of AGM batteries. At 80% SoC, as the charger typically switches to the di / dt stage, the charge flattens out because the battery will no longer accept batch rate current. Figure 10b This illustrates graph 1000b, showing the dv / dt curve 1002b relative to the battery voltage curve 1004b for a submerged lead-acid battery charged for 120 minutes at a constant current of 2.0A. For illustrative purposes, the voltage range is from 11.34 to 14.77 volts (1.890 to 2.462 V). CELL The dv / dt is measured at 60-second intervals. This allows for testing various battery capacities using a relatively small current. Based on this comparison, the processor 128 can identify the battery type at step 408 and label it accordingly.

[0164] In another example, battery charger 100 may apply a test load to battery 104 and then record the response of battery 104 to the test load in random access memory 120. Processor 128 may then compare the response to the load with a predetermined load response stored in data storage 122 or read-only memory 118. The load applied to battery 104 is a percentage of the current required to start the vehicle. Measuring the corresponding voltage drop and multiplying it by the percentage produces the expected drop during actual engine start-up. If the value is lower than the nominal required voltage, then it is determined that the battery's SoH is below 60%, and battery 104 should be replaced. Based on this comparison, processor 128 may identify the battery type. In another example, voltage may be applied to battery 104 in series with a known resistor to form a voltage divider circuit. The voltage across battery 104 may then be measured to determine the impedance of battery 104. Different battery types have different impedance values, so processor 128 may determine the battery type by comparing the calculated impedance with values ​​stored in read-only memory 118 and / or data storage 122.

[0165] A temperature sensor records the temperature of battery 104 and delivers the information to processor 128. The temperature of the battery can affect its response to load and voltage. The processor may be able to include the temperature of battery 104 in its response comparisons. In some respects, read-only memory 118 or data storage 122 may have stored voltage and load responses corresponding to various battery types at various temperatures.

[0166] Desulfurization mode 500. Figure 5 This describes a demonstrative desulfurization process 500. If the system determines that battery 104 is a lead-acid battery, then during the first part of the charging cycle (e.g., during soft-start mode 208), the system checks for sulfation conditions. Sulfation conditions are typically indicated by a low initial voltage, followed by a rapid voltage rise once battery 104 is connected to the charger. For example, in a 12-volt battery, if the peak voltage is >11 volts, but the initial voltage is less than 3 volts, the system assumes sulfation conditions are present and initiates desulfurization charging.

[0167] At step 502, the battery charger 100 determines whether the battery 104 is a lead-acid battery (e.g., using battery type detection process 400). At step 504, the battery charger 100 (via processor 128) determines whether the battery 104 is sulfated. This can be achieved by continuously monitoring V. MAX With V MINThe difference between the values ​​is used to detect sulfation. If the difference exceeds a predetermined value (e.g., 8 volts), then battery 104 is considered to be under sulfation conditions, and at step 506, battery 104 is indicated as sulfated on display device 114. As explained in steps 508 to 512, desulfurization charge is conducted for a predetermined time frame (e.g., 8 hours, as indicated at step 508). After the predetermined time frame, desulfurization charging is terminated at step 516. During the desulfurization charging cycle, at step 510, the voltage of battery 104 is regulated to a predetermined voltage (e.g., 5.4 volts) by means of a current pulse applied to battery 104. At step 512, a current pulse is applied to battery 104 until battery 104 accepts charge. If battery 104 accepts charge at step 512, then at step 514, battery charger 100 can begin a normal charging cycle.

[0168] Processor 128 can determine whether battery 104 is accepting charge by comparing the operating cycle with the maximum sulfation and by comparing the periodic peak voltage with a predetermined voltage (e.g., 11 volts). Specifically, if the operating cycle is greater than the maximum sulfation or the periodic peak voltage is less than the predetermined voltage (e.g., 11 volts), then it is determined that battery 104 is not accepting charge, and the desulfurization process continues to step 508.

[0169] If battery 104 does not recover within a predetermined time (e.g., 8 hours), then battery charger 100 will abort desulfurization process 500. At step 516, processor 128 will determine that battery 104 has a low SoH, and display device 114 will indicate that battery 104 has become defective. If at step 512 it is determined that the battery needs desulfurization (i.e., accepting charge), then a charging cycle will begin at 514. Commonly owned U.S. Patent No. 8,575,899B2 describes a process for determining whether a battery is sulfated and a desulfurization process during desulfurization mode.

[0170] Load detection cycle 600. Figure 6 An exemplary load detection loop 600 for use in battery charger 100 is shown. A significant voltage drop on battery 104 indicates that the engine coupled to battery 104 is attempting to start. Therefore, throughout the charging cycle, processor 128 may loop load detection loop 600 to dynamically monitor battery 104 until a drop is detected at step 602; otherwise, load detection loop 600 proceeds to step 610, where battery charger 100 continues its current charging mode.

