Adaptive battery charging system with dynamic current enhancement

Abstract

A method of charging a battery pack includes: receiving a current request, setting a charging setpoint based on the current request and a maximum output current; and configuring the converter based on the charging setpoint.

Description

[0001] Related applications This application claims the benefit of U.S. Provisional Application No. 63 / 709,209, filed October 18, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The examples described in this invention generally relate to battery charging systems, and more specifically to an adaptive charging method that dynamically enhances current transfer based on real-time measurements and communication between the charger and the battery pack. Summary of the Invention

[0003] Battery charging technology has evolved to accommodate a wide range of power sources and battery types. However, some charging methods face limitations when dealing with uncertain or variable power sources. For example, chargers may not know how much current they can supply to the battery pack until their output is measured. This uncertainty can lead to inefficient charging or potential safety issues.

[0004] Additionally, some power sources, such as solar panels, may inaccurately report their actual capabilities to the charger. This misrepresentation can cause the charger to either underutilize available power or attempt to extract more power than the source can provide, resulting in suboptimal charging performance.

[0005] Furthermore, some methods involve charging timers within the battery pack. These timers require accurate current information to function properly. When the charger cannot provide this accurate information, the charging timer may trip prematurely, interrupting the charging process. Some methods struggle to maximize power delivery throughout the entire charging cycle. These methods may not effectively adapt to changing conditions, such as variations in power output or the battery's changing demands during charging.

[0006] An example of the present invention provides a method for charging a battery pack that enhances power delivery while ensuring compatibility with a variety of power sources and battery packs.

[0007] In some implementations, a method for charging a battery pack includes: receiving a current request, setting a charging setpoint based on the current request and a maximum output current; and configuring a converter based on the charging setpoint.

[0008] The method includes receiving a current request from a battery pack, the current request corresponding to the battery pack's power requirements. Based on the current request and a predetermined maximum output current, the method includes setting a charging setpoint. The charging setpoint helps determine the actual power to be delivered. The method includes configuring the power converter based on the charging setpoint.

[0009] To further enhance the charging process, the method may include using a power converter to measure the actual current delivered to the battery pack. The method can then verify whether the expected current is being delivered based on the measured current. Based on the measured current and the charging setpoint, the method can adjust the advertised maximum output current. This adaptive approach allows for improvements to the charger's performance based on real-time data. In some examples, the initial maximum output current can be set to the thermal maximum value of the charging device. This approach enables the charger to start at the highest safe operating level, potentially allowing for faster charging.

[0010] The method may also include receiving a request for maximum available current from the battery pack. The method can configure the converter to provide a current slightly higher than the requested current. This increase provides a buffer that can help detect when more power is available, thus potentially enhancing the charging process.

[0011] To accommodate different stages of the charging cycle, some examples of this method include switching the converter from constant power mode to constant voltage mode when a predetermined battery voltage is reached.

[0012] In some examples, the method includes reducing the advertised maximum output current based on the measured current being less than the requested current. Therefore, the charger can adapt to scenarios where the power supply cannot provide the initially advertised current, ensuring safe and efficient charging even when using variable or limited power sources.

[0013] According to some examples of the present invention, the charging system includes a power management controller. The power management controller can be configured to receive current requests from the battery pack, set a charging setpoint based on these requests and the maximum output current, and adjust the reported maximum output current. The power management controller can continuously analyze data from other components to enhance the charging process.

[0014] The power converter can be a buck / boost converter. This converter delivers the requested current to the battery pack based on a charging setpoint determined by the power management controller. It can also switch between constant power and constant voltage modes as the charging cycle progresses.

[0015] The charging system may include a current measurement module. This module measures the actual current supplied to the battery pack in real time. The current measurement module then provides this data back to the power management controller for precise adjustment of the charging parameters.

[0016] A dedicated communication interface facilitates communication between the charger and the battery pack. The communication interface receives current requests from the battery pack and announces the charger's maximum output current capability.

[0017] The charging system may further include a thermal management component. This module monitors the temperature of the charging device and helps set the initial maximum output current based on the charger's thermal limits.

[0018] The charging system may include a mode switching module to manage different stages of charging. The mode switching module monitors the battery voltage and initiates a switch from constant power mode to constant voltage mode when the battery reaches a predetermined voltage level, ensuring optimal charging throughout the entire cycle.

