Charging control method and charger

Abstract

The invention relates to the technical field of vehicle battery charging, in particular to a charging control method and a charger, and the method comprises the steps: connecting the charger with a to-be-charged battery, connecting the charger with the to-be-charged battery, receiving a battery selection instruction input by a user, obtaining the type of the battery, and carrying out the terminal voltage detection of the battery; and calling a preset charging time sequence for charging based on the initial judgment result and the real-time voltage of the battery type, performing secondary terminal voltage detection on the battery when the battery is in a fully charged state to obtain a final judgment result, and if the final judgment result is normal, completing the charging. By setting a dual voltage detection mechanism before and after charging and combining battery type self-adaptive charging time sequence control, safe charging of multiple types of batteries is realized, and the problem that in the prior art, different battery types cannot be adapted and health state diagnosis cannot be carried out to realize safe charging is solved.

Description

Technical Field

[0001] This application relates to the technical field of vehicle battery charging, and in particular to a charging control method and a charger. Background Technology

[0002] Battery chargers are key components in various electronic devices and power tools. They replenish batteries by converting AC power from the grid into controlled DC power to maintain the continuous operation of the equipment. During the charging process, the compatibility with different battery types and the accuracy of battery health status diagnosis are core parameters affecting charging efficiency, battery life, and safety. Therefore, achieving intelligent management and safety control is an important aspect of improving charger performance.

[0003] Currently, existing charging control technologies mainly rely on simple constant current and constant voltage charging or fixed charging processes for a single battery type. The first common method uses basic power management chips to achieve indiscriminate charging cutoff, lacking battery type identification. The second technical solution pre-sets simple multi-stage charging curves for specific batteries (such as lead-acid batteries), which improves charging efficiency to some extent.

[0004] However, existing technologies not only suffer from the risks of overcharging or undercharging due to their single charging mode and inability to adapt to various battery chemical characteristics; their fixed-process charging strategies lack effective diagnosis of the initial health state of the battery and cannot identify damaged or degraded batteries; at the same time, they lack the ability to coordinate and judge multiple parameters such as battery type, real-time voltage and internal resistance changes throughout the charging process, and cannot provide dynamic decision support for safe and accurate charging, which seriously restricts the adaptability and safety of the charging process. Summary of the Invention

[0005] In view of this, this application provides a charging control method and a charger, which solves the problem in the prior art that it is impossible to adapt to different battery types and perform health status diagnosis in order to achieve safe charging.

[0006] This application provides a charging control method and a charger, which adopt the following technical solution: A charging control method, comprising: Connect the charger to the battery to be charged and receive the user's battery selection command to obtain the battery type; The battery terminal voltage is detected to obtain an initial judgment result; Based on the initial judgment result and the real-time voltage of the battery type, the preset charging sequence is invoked for charging; When the battery is fully charged, the secondary terminal voltage of the battery is detected to obtain the final judgment result; If the final result is normal, then charging is complete.

[0007] By employing the above technical solution, and performing two critical terminal voltage checks on the battery before and after charging, abnormal batteries such as those with reverse connection or damage can be identified. During the initial check, undervoltage batteries are attempted to be activated through repair or forced start modes, thus preventing the accidental charging of unqualified batteries at the source and improving safety. Simultaneously, the charging sequence is dynamically selected based on battery type and real-time voltage, ensuring that each battery follows its optimal charging curve. Finally, a second voltage check after full charge re-verifies battery health, improving the adaptability and reliability of the charging process.

[0008] Optionally, the battery terminal voltage is detected to obtain an initial judgment result, which may include: The connection status of the charger and battery is reversed to obtain the connection determination result. If the connection determination result is a normal connection, the battery terminal voltage is detected; otherwise, a reverse connection alarm signal is generated.

[0009] By adopting the above technical solution, reverse connection detection is performed first, which can identify the dangerous situation of reversed positive and negative terminals of the battery at the initial stage of power connection, and immediately cut off the charging circuit and issue an alarm signal. This avoids serious safety accidents such as damage to the internal circuit of the charger or short circuit and fire caused by reverse connection, and ensures that voltage detection and charging process will only be performed when the connection is correct, thereby improving the intrinsic safety level of the charger.

[0010] Optional battery types include lead-acid batteries, AGM batteries, and lithium batteries; The charging sequence includes a pulse charging stage, a constant current charging stage, and a constant voltage charging stage. Based on the initial assessment results and the real-time voltage of the battery type, a preset charging sequence is invoked for charging, including: If the initial assessment result is normal, and the battery type is lead-acid battery or AGM battery, the charging process will sequentially switch between pulse charging stage, constant current charging stage and constant voltage charging stage based on the real-time voltage of the battery. If the initial assessment result is normal and the battery type is lithium battery, the constant current charging stage and constant voltage charging stage will be switched sequentially based on the real-time voltage of the battery.