[0171] At step 602, a voltage drop indicates to processor 128 that the engine coupled to battery 104 is starting or attempting to start. If a voltage drop is detected at step 602, load detection loop 600 proceeds to step 604. At step 604, a predetermined external load is applied to battery 104. Processor 128 then records the lowest battery voltage during the remainder of the engine start-up phase. During this phase, if the voltage of battery 104 drops below a predetermined value, battery 104 is considered to have low SoH, and display device 114 will indicate this (e.g., a faulty battery indicator). For example, for a nominal 12-volt battery, if at step 606 the voltage drops below 7 volts during this phase, battery 104 is considered to have low SoH. Processor 128 will identify the low SoH, and at step 614, outputs to display device 114 that battery 104 is faulty and charging operation or mode can be aborted.

[0172] If the voltage drop remains at or above 7 volts at step 606, the process continues to step 608. At step 608, processor 128 compares the current battery voltage with the battery voltage before the ignition attempt (e.g., the last stored voltage). If the current voltage is less than the voltage before the sudden drop at step 608, the external load is reapplied at step 604, and the battery test is repeated. If the current voltage is greater than or equal to the voltage before the sudden drop at step 608, the battery charging process continues at step 610, where battery charger 100 continues (or returns to) its current charging mode. After returning to the charging mode at step 610, battery charger 100 dynamically measures and records the battery voltage at step 612 until a voltage drop is detected at step 602 to indicate that the engine coupled to battery 104 is starting or attempting to start.

[0173] Battery engine start detection cycle 700. In addition to, or instead of, the aforementioned battery SoH determination and display method, display device 114 may display whether the battery is fully charged and / or at a sufficient SoH, enabling it to start the vehicle. Therefore, display device 114 may be configured to provide indications (e.g., icons, words, etc.) that the battery 104 is not expected to start the engine, at least in part based on the SoC and / or SoH of the battery 104. Figure 7 An exemplary battery engine start detection cycle 700 is shown for use in a battery charger 100 or other device (e.g., vehicle, battery monitor, etc.). After starting at step 702, the processor 128 can immediately cycle through one or more steps to determine whether the battery 104 is capable of starting the internal combustion engine.

[0174] At step 704, processor 128 determines the initial voltage difference (ΔV). According to one aspect, the initial voltage difference (ΔV) can be the initial difference between the peaks and troughs of the voltage signal. For example, the voltage difference (ΔV) can be measured during the zero-crossing cycle of a 60Hz AC input line (e.g., AC power supply 102).

[0175] At step 706, the battery charger 100 may supply multiple predetermined currents to the battery 104 and detect / monitor the results. This is possible for several reasons. First, as the battery 104 begins to accept charge, the value of the voltage difference (ΔV) will decrease. Second, the value of the voltage difference (ΔV) varies as a function of the amount of current that the battery charger 100 is supplying to the battery 104. At step 704, by delivering multiple different predetermined currents to the battery 104, the battery charger 100 may dynamically monitor the voltage response (e.g., ΔV) and record it in the random access memory 120. Using the voltage response, the processor 128 may generate a database of data comparing the current delivered to the battery with ΔV. Using this database, the processor 128 may dynamically monitor trends to determine whether the battery 104 is accepting charge. If the processor 128 determines that the battery 104 is not accepting charge, then at step 718, the display device 114 may be able to display (e.g., in addition to poor battery conditions) that starting the engine / vehicle is not expected by the battery 104.

[0176] At step 708, the battery charger 100 determines the capacity of the battery 104. If the processor 128 determines that the capacity is below a predetermined capacity threshold, then at step 718, the display device 114 may be able to display that the battery 104 is not expected to start the engine / vehicle.

[0177] At step 710, the battery charger 100 determines the internal resistance of the battery 104. If the processor 128 determines that the resistance is below a predetermined capacity threshold, then at step 718, the display device 114 may be able to display (e.g., in addition to poor battery conditions) that the battery 104 is not expected to start the engine / vehicle.

[0178] At step 712, the battery charger 100 determines the number of attempts to start the vehicle, thereby causing a counter to increment by 1 at step 720 for each ignition attempt.

[0179] At step 714, the battery charger 100 analyzes the waveforms during startup. For example, the processor 128 may compare two or more ignition waveforms (e.g., two consecutive ignition attempts) to compare the valley voltage of each waveform. Additionally, consecutive starts also help restore some of the battery's capacity. The minimum voltage required to exit before the vehicle's starter solenoid or electronic ignition is typically 6 volts. For example, if during a startup attempt, the valley voltage drops below a 7.2-volt threshold or the percentage difference between two consecutive voltages is greater than 5%, then it is determined that the battery's SoH is below 60%, and at step 718, the display device 114 may be able to display (e.g., in addition to poor battery conditions) an unexpected start of the engine / vehicle by the battery 104.