[0019] To handle varying power capabilities, the charging system employs an adaptive current module. This module compares the measured current with the requested current and reduces the advertised current if the measured current is lower than the requested current.

[0020] The charging system may include a power analyzer configured to assess the capabilities of the connected power source. The power analyzer provides input to the power management controller to enhance the charging setpoint based on the actual capabilities of the power source, rather than solely relying on what the power source can claim to provide.

[0021] Before explaining any examples in detail, it should be understood that the application of the examples is not limited to the details of the configuration and arrangement of the components described in the following description or shown in the accompanying drawings. These examples can be practiced or implemented in various ways. Furthermore, it should be understood that the wording and terminology used in this invention are for illustrative purposes and should not be considered limiting. The use of "comprising," "including," or "having," and variations thereof, is intended to cover the items listed thereafter and their equivalents, as well as additional items. Unless otherwise stated or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used extensively and cover direct and indirect mounting, connection, support, and coupling.

[0022] Furthermore, it should be understood that examples may include hardware, software, and electronic components or modules, which, for the purposes of discussion, may be shown and described as if most components were implemented solely in hardware. However, those skilled in the art, based on reading this detailed description, will recognize that in at least one embodiment, the electronic aspects may be implemented as software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units (such as microprocessors and / or application-specific integrated circuits (“ASICs”)). Therefore, it should be noted that examples may be implemented using a plurality of hardware and software-based devices and a plurality of different structural components. For example, “server,” “computing device,” “controller,” “processor,” etc., described in the specification may include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connectors (e.g., system buses) for connection components.

[0023] Related terms used in conjunction with quantities or conditions, such as “about,” “approximately,” “generally,” etc., will be understood by a person skilled in the art to include the value and have a meaning defined by the context (e.g., the term includes at least the degree of error associated with the accuracy of the measurement, the tolerance associated with a particular value [e.g., manufacturing, assembly, use, etc.]). Such terms should also be considered to disclose a range defined by the absolute values ​​of two endpoints. For example, the expression “about 2 to about 4” also discloses a range of “2 to 4.” Related terms may refer to a percentage added to or subtracted from the indicated value (e.g., 1%, 5%, 10% or more).

[0024] It should be understood that although some figures illustrate hardware and software within a particular device, these depictions are for illustrative purposes only. Functions described herein as being performed by a single component can be performed by multiple components in a distributed manner. Similarly, functions performed by multiple components can be combined and performed by a single component. In some examples, the illustrated components can be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing can be distributed among multiple electronic processors, rather than residing within and being performed by a single electronic processor. Regardless of how the hardware and software components are combined or divided, they can reside on the same computing device or be distributed among different computing devices connected via one or more networks or other suitable communication links. Similarly, components described as performing specific functions can also perform additional functions not described herein. For example, a device or structure "configured" in a certain way is at least configured in that manner, but may also be configured in a manner not explicitly listed.

[0025] Other aspects of the examples will become apparent by referring to the detailed descriptions and accompanying drawings. Attached Figure Description

[0026] Figure 1 Exemplary power tool battery packs and battery pack chargers are shown according to some examples.

[0027] Figure 2 The following are examples. Figure 1 A schematic diagram of a battery pack charger.

[0028] Figure 3 Timing diagrams are shown for methods of charging a battery pack, based on some examples.

[0029] Figure 4 A flowchart of a method for charging a battery pack, based on some examples, is shown.

[0030] Figure 5 A flowchart of a method for charging a battery pack, based on some examples, is shown. Detailed Implementation

[0031] Figure 1 An exemplary battery pack charger 100 is shown. The battery pack charger 100 includes a charger housing 105, a battery pack interface 110 configured to removably receive a battery pack 115, and a user interface. In the illustrated embodiment, the battery pack interface 110 is disposed on the bottom side of the charger housing 105 (e.g., on a first side of the charger housing 105). The battery pack interface 110 is configured to removably (e.g., slidably) receive the battery pack 115. Although not shown, the battery pack interface 110 includes a terminal block comprising terminals (e.g., power terminals and communication terminals) for connection to a corresponding battery pack terminal block of the battery pack 115. In some examples, the battery pack charger 100 may have... Figure 1 The different configurations shown.