[0011] By adopting the above technical solutions, for traditional lead-acid and AGM batteries, introducing a pulse charging stage helps break sulfation crystals and activate the active materials inside the battery, thereby improving charging efficiency and extending battery life; then, a constant current and constant voltage stage is used to complete the main charge replenishment. For lithium batteries, which are more sensitive to charging curves, a standard constant current and constant voltage charging method is directly adopted to avoid unnecessary internal stress caused by the pulse stage, ensuring the safety and stability of the charging process. By pre-setting different charging processes for each type of battery, compatibility is improved while achieving precise adaptation to the optimal charging mode for various types of batteries.

[0012] Optionally, the constant current charging stage includes a half-power constant current sub-stage and a full-power constant current sub-stage; When the real-time voltage reaches the preset first voltage threshold, the battery will switch from the pulse charging stage to the half-power constant current stage. When the real-time voltage reaches the preset second voltage threshold, the battery will switch from the half-power constant current stage to the full-power constant current stage. The first voltage threshold is less than the second voltage threshold.

[0013] By adopting the above technical solution and setting two sub-stages, half-power and full-power, the charger can gradually apply charging current according to the recovery of battery voltage. When the battery voltage is low, half-power constant current charging can avoid excessive current surges to the not-yet-fully-activated battery. Once the battery voltage rises to a higher level and its withstand capacity increases, it can switch to full-power constant current charging to shorten charging time, thus ensuring charging safety while balancing charging efficiency and battery protection.

[0014] Optionally, based on the initial determination result and the real-time voltage of the battery type, charging is performed using a preset charging sequence, which also includes: The charging sequence also includes a repair mode phase; If the initial judgment result is abnormal, and the battery type is lead-acid battery or AGM battery, then the repair mode phase will be executed to repair and charge. When the repair mode stage is executed for the first preset duration, the battery terminal voltage is detected to obtain intermediate detection results; If the intermediate test result is normal, the intermediate test result will replace the initial judgment result. If the intermediate test result is abnormal, the battery is determined to be damaged, charging is stopped, and a bad battery alarm signal is generated.

[0015] By adopting the above technical solution, when an abnormal voltage is detected in a battery due to prolonged inactivity or slight sulfation, it is not immediately judged as a faulty battery and charging is refused. Instead, it first enters repair mode, attempting to repair the battery with a small current and a specific voltage using pulsed or constant current methods. By activating the battery's deep active materials and eliminating slight sulfation, the battery's condition is reassessed based on intermediate test results after repair. This accurately distinguishes between recoverable undervoltage batteries and irreversibly damaged batteries. This not only improves the charger's fault tolerance and battery utilization but also avoids battery failure due to misjudgment, demonstrating the humanization and intelligence of the charging process.

[0016] Optionally, the charging sequence may also include a forced start phase: If the initial judgment result is abnormal and the battery type is lithium battery, then a forced start-up phase will be executed to perform forced activation and charging. When the forced start phase is executed for the second preset duration, the battery terminal voltage is detected to obtain the activation detection result; If the activation test result is normal, the activation test result will replace the initial judgment result. If the activation detection result is abnormal, the battery is determined to be damaged, charging will be stopped and a bad battery alarm signal will be generated.

[0017] By adopting the above technical solution, when the lithium battery voltage is detected to be below the normal operating range but not completely damaged, a forced start-up phase is initiated. A controlled, low-current is used to briefly and tentatively charge the battery, activating its internal protection circuit or raising the voltage to a threshold for normal charging. This solves the problem of traditional chargers directly refusing to charge due to their inability to recognize the battery, leading to the misjudgment of some repairable lithium batteries as unusable. Through a secondary detection after activation, the system can accurately determine whether the repair was successful, thus achieving the repair of recoverable lithium batteries and the safe isolation of batteries that are confirmed to be damaged.

[0018] Optionally, when the battery is fully charged, the secondary terminal voltage of the battery is detected to obtain the final judgment result, including: When the battery is fully charged and continues for a preset third time, the secondary terminal voltage of the battery is detected to obtain the final judgment result. If the final judgment result is not lower than the preset health voltage threshold, and the battery type is lead-acid battery or AGM battery, then the float charge maintenance mode is activated to perform maintenance charging on the battery at a float charge voltage lower than that of the constant voltage charging stage. If the final judgment result is lower than the preset health voltage threshold, and the battery type is lead-acid battery or AGM battery, the battery is judged to be damaged and a bad battery alarm signal is generated. If the final result is not lower than the preset health voltage threshold and the battery type is lithium battery, then the charging is considered complete. If the final judgment result is lower than the preset health voltage threshold, and the battery type is lithium battery, then the battery is judged to be damaged and a bad battery alarm signal is generated.

[0019] By adopting the above technical solution, voltage detection is performed after the battery is fully charged and left to stand for a short time. This eliminates interference from surface voltage during charging, reflecting the battery's open-circuit voltage and retention capacity. Based on the assessment of the battery's internal health, lead-acid or AGM batteries are automatically switched to float charging maintenance mode to prevent self-discharge and extend standby time with a lower maintenance voltage. For lithium batteries, the charging is promptly shut off to avoid overcharging risks. Regardless of battery type, any abnormal voltage drop after standing is accurately identified as damage and an alarm is triggered, ensuring that only truly healthy batteries are delivered for use, greatly improving the safety and reliability of the entire charging process.