[0180] At step 716, the battery charger 100 is configured to apply a microload (e.g., approximately 80 to 250 A) for a predetermined time frame (e.g., 1 to 10 milliseconds, more preferably 2 to 7 milliseconds, and most preferably 3 to 5 milliseconds). Analysis of the voltage response can be used to indicate the ability of the battery 104 to start the vehicle.

[0181] In step 718, the battery charger 100 is configured such that the display device 114 is able to display that the battery 104 is not expected to start the engine / vehicle at step 718. For example, the display device 114 may display an icon (e.g., an engine graphic with a slash or an X) or a phrase (e.g., no engine starting).

[0182] In another example, battery charger 100 may apply a test load to battery 104 and then record the battery 104's response (to the test load) in random access memory 120. Processor 128 may then compare the response to the test load with a predetermined load response stored in data storage 122 or read-only memory 118. The load applied to battery 104 is a percentage of the current required to start the vehicle. Measuring the corresponding voltage drop and multiplying it by the percentage produces the expected drop during actual engine start-up. If the value is lower than the nominal required voltage, then it is determined that the battery's SoH is below 60%, and battery 104 should be replaced. Based on this comparison, processor 128 may identify the battery type. In another example, voltage may be applied to battery 104 in series with a known resistor to form a voltage divider circuit. The voltage across battery 104 may then be measured to determine the impedance of battery 104. Different battery types have different impedance values, so processor 128 may determine the battery type by comparing the calculated impedance with values ​​stored in read-only memory 118 and / or data storage 122.

[0183] As discussed above, in some embodiments, the battery charger 100 may be configured to charge or start (i.e., “boost,” “jump,” or “jump start”) the engine coupled to the battery. When starting the battery-coupled engine, if the voltage of the battery 104 drops below a certain threshold voltage, there is an indication that the battery 104 has a low SoH (Solar Hourly Rate). Therefore, if the battery 104 is deemed insufficient to start the vehicle's engine, the processor 128 may automatically initiate a jump start mode to provide jump start functionality. In jump start mode, the battery charger 100 may use one or more of an auxiliary power supply 108, a linear transformer, and / or a mode-switching transformer to provide additional current for jump start of the vehicle.

[0184] While the various battery monitoring and testing techniques disclosed herein are described in conjunction with a battery charger used to charge a battery, those skilled in the art will understand that one or more of these features, techniques, etc., may be embodied in other devices. These other devices may include, in particular, the vehicle itself (i.e., with one or more onboard vehicle systems), monitoring-only devices (e.g., a battery charger 100 without charging capability), portable battery jump starters (e.g., with an internal power supply), etc. In some aspects, for example, the various battery monitoring and testing techniques may be implemented as pass-through devices coupled to a battery charger. For example, such pass-through devices may be coupled to and receive power from the battery, and optionally send instructions (e.g., as feedback) to the battery charger.

[0185] The aforementioned patents and patent disclosures are hereby incorporated herein by reference in their entirety. Where the definitions or uses of terms in the references incorporated herein by reference are inconsistent with or contrary to the definitions or understandings of the terms provided herein, the meanings of the terms provided herein shall prevail, and the definitions of the terms in the references shall not necessarily apply. Although various embodiments have been described with reference to specific arrangements of components, features, etc., these are not intended to exhaustively explore all possible arrangements or features, and in fact, those skilled in the art will be able to identify many other embodiments, modifications, and variations. Therefore, it should be understood that the teachings of this disclosure may be practiced in ways different from those specifically described above.

Claims

1. A battery charger configured to identify unfavorable battery conditions for lead-acid batteries, the battery charger comprising: A processor that is coupled to a voltage sensor in an operational manner; A non-transitory memory device operatively coupled to the processor; A power management device that receives input power and outputs current during the charging process; A display device electrically coupled to the processor; as well as A pair of electrical conductors for electrically coupling to the lead-acid battery, wherein the battery charger is configured to: The voltage sensor is used to monitor the voltage measured across the pair of electrical conductors to identify a voltage drop, which indicates the ignition process of the engine coupled to the lead-acid battery, wherein the voltage measured across the pair of electrical conductors is stored in the non-transitory memory device. An external load is applied to the lead-acid battery during the ignition process of the engine; When the external load is applied to the lead-acid battery, the voltage sensor is used during the ignition process of the engine to monitor the applied voltage across the pair of electrical conductors. as well as If the load voltage drops below the voltage value stored in the non-transitory memory device during the ignition process of the engine, a bad battery indicator is displayed via the display device. During the charging process, the battery charger is further configured to: Thermal runaway conditions are identified in response to the detection of an increase in charging current relative to time; and In response to the identified thermal runaway condition, a faulty battery indicator is displayed via the display device.

