Battery Charger Controller with Saturation Protection
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Solution Overview
Problem
Conventional battery charging circuits face accuracy issues due to the use of isolated converters for feedback information transfer, leading to increased complexity and cost, and are prone to transformer saturation problems.
Innovation Solution
A battery charging circuit with a charger controller that monitors battery status and selects a charging mode to adjust charging power, incorporating a state machine to store predetermined saturation statuses and switch to a protection mode when saturation is detected, thereby directly sensing charging voltage and current signals to enhance accuracy and integrate pulse width