[0020] Optional, also includes: Real-time monitoring of the charger's internal temperature; When the temperature exceeds the preset first temperature threshold, the output current is reduced according to the preset derating curve; When the temperature exceeds the preset second temperature threshold, charging will stop and a high temperature alarm signal will be generated.

[0021] By adopting the above technical solution, the charger's working status and heat dissipation conditions can be actively sensed by monitoring the internal temperature in real time. When the temperature rises to the first threshold, the output current is smoothly reduced according to the preset derating curve. When the temperature rises further to the second threshold, the shutdown protection is decisively executed and an alarm is issued, preventing circuit failures or safety accidents that may be caused by overheating.

[0022] A charger, comprising: Main controller module; The power conversion module, connected to the main controller module, is used to convert the input AC power into controlled DC power to charge the battery. The voltage and current sampling module is connected to the main controller module and is used to collect the voltage and current signals at the battery terminal in real time. The human-computer interaction module, connected to the main controller module, is used to receive user input for battery selection and display the charging status. Specifically, it includes: The display unit is used to display a first specific icon when the charger is in the repair mode stage, a second specific icon when it is in the forced start stage, and to display the corresponding stage indicator icon according to the current stage of the charging sequence. The button unit includes at least a mode button for selecting the battery type and a confirmation button for confirming the operation; The main controller module is configured to execute any one of the charging control methods.

[0023] By adopting the above technical solutions, the power conversion module and the voltage and current sampling module complete accurate energy output and status monitoring under the command of the main controller. The human-machine interaction module, which integrates mode key, confirmation key and multi-functional display unit, provides users with an intuitive type selection and status feedback channel, realizing a safe, adaptive and user-friendly battery management and charging experience.

[0024] Optionally, a protection circuit module may also be included, which includes: Input over / under voltage protection circuit, used to shut down the output when the input voltage exceeds the normal operating range; Output reverse connection protection circuit, used to cut off the output circuit when reverse connection of battery is detected; The over-temperature protection circuit is used to monitor the internal temperature of the charger and is linked with the main controller module.

[0025] By adopting the above technical solutions, the input over / under voltage protection circuit ensures the safety of the equipment itself when the power grid fluctuates, the output reverse connection protection circuit can instantly cut off the dangerous circuit caused by reverse battery connection, and the over-temperature protection circuit forms a dual monitoring system with the main controller, further strengthening thermal safety management.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. Connect the charger to the battery to be charged and receive the user's battery selection command to obtain the battery type. Perform terminal voltage detection on the battery to obtain an initial judgment result. If the initial judgment result is normal, charge according to the preset charging sequence based on the real-time voltage of the battery type. When the battery is fully charged, perform a second terminal voltage detection on the battery to obtain a final judgment result. If the final judgment result is normal, charging is complete. By setting a dual voltage detection mechanism before and after charging, combined with battery type-adaptive charging sequence control, safe charging of multiple battery types is achieved, solving the problem in existing technologies that cannot adapt to different battery types and perform health status diagnosis to achieve safe charging.

[0027] 2. By setting a reverse connection detection step before charging and linking it with an alarm signal, the device damage and safety accidents caused by reverse battery connection are prevented, thereby improving the safety and reliability of the charging process; 3. By setting a repair mode for lead-acid or AGM batteries and a forced start-up stage for lithium batteries, and by performing secondary diagnosis on the repair or activation results, intelligent identification and classification of abnormal batteries are achieved. This not only avoids battery scrapping due to misjudgment, but also enhances the safety of the subsequent charging process. Attached Figure Description

[0028] Figure 1 This is a flowchart of the steps of a charging control method provided in Embodiment 1 of this application; Figure 2 This is a structural block diagram of a charger provided in Embodiment 2 of this application; Figure 3 This is a schematic diagram of a charger provided in Embodiment 2 of this application. Detailed Implementation

[0029] This application is applicable to a variety of battery charging and power management scenarios, such as: automotive battery maintenance, power tool battery charging, UPS backup power system maintenance, new energy storage system equalization charging, and intelligent charging management of consumer electronic devices.

[0030] The charging control method provided in this application embodiment can be applied to various intelligent charging devices, embedded power management systems, battery maintenance workstations or cloud battery management platforms. Its execution entity can be the microcontroller (MCU) built into the charger, the main control chip of the battery management system (BMS), the central processing unit of the external intelligent charging pile or the cloud battery data analysis algorithm.

[0031] Specifically, provided the charger starts normally and passes the safety self-test, this application enables safe and intelligent charging of various battery types. For example, when charging automotive lead-acid batteries, this method can automatically identify the battery type and execute a complete charging sequence including a repair mode, effectively restoring batteries whose performance has degraded due to sulfation. Furthermore, when charging over-discharged lithium battery packs, the system can automatically initiate a forced activation program to attempt to salvage batteries deemed faulty by traditional chargers, significantly improving battery utilization.