[0032] Battery pack 115 is, for example, a power tool battery pack configured for operating a battery-powered power tool. In some examples, battery pack 115 is a power tool battery pack with a nominal voltage of 18 volts and a lithium-ion chemistry-based system. In other examples, battery pack 115 may have different nominal voltages (e.g., 12 volts, 36 volts, 72 volts, etc.) and different chemistry systems (e.g., nickel-based). Battery pack 115 may include a connection portion 120 having two parallel, spaced-apart tracks 125 configured such that battery pack 115 can slidably engage with a sliding battery pack interface of the power tool. Connection portion 120 also includes battery terminals 130 for electrically connecting battery pack 115 to charger terminals of battery pack charger 100 or to another device such as the power tool.

[0033] The battery pack charger 100 may include one or more power input sections (e.g., such as...). Figure 2 As shown, there is a power input unit 200. One or more power input units include, for example, a power cord for connecting to a wall socket, a DC interface for connecting to a solar panel, etc. The DC interface includes, for example, a USB-C bidirectional power delivery interface. The DC interface can be used to connect to a USB-C power source to receive charging power to charge the battery pack 115.

[0034] Figure 2A schematic diagram of an example configuration of a battery pack charger 100 is shown. In the example shown, the battery pack charger 100 includes a power input section 200, a charging circuit 205, a controller 210, and one or more sensors 260. The power input section 200 includes, for example, a power cord that can be plugged into a wall socket to receive power from the grid or a generator (e.g., external AC power). The power input section 200 may also include an interface for connecting to a solar panel or other power source. The power input section 200 is electrically connected to the charging circuit 205, which is electrically connected to the battery pack interface 110.

[0035] In one example, charging circuit 205 includes an AC-DC converter (e.g., a rectifier) ​​to convert AC power from power input 200 into DC power and supply the DC power to battery pack 115. Charging circuit 205 also includes a buck / boost converter 215 to convert the input power into appropriate power for charging battery pack 115 (e.g., at the requested power). Buck / boost converter 215 is, for example, a flyback converter, which can be controlled by controller 210 to change the amount of current or power supplied on the second side (i.e., the output side) of buck / boost converter 215. One or more sensors 260 include, for example, current sensors. The controller uses the current sensors to determine the current flow in battery pack charger 100.

[0036] The controller 210 includes a combination of hardware and software operable to control the operation of the battery pack charger 100. For example, the controller 210 particularly includes a processing unit 220 (e.g., a microprocessor, microcontroller, electronic processor, electronic controller, or other suitable programmable device), a memory 225, an input unit 230, and an output unit 235. The processing unit 220 particularly includes a control unit 240, an arithmetic logic unit (“ALU”) 245, and a plurality of registers 250 (in... Figure 2 The system is shown as a set of registers and is implemented using a known computer architecture (e.g., a modified Harvard architecture, von Neumann architecture, etc.). Processing unit 220, memory 225, input unit 230, and output unit 235, as well as various modules or circuits connected to controller 210, are connected via one or more control and / or data buses (e.g., common bus 255). For illustrative purposes, in... Figure 2 The control and / or data bus is roughly shown in the diagram. Although controller 210 is... Figure 2 While shown as a single controller, controller 210 may also include multiple controllers configured to work together to achieve a desired level of control over the battery pack charger 100. Thus, any control functions and processes described in connection with controller 210 can also be performed by two or more controllers operating in a distributed manner.

[0037] Memory 225 is a non-transitory computer-readable medium, including, for example, a program storage area and a data storage area. The program storage area and data storage area may include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable ROM (“EEPROM”), flash memory, hard disk, SD card, or other suitable magnetic, optical, physical, or electronic memory devices. Processing unit 220 is connected to memory 225 and configured to execute software instructions that can be stored in the RAM of memory 225 (e.g., during execution), the ROM of memory 225 (e.g., on a substantially permanent basis), or another non-transitory computer-readable medium (such as another memory or disk). Software included in the implementation of battery pack charger 100 and controller 210 may be stored in memory 225 of controller 210. Software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. Controller 210 is configured to retrieve from memory 225 and execute instructions related to the control processes and methods described in this invention. In other embodiments, controller 210 may include additional, fewer, or different components.

[0038] The battery pack charger 100 includes additional components that have been omitted from the drawings and this specification for the sake of simplicity. For example, the battery pack charger 100 may include a socket for powering an external device using power from the battery pack 115. Additionally, the battery pack charger 100 may include various FETs and gate drivers for controlling the FETs. For example, a charging FET may be connected between the charging circuit 205 and the battery pack interface 110.