2. The battery charger of claim 1, wherein the voltage drop is at least 2 volts.

3. The battery charger of claim 1, wherein if the applied voltage drops below the voltage value, the battery charger is configured to terminate the charging process.

4. The battery charger according to claim 3, wherein the lead-acid battery has a nominal voltage of 12 volts, and the voltage value is 7 volts.

5. The battery charger according to claim 1, wherein, If the applied voltage does not drop below the voltage value, then the battery charger is configured to determine whether the applied voltage is less than the voltage measured across the pair of electrical conductors.

6. The battery charger according to claim 5, wherein, If the applied voltage is not less than the voltage measured across the pair of electrical conductors, then the charging process continues.

7. The battery charger of claim 1, further comprising a wireless device configured to facilitate wireless communication between the processor and the portable electronic device.

8. The battery charger of claim 7, wherein the battery charger is configured to communicate data on adverse battery conditions to the portable electronic device via the wireless device.

9. A battery charger configured to identify unfavorable battery conditions for lead-acid batteries, the battery charger comprising: A processor that is coupled to a voltage sensor in an operational manner; A non-transitory memory device operatively coupled to the processor; A power management device that receives input power and outputs current during the charging process; A display device electrically coupled to the processor; as well as A pair of electrical conductors for electrically coupling to the lead-acid battery, wherein the battery charger is configured to: The voltage sensor is used to measure the first battery voltage of the lead-acid battery. The voltage sensor is used to measure the second battery voltage of the lead-acid battery after the first time period; Calculate the difference between the first battery voltage and the second battery voltage to determine the voltage increase for the first time period; If the voltage increase is less than the voltage value stored in the non-transitory memory device, then a faulty battery indicator is displayed via the display device; and During the charging process, the battery charger is further configured to: Thermal runaway conditions are identified in response to the detection of an increase in charging current relative to time; and In response to the identified thermal runaway condition, a faulty battery indicator is displayed via the display device.

10. The battery charger of claim 9, wherein the lead-acid battery has a nominal voltage of 12 volts, the first time period is at least 20 minutes, and the voltage value is at least 0.05 volts.

11. The battery charger of claim 9, further comprising a wireless device configured to facilitate wireless communication between the processor and the portable electronic device.

12. The battery charger of claim 11, wherein the battery charger is configured to communicate data on adverse battery conditions to the portable electronic device via the wireless device.

13. The battery charger of claim 12, wherein the portable electronic device is configured to display a message or icon indicating the poor battery condition.

14. A method for identifying defective battery conditions via a battery charger during the charging process of a lead-acid battery, the battery charger having a display device, the method comprising: Determine the state of charge for the lead-acid battery, which is connected to the battery charger across a pair of electrical conductors; The first battery voltage of the lead-acid battery is measured using a voltage sensor; The voltage sensor is used to measure the second battery voltage of the lead-acid battery after the first time period; A processor operatively coupled to the voltage sensor and memory device calculates a first rate of change based on the first battery voltage, the second battery voltage, and the first time period. The processor compares the first rate of change with a first rate of change value stored in the memory device, wherein the first rate of change value changes with the state of charge of the lead-acid battery. as well as If the first rate of change is greater than or equal to the first rate of change value, then a faulty battery indicator is displayed via the display device. During the charging process, the battery charger is configured to: Thermal runaway conditions are identified in response to the detection of an increase in charging current relative to time; and In response to the identified thermal runaway condition, a faulty battery indicator is displayed via the display device.

15. The method of claim 14, further comprising the following steps: The voltage sensor was used to measure the third cell voltage of the lead-acid battery after the second time period; The processor calculates the second rate of change based on the second battery voltage, the third battery voltage, and the second time period; The processor compares the second rate of change with a second rate of change value stored in the memory device, wherein the second rate of change value is different from the first rate of change value. as well as If the second rate of change is greater than or equal to the second rate of change value, then a faulty battery indicator is displayed via the display device.

16. The method of claim 15, further comprising the step of initiating a desulfurization process if the second rate of change is greater than or equal to the second rate of change value.

17. The method of claim 15, further comprising the step of providing charging current to the lead-acid battery if the second rate of change is less than the second rate of change value.

18. The method of claim 14, further comprising the step of monitoring the voltage of the lead-acid battery during a time period to identify a lack-progression state, wherein the lack-progression state exists when the voltage does not increase by at least a predetermined amount during the time period.

19. The method of claim 18, further comprising the step of terminating the charging process if the lack of progress state is identified.

20. The method of claim 15, wherein the second rate of change is less than the first rate of change.

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