[0032] The charging control method and charger provided in this application can be widely used in areas such as improving battery life, ensuring charging safety, and realizing intelligent power management. For example, they can be used in typical scenarios such as intelligent battery maintenance in 4S shops, battery management in power tool rental stations, and UPS system maintenance in data centers. During the deployment and operation of the charger, the triggering conditions and permissions of each protection function should be clearly defined, based on compliance with electrical safety standards, battery management specifications, and user operation guidelines, to achieve intelligent charging functionality while ensuring safe use and equipment reliability.

[0033] It should be noted that the charging control method described in this application is applied to a charger, which includes a main controller module, a power conversion module, a voltage and current sampling module, and a human-machine interaction module.

[0034] Preferably, a modular integrated architecture is adopted for construction. The core of the charger consists of a main controller module, a power conversion module, a voltage and current sampling module, and a human-machine interaction module. Among them, the main controller module, as the computing center of the system, undertakes the core functions of battery type identification, charging timing control, and safety policy execution; the power conversion module, as the energy supply unit, is responsible for converting input electrical energy into controlled charging power; the voltage and current sampling module, as the status sensing unit, is responsible for collecting battery electrical parameters in real time; and the human-machine interaction module, as the user interface, is responsible for receiving commands and displaying status. Example

[0035] Please refer to Figure 1 A charging control method, applied to a charger, comprising: Step 101: Connect the charger to the battery to be charged and receive the user's input battery selection command to obtain the battery type.

[0036] In this first embodiment, the charger is connected to the battery to be charged, that is, the charger's charging output terminal forms physical contact with the battery electrodes to establish a charging circuit.

[0037] The battery selection command refers to the signal input through the mode key of the human-computer interaction module, which is used to select the target battery type from the preset battery type library.

[0038] The battery type library refers to the set of battery parameters pre-stored in the non-volatile memory of the main controller module, including but not limited to three options: lead-acid battery, AGM battery, and lithium battery. Each type is associated with a corresponding charging timing control strategy.

[0039] In this first embodiment, after the charger is powered on, it first performs a self-test process to confirm that all modules are working properly before entering standby mode. At this time, the user selects the type option that matches the actual battery being charged using the mode key and completes the command input using the confirmation key.

[0040] Preferably, after the charger is powered on, it performs a self-test process, the icons on the display screen light up for 2 seconds, the buzzer sounds for 2 seconds, and then it enters standby mode, the output voltage is 0V, and the current battery voltage value is displayed on the display unit.

[0041] Preferably, the mode button is a short press operation, which cycles through the preset battery type options for one second, including but not limited to: 12V lead-acid battery mode, 12V AGM battery mode, and 12V lithium battery mode. After power failure, the charger remembers the last battery type selected by the user and restores the default mode upon power-up.

[0042] Preferably, the user confirms the selected battery type using the confirmation button. A short press of the confirmation button for one second will trigger a single beep, and the charger will begin the charging process based on the selected type. Switching battery types is prohibited while the charger is in operation to ensure a safe and stable charging process.

[0043] Step 102: Perform a reverse connection test on the connection status of the charger and the battery to obtain the connection determination result.

[0044] Connection status refers to the physical connection relationship and electrical polarity matching between the charger output terminal and the battery electrode.

[0045] Preferably, a direction-sensitive circuit is provided in the charging circuit, which will immediately generate an abnormal level signal when it detects that the polarity of the positive and negative terminals of the battery is opposite to that of the charging output terminal.

[0046] In this first embodiment, if the connection determination result is a normal connection, then proceed to step 103 to detect the battery terminal voltage; if the connection determination result is a reverse connection abnormality, then immediately cut off the output of the power conversion module, and display a reverse connection warning icon through the display unit of the human-machine interaction module, while triggering the charger's buzzer to emit a continuous alarm signal until the connection is disconnected.

[0047] Step 103: Detect the terminal voltage of the battery to obtain the initial judgment result.

[0048] In this first embodiment, the terminal voltage detection is performed after confirming a normal connection by accurately measuring the battery open-circuit voltage using a high-precision ADC sampling circuit. Preferably, the sampling frequency is 10 times per second. After 10 consecutive samplings, the maximum and minimum values ​​are discarded, and the average of the middle 8 values ​​is taken as the final detected voltage value to eliminate transient interference.

[0049] Preferably, the initial judgment result is based on a preset voltage threshold range for graded judgment: For 12V lead-acid and AGM battery systems: When the detection voltage is within the range of 10.5V to 18.0V, it is considered normal. When the detection voltage is within the range of 4.6V to 8.0V, it is considered abnormal; When the detection voltage is within the range of 0.5V to 4.5V, it is judged as a serious abnormality and directly identified as a faulty battery.

[0050] For 12V lithium battery systems: When the detection voltage is within the range of 10.5V to 18.0V, it is considered normal. When the detection voltage is within the range of 7.0V to 10.5V, it is considered abnormal; When the detected voltage is below 7.0V, it is judged as a serious abnormality and directly identified as a faulty battery.

[0051] Preferably, the determination process also incorporates voltage stability analysis: if the voltage fluctuation range exceeds ±0.5V within a 2-second detection window, the connection is determined to be unstable and the connection test needs to be repeated.