[0039] Battery pack charger 100 and battery pack 115 communicate to negotiate power requirements during charging. The available power (e.g., maximum current) of battery pack charger 100 for charging battery pack 115 can vary over time. For example, the available power for charging can vary based on the amount of incident sunlight on a solar panel connected to the USB-C interface of battery pack charger 100. Battery pack charger 100 and battery pack 115 iteratively communicate to negotiate charging current requirements based on the available power for charging.

[0040] Figure 3A timing diagram 300 showing the negotiation between battery pack charger 100 and battery pack 115 is shown. Battery pack charger 100 announces the maximum charging current to battery pack 115 (at block 310). Controller 210 can detect that battery pack 115 is connected to battery pack interface 110. In response, controller 210 transmits an initial maximum charging current to battery pack 115. Controller 210 can determine the maximum charging current based on communication with, for example, a power source (e.g., a solar panel). Controller 210 can set the maximum charging current to a value received from the power source.

[0041] Battery pack charger 100 receives a charging current request from battery pack 115 (at block 320). The charging current request from battery pack 115 can be equal to or less than the maximum charging current. In one example, when the maximum charging current is equal to or less than the maximum current that battery pack 115 can be charged, battery pack 115 can request a charging current equal to the maximum charging current. When the maximum charging current is greater than the maximum current that battery pack 115 can be charged, battery pack 115 can request a charging current less than the maximum charging current. As described below, controller 210 configures buck / boost converter 215 to provide charging current (e.g., current flow) to battery pack 115.

[0042] Battery pack charger 100 measures current flow (at block 330). Controller 210 uses, for example, a current sensor to measure the current. Controller 210 can then compare the measured current with the requested charging current to determine whether the negotiated charging current is provided to battery pack 115. Battery pack charger 100 can increase the current provided to battery pack 115 to slightly exceed the requested current to determine if battery pack charger 100 is able to provide higher power (at block 340).

[0043] Battery pack charger 100 re-announces the maximum charging current to battery pack 115 (at block 350). Controller 210 may reset the maximum charging current to a new value received from the power source and / or based on the measured current flow. Controller 210 then provides the maximum charging current to battery pack 115. Battery pack charger 100 receives a new charging current request from battery pack 115 based on the maximum charging current (at block 360).

[0044] Figure 4This is a flowchart of an exemplary method 400 for charging battery pack 115. Method 400 can be implemented by controller 210. In the example shown, method 400 includes receiving a charging current request from battery pack 115 (at block 410). For example, after the initial connection of battery pack 115 to battery pack charger 100, controller 210 notifies battery pack 115 of a maximum charging current. The charging current request can be received in response to the notification of the maximum charging current from battery pack 115.

[0045] Method 400 includes using controller 210 to determine whether the requested charging current is less than the maximum charging current (at block 420). Controller 210 compares the requested current with the advertised current to determine whether the requested current is less than the advertised current. Method 400 includes using controller 210 to set the charging setpoint to the requested charging current when the requested charging current is less than the maximum charging current (at block 430). Method 400 further includes using controller 210 to set the charging setpoint to a modified current when the requested charging current is not less than the maximum charging current (at block 440). The modified current is, for example, an offset greater than the requested current (i.e., I0). 请求 +I 偏移 ).

[0046] Method 400 includes configuring buck / boost converter 215 (at block 450) based on a charging setpoint using controller 210. The charging setpoint can be set in block 430 or block 440. Controller 210 configures and / or controls buck / boost converter 215 based on the charging setpoint. For example, controller 210 can perform PWM control on a switch (e.g., a FET in a flyback converter) to adjust the amount of current supplied to battery pack 115 according to the charging setpoint. Controller 210 can further clamp the current output of battery pack charger 100 to a thermal maximum current. The thermal maximum current is a preset maximum current of battery pack charger 100, independent of available power from the power source. Keeping the current below the thermal maximum current reduces the likelihood of thermal failure of battery pack charger 100. Method 400 returns to block 410 as described above to iteratively negotiate power requirements with battery pack 115.

[0047] Figure 5A flowchart of an exemplary method 500 for charging battery pack 115 is shown. Method 500 may be implemented by controller 210, for example, after block 450 and before method 400 returns to block 410. In the example shown, method 500 includes using a sensor to determine the output current of battery pack charger 100 (at block 510). Controller 210 may use a current sensor to determine the output current to battery pack 115. Method 500 includes using controller 210 to determine whether the output current is not equal to a requested current (at block 520). Controller 210 may determine whether the output current is within the tolerance level of the requested current.