[0052] It should be noted that the charger monitors the input AC voltage in real time. If the voltage is below 90V or above 265V, the power conversion module will be immediately shut down, all charging processes will be stopped, and the system will enter input undervoltage / overvoltage protection mode. Once the input voltage returns to the normal range, the system will automatically restart and begin execution from step 101.

[0053] Step 104: Based on the initial judgment result and the real-time voltage of the battery type, call the preset charging sequence to start charging.

[0054] The preset charging sequence refers to a multi-stage charging strategy pre-set for different battery types and states, including control logic such as switching conditions, charging parameters and execution duration for each stage.

[0055] It should be noted that the preset charging sequence includes a repair mode stage, a forced start stage, a pulse charging stage, a constant current charging stage, and a constant voltage charging stage. The constant current charging stage includes a half-power constant current sub-stage and a full-power constant current sub-stage.

[0056] Preferably, users can switch between fast charging and slow charging modes by pressing and holding the confirmation button for 2 seconds. When fast charging mode is selected, the current for the corresponding constant current charging stage is set to 6A; when slow charging mode is selected, the current for the corresponding constant current charging stage is set to 3A. The system displays the current charging mode status in real time through the corresponding icon on the human-computer interaction module, and allows dynamic switching during charging to meet the charging needs of different scenarios, achieving the best balance between charging efficiency and battery life.

[0057] Preferably, step 104 includes the following sub-steps: S41. If the initial judgment result is normal, and the battery type is lead-acid battery or AGM battery, the charging is performed by sequentially switching between pulse charging stage, constant current charging stage and constant voltage charging stage based on the real-time voltage of the battery.

[0058] Preferably, before entering the pulse charging stage, the battery parameters are obtained through the following steps: 1) Capacity estimate Acquisition: Based on battery nominal capacity The initial internal resistance of the battery and current internal resistance The estimation is performed using the following formula: ; 2) Current internal resistance Acquisition: At the moment the charger and battery are connected and initial charging begins (usually during repair mode or low-current pre-charge), the DC internal resistance measurement method is used. A small current step ΔI is applied, and the instantaneous change in battery terminal voltage ΔU is accurately measured. The result is then obtained using the formula... The calculation yielded the result.

[0059] 3) Voltage holding capability parameters Estimation: In repair mode or pre-charge phase, a short-time resting method is used for estimation. Specifically, this involves applying a known small current. After charging the battery for a certain period of time (e.g., 60 seconds), disconnect the charging circuit and let it stand for a short period of time (e.g., 10 seconds). Measure the voltage difference ΔV before and after the standby period, and then use the formula... To approximate the voltage retention characteristics of a battery, by... This parameter is used to equivalently replace the voltage drop over a long period of rest.

[0060] In this first embodiment, when the real-time battery voltage is in the range of 8.1V to 10.5V, the pulse charging stage is entered; Preferably, pulse current charging is used during the pulse charging phase, and the frequency and duty cycle can be dynamically adjusted according to the battery health state; the battery health state (SOH) is calculated using the following formula: ; in, The real-time capacity is estimated based on the internal resistance. This refers to the battery's nominal rated capacity. This is the standard initial internal resistance for this type of battery. This is the measured current internal resistance. The voltage drop ratio parameter is estimated based on short-time testing. This is the battery's rated voltage.

[0061] Based on this, the pulse frequency and duty cycle are dynamically adjusted according to the battery health status. When the battery health status is poor, the frequency can be reduced and the duty cycle increased to enhance the desulfation repair effect and avoid over-polarization. When the battery health status is good, the frequency can be increased and the duty cycle optimized to improve charging efficiency while ensuring safety, thereby achieving the best balance between battery repair and charging speed.

[0062] The voltage range during the pulse charging phase is 8.1V to 10.5V. In fast charging mode, the pulse charging current is 0.4A (approximately 2A effective value); in slow charging mode, the pulse charging current is 0.2A (approximately 1A effective value).

[0063] Preferably, when the real-time voltage reaches a preset first voltage threshold, the battery is switched from the pulse charging stage to the half-power constant current stage. When the real-time voltage reaches the preset second voltage threshold, the battery will switch from the half-power constant current stage to the full-power constant current stage. When the real-time voltage reaches the preset third voltage threshold, the battery is switched from the full-power constant current stage to the constant voltage charging stage.

[0064] Preferably, when the real-time voltage reaches 10.5V, it enters the half-power constant current stage: the current in fast charging mode is 3A, and the current in slow charging mode is 1.5A.

[0065] When the real-time voltage reaches 12.0V, it enters the full-power constant current stage: the current in fast charging mode is 6A, and the current in slow charging mode is 3A.

[0066] When the real-time voltage reaches 14.0V, it enters the constant voltage charging stage: the voltage range of fast charging mode is 14.0V-14.4V, and the current gradually decreases to less than 0.4A (fast charging) or less than 0.15A (slow charging) when it is considered fully charged.

[0067] In this first embodiment, the voltage range of the pulse charging stage is 8.1V-10.5V, the voltage range of the half-power constant current stage is 10.5V-12.0V, the voltage range of the full-power constant current stage is 12.0V-14.0V, and the voltage range of the constant voltage charging stage is 14.0V-14.4V.

[0068] S42. If the initial judgment result is normal and the battery type is lithium battery, the constant current charging stage and constant voltage charging stage are switched sequentially based on the real-time voltage of the battery.

[0069] In this first embodiment, if the battery type is a lithium battery, the voltage range during the constant current charging stage is 7.2V to 14.0V: the current in fast charging mode is 6A, and the current in slow charging mode is 3A.

[0070] During the constant voltage charging phase, the voltage range is 14.0V to 14.4V. In fast charging mode, the current gradually decreases to less than 0.3A, and in slow charging mode, the current decreases to less than 0.15A. When the current is fully charged, the output is turned off.

[0071] S43. If the initial judgment result is abnormal, and the battery type is lead-acid battery or AGM battery, then the repair mode phase is executed to perform repair charging.

[0072] In this first embodiment, if the initial judgment result is abnormal, that is, if the detected terminal voltage is in the range of 4.6V to 8.0V and the battery type is lead-acid battery or AGM battery, it is judged as abnormal.

[0073] Preferably, the repair mode charges the battery with a first preset voltage (14.7V) and a first preset small current (0.2A), and dynamically adjusts the pulse duty cycle based on the degree of sulfation in the electrochemical impedance spectroscopy; the higher the degree of sulfation, the lower the duty cycle. This is because severely sulfated batteries exhibit greater capacitive impedance, and their phase angle θ is biased towards a negative value. By dynamically adjusting, the phase angle information can be linearly converted into a duty cycle control signal, enabling adaptive adjustment of the charging pulse width according to the degree of sulfation, thus avoiding excessive current surges that could further damage the battery.

[0074] The duty cycle is calculated using the following formula: ; Where θ is the phase angle of the battery impedance measured at a test frequency of 1kHz using the AC injection method.

[0075] Preferably, when the repair mode stage is executed for a preset first duration (5 minutes), the system pauses charging and detects the battery terminal voltage to obtain an intermediate detection result. If the intermediate detection result is normal (voltage ≥ 8.0V), it indicates that the repair is effective, and the initial judgment result will be replaced with this normal result, and the normal charging process will begin; if the intermediate detection result is still abnormal (voltage < 8.0V), it is determined that the battery is damaged, charging is stopped, and a bad battery alarm signal is generated.

[0076] S44. If the initial judgment result is abnormal and the battery type is lithium battery, then a forced start-up phase will be performed to perform forced activation charging.

[0077] In this first embodiment, if the initial determination result is abnormal, that is, the initial determination result is that the voltage is lower than the first threshold (7.0V) and the battery type is lithium battery, then the forced activation mode is entered.

[0078] Preferably, the forced activation mode charges the battery continuously for 10 seconds at a second preset voltage (14.7V) and a second preset current (1A) to activate the lithium battery that has entered a protection state due to over-discharge. This stage employs a dynamic current adjustment strategy to ensure the safety and effectiveness of the activation process; the charging current is calculated in real time using the following formula: ; in This is the maximum permissible current (typical value 1A). , This is an adjustment factor set according to battery characteristics. Rated voltage (12V). To measure voltage in real time, This refers to the battery's internal resistance. The state of charge is estimated based on the voltage-capacity curve.

[0079] Preferably, when the forced start phase lasts for a preset second duration (10 seconds), the system pauses charging output and detects the battery terminal voltage to obtain an activation detection result. If the activation detection result shows that the battery voltage has recovered to the normal threshold (≥7.2V), it indicates that the battery has been successfully activated. The system will replace the initial judgment result with this normal result and switch to the constant current charging phase to continue charging. If the activation detection result still shows that the voltage is lower than the normal threshold (<7.0V), it is determined that the battery is damaged, and the charging process is stopped. A bad battery alarm signal is generated, and a battery damage icon is displayed through the human-machine interaction module, triggering a buzzer alarm until the connection is disconnected.

[0080] It should be noted that the charging sequence of lithium batteries does not include a pulse charging stage. After successful forced activation, it directly enters the constant current charging stage, which is significantly different from the charging process of lead-acid / AGM batteries.

[0081] Step 105: When the battery is fully charged, perform secondary terminal voltage detection on the battery to obtain the final judgment result.

[0082] Preferably, for lead-acid batteries and AGM batteries, the full charge determination voltage is 14.4V (lead-acid) or 14.7V (AGM). Once fully charged, all charging indicator lights will remain constantly lit.

[0083] After waiting for 1 minute, the secondary terminal voltage is detected. If the voltage is lower than 12.4V, the battery is determined to be damaged and a bad battery alarm signal is generated. If the voltage is higher than 12.4V, the float charge maintenance mode is activated for the lead-acid / AGM battery, and maintenance charging is performed at a voltage of 13.6V±0.1V and a current of 0.2A.

[0084] For lithium batteries, the full charge determination voltage is 14.4V, and the output is completely shut off after full charge. The system waits for 1 minute before checking the secondary terminal voltage. If the voltage is lower than 12.4V, the battery is considered damaged, and a low battery alarm signal is generated.