[0048] Method 500 includes setting the maximum charging current to the output current using controller 210 when the output current is not equal to the requested current (at block 530). Controller 210 can replace the maximum charging current value with a new value of the measured output current. That is, controller 210 can reduce the advertised maximum current to the output current based on the output current being less than the requested current. Method 500 includes requesting a new charging current from battery pack 115 (at block 540). Controller 210 requests the new charging current after block 530 and / or when the measured output current is equal to (e.g., within tolerance) the requested current. For example, controller 210 can return to block 410 of method 400.

[0049] Therefore, the embodiments described in this invention particularly provide a battery pack charger and method for adaptive battery pack charging.

Claims

1. A method for charging a battery pack, comprising: The controller of the battery pack charger receives current requests; The controller is used to set the charging setpoint based on the current request and the announced maximum current. and The controller is used to configure the converter of the battery pack charger based on the charging setpoint.

2. The method according to claim 1, further comprising: The output current is measured using the current sensor of the battery pack charger; and The controller is used to adjust the announced maximum current based on the output current and the charging setpoint.

3. The method according to claim 2, wherein, Adjusting the announced maximum current includes: In response to the output current being less than the requested current, the controller is used to reduce the reported maximum current.

4. The method according to claim 1, wherein, The announced maximum current is set as the thermal maximum current.

5. The method of claim 1, further comprising: The controller is used to receive the announced maximum current from the power supply.

6. The method of claim 1, further comprising: Based on the fact that the requested current is equal to the announced maximum current, the controller is used to set the charging setpoint to a value higher than the requested current.

7. The method according to claim 1, wherein, The converter is a flyback converter.

8. The method of claim 7, further comprising: The controller is used to perform PWM control on the switching of the converter to adjust the amount of current supplied to the battery pack.

9. A battery pack charger, comprising: Device housing; Power input section; A battery pack interface is disposed on the device housing and configured to removably receive a battery pack; A converter, which is electrically connected between the power input section and the battery pack interface; and A controller, electrically connected to the power input unit, the battery pack interface, and the converter, and configured to: Receive current request; The charging setpoint is set based on the current request and the announced maximum current. and Configure the converter according to the charging setpoint.

10. The battery pack charger as claimed in claim 9, wherein, The controller is further configured as follows: The output current is measured using a current sensor; and The announced maximum current is adjusted based on the output current and the charging setpoint.

11. The battery pack charger as claimed in claim 10, wherein, The controller is configured as follows: The maximum current announced is reduced based on the fact that the output current is less than the requested current.

12. The battery pack charger as claimed in claim 9, wherein, The announced maximum current is set as the thermal maximum current.

13. The battery pack charger as claimed in claim 9, wherein, The controller is configured as follows: Receive the maximum current reported from the power source.

14. The battery pack charger as claimed in claim 9, wherein, The controller is further configured as follows: Based on the fact that the requested current is equal to the announced maximum current, the charging setpoint is set to a value higher than the requested current.

15. The battery pack charger as claimed in claim 9, wherein, The converter is a flyback converter.

16. The battery pack charger as claimed in claim 15, wherein, The controller is configured as follows: PWM control is applied to the switching of the converter to adjust the amount of current supplied to the battery pack.

17. A battery pack charger, comprising: Device housing; A power input unit configured to be connected to a power source; A battery pack interface is disposed on the device housing and configured to removably receive a battery pack; A converter, which is electrically connected between the power input section and the battery pack interface; and A controller, electrically connected to the power input unit, the battery pack interface, and the converter, and configured to: The maximum charging current is determined based on communication with the power source; Receive charging current request from the battery pack; Set the charging setpoint based on the maximum charging current and the charging current request; Configure the converter based on the charging setpoint; The output current of the battery pack charger is measured using a current sensor. and The maximum charging current is adjusted according to the output current.

18. The battery pack charger as claimed in claim 17, wherein, The controller is configured as follows: The maximum charging current is reduced based on the fact that the output current is less than the charging current request.

19. The battery pack charger as claimed in claim 17, wherein, The controller is further configured as follows: Based on the fact that the requested current is equal to the advertised maximum current, the charging setpoint is set to a value higher than the requested current.

20. The battery pack charger of claim 17, wherein, The power input section is a USB-C power delivery interface.

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