[0085] Specifically, step 105 includes the following sub-steps: S51. When the battery is fully charged and has been running for a preset third time (1 minute), the secondary terminal voltage of the battery is detected to obtain the final judgment result. This resting period is used to eliminate polarization effects and ensure the accuracy of voltage measurement.

[0086] S52. If the final judgment result is not lower than the preset health voltage threshold (12.4V) and the battery type is lead-acid battery or AGM battery, then start the float charge maintenance mode to perform maintenance charging on the battery at a float charge voltage (13.6V) lower than that of the constant voltage charging stage.

[0087] S53. If the final judgment result is lower than the preset health voltage threshold (12.4V), and the battery type is lead-acid battery or AGM battery, then the battery is judged to be damaged and a bad battery alarm signal is generated.

[0088] S54. If the final determination result is not lower than the preset health voltage threshold (12.4V) and the battery type is lithium battery, then the charging is determined to be complete and the output is completely cut off.

[0089] S55. If the final judgment result is lower than the preset health voltage threshold (12.4V) and the battery type is lithium battery, then the battery is judged to be damaged and a bad battery alarm signal is generated.

[0090] In this first embodiment, by allowing the battery to stand after full charging before testing, interference from charging polarization voltage is eliminated, allowing for a more accurate reflection of the battery's voltage retention capability. The healthy voltage threshold is set based on the characteristics of different battery types and is used to determine battery health. Simultaneously, this secondary testing accurately identifies degraded batteries that, although able to complete the charging process, actually exhibit capacity decay or internal short circuits, preventing them from being mistakenly identified as qualified products. This improves battery safety and reliability, and reduces the accident rate.

[0091] Step 106: If the final result is normal, the charging is complete.

[0092] In this first embodiment, if the secondary terminal voltage detection result is not less than 12.4V, the final determination result is considered normal, and charging is completed.

[0093] Preferably, the signs of charging completion include: the display unit showing a full charge indicator, all charging indicator lights remaining on, the buzzer emitting a prompt sound, the power conversion module entering standby mode, and the output current dropping to zero.

[0094] Step 107: Monitor the internal temperature of the charger in real time.

[0095] Preferably, when the temperature exceeds a preset first temperature threshold (80°C), the output current is reduced according to a preset derating curve, specifically, the output current is reduced by 2% of the rated value for every 1°C increase in temperature; when the temperature exceeds a preset second temperature threshold (100°C), charging is stopped and a high-temperature alarm signal is generated, and an over-temperature icon is displayed on the display unit. Charging is only allowed to resume after the temperature drops to a safe range (below 80°C), as detailed in the table below: Table 1: Temperature-Current Correspondence Table The implementation principle of this application embodiment is as follows: The charger is connected to the battery to be charged and receives the user's battery selection command to obtain the battery type. A terminal voltage test is performed on the battery to obtain an initial judgment result. If the initial judgment result is normal, a preset charging sequence is invoked based on the real-time voltage of the battery type for charging. When the battery is fully charged, a second terminal voltage test is performed to obtain a final judgment result. If the final judgment result is normal, charging is complete. By performing two critical terminal voltage tests on the battery before and after charging, abnormal batteries such as those with reverse connection or damage can be identified. During the initial test, undervoltage batteries are attempted to be activated through repair or forced start mode, thus preventing the accidental charging of unqualified batteries at the source and improving safety. Simultaneously, the corresponding charging sequence is dynamically invoked based on the battery type and real-time voltage, ensuring that each battery follows its optimal charging curve. Finally, a second voltage test after full charge verifies the battery health again, improving the adaptability and reliability of the charging process. Example 2: Please refer to Figure 2 , Figure 3 A charger, comprising: Main controller module 201; The power conversion module 202 is connected to the main controller module and is used to convert the input AC power into controlled DC power to charge the battery. The voltage and current sampling module 203 is connected to the main controller module and is used to collect the voltage and current signals at the battery terminal in real time. The human-computer interaction module 204, connected to the main controller module, is used to receive user input battery selection commands and display charging status, specifically including: The display unit is used to display a first specific icon when the charger is in the repair mode stage, a second specific icon when it is in the forced start stage, and to display the corresponding stage indicator icon according to the current stage of the charging sequence. The button unit includes at least a mode button for selecting the battery type and a confirmation button for confirming the operation; The main controller module is configured to execute any one of the charging control methods.

[0096] Preferably, it further includes a protection circuit module, which includes: Input over / under voltage protection circuit, used to shut down the output when the input voltage exceeds the normal operating range; Output reverse connection protection circuit, used to cut off the output circuit when reverse connection of battery is detected; The over-temperature protection circuit is used to monitor the internal temperature of the charger and is linked with the main controller module.

[0097] In this second embodiment, the main controller module is configured to execute a charging control method of one embodiment, which will not be described again here.

[0098] The embodiments described in this specific implementation are preferred embodiments of this application and are not intended to limit the scope of protection of this application. Identical components are represented by the same reference numerals. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A charging control method, applied to a charger, characterized in that, include: Connect the charger to the battery to be charged and receive the user's battery selection command to obtain the battery type; The battery terminal voltage is detected to obtain an initial judgment result; Based on the initial determination result and the real-time voltage of the battery type, a preset charging sequence is invoked for charging; When the battery is fully charged, the secondary terminal voltage of the battery is detected to obtain the final judgment result; If the final determination result is normal, then charging is complete.

2. The charging control method according to claim 1, characterized in that, Before performing terminal voltage detection on the battery to obtain an initial determination result, the process also includes: The connection status of the charger and the battery is reversed to detect the connection determination result. If the connection determination result is a normal connection, the battery terminal voltage is detected; otherwise, a reverse connection alarm signal is generated.

3. The charging control method according to claim 1, characterized in that, The battery types include lead-acid batteries, AGM batteries, and lithium batteries; The charging sequence includes a pulse charging phase, a constant current charging phase, and a constant voltage charging phase. The step of charging based on the initial determination result and the real-time voltage of the battery type, and calling a preset charging sequence, includes: If the initial determination result is normal, and the battery type is a lead-acid battery or an AGM battery, the charging process is performed by sequentially switching between the pulse charging stage, the constant current charging stage, and the constant voltage charging stage based on the real-time voltage of the battery. If the initial determination result is normal, and the battery type is a lithium battery, the constant current charging stage and constant voltage charging stage are switched sequentially based on the real-time voltage of the battery.

4. The charging control method according to claim 3, characterized in that, The constant current charging stage includes a half-power constant current sub-stage and a full-power constant current sub-stage; When the real-time voltage reaches a preset first voltage threshold, the battery is switched from the pulse charging stage to the half-power constant current stage; When the real-time voltage reaches a preset second voltage threshold, the battery is switched from the half-power constant current stage to the full-power constant current stage; The first voltage threshold is less than the second voltage threshold.

5. The charging control method according to claim 3, characterized in that, The step of charging based on the initial determination result and the real-time voltage of the battery type, and calling a preset charging sequence, further includes: The charging sequence also includes a repair mode phase; If the initial judgment result is abnormal, and the battery type is a lead-acid battery or an AGM battery, then the repair mode phase is executed to perform repair charging. When the repair mode stage is executed for a preset first duration, the battery terminal voltage is detected to obtain intermediate detection results; If the intermediate detection result is normal, then the intermediate detection result replaces the initial judgment result; If the intermediate detection result is abnormal, the battery is determined to be damaged, charging is stopped, and a bad battery alarm signal is generated.

6. The charging control method according to claim 5, characterized in that, The charging sequence also includes a forced start phase: If the initial determination result is abnormal, and the battery type is a lithium battery, then the forced start-up phase is executed to perform forced activation charging. When the forced start-up phase is executed for a preset second duration, the battery terminal voltage is detected to obtain the activation detection result; If the activation detection result is normal, then the activation detection result replaces the initial determination result; If the activation detection result is abnormal, the battery is determined to be damaged, charging is stopped, and a bad battery alarm signal is generated.

7. The charging control method according to claim 3, characterized in that, When the battery is fully charged, the secondary terminal voltage of the battery is detected to obtain a final determination result, including: When the battery is fully charged and continues for a preset third time period, the secondary terminal voltage of the battery is detected to obtain the final judgment result. If the final determination result is not lower than the preset health voltage threshold, and the battery type is a lead-acid battery or an AGM battery, then the float charge maintenance mode is activated to perform maintenance charging on the battery at a float charge voltage lower than that of the constant voltage charging stage. If the final determination result is lower than the preset health voltage threshold, and the battery type is a lead-acid battery or an AGM battery, then the battery is determined to be damaged and a bad battery alarm signal is generated. If the final determination result is not lower than the preset health voltage threshold, and the battery type is a lithium battery, then the charging is determined to be complete. If the final determination result is lower than the preset health voltage threshold, and the battery type is a lithium battery, then the battery is determined to be damaged and a bad battery alarm signal is generated.

8. The charging control method according to claim 1, characterized in that, It also includes real-time monitoring of the temperature inside the charger; When the temperature exceeds a preset first temperature threshold, the output current is reduced according to a preset derating curve; When the temperature exceeds a preset second temperature threshold, charging stops and a high temperature alarm signal is generated.

9. A charger, characterized in that, include: Main controller module; A power conversion module, connected to the main controller module, is used to convert the input AC power into controlled DC power to charge the battery; A voltage and current sampling module, connected to the main controller module, is used to collect voltage and current signals from the battery in real time. The human-computer interaction module, connected to the main controller module, is used to receive user input of battery selection commands and display charging status, specifically including: The display unit is used to display a first specific icon when the charger is in the repair mode stage, a second specific icon when it is in the forced start stage, and to display the corresponding stage indicator icon according to the current stage of the charging sequence. The button unit includes at least a mode button for selecting the battery type and a confirmation button for confirming the operation; The main controller module is configured to execute the charging control method as described in any one of claims 1-8.

10. The charger according to claim 9, characterized in that, It also includes a protection circuit module, which comprises: Input over / under voltage protection circuit, used to shut down the output when the input voltage exceeds the normal operating range; Output reverse connection protection circuit, used to cut off the output circuit when reverse connection of battery is detected; An over-temperature protection circuit is used to monitor the internal temperature of the charger and is linked with the main controller module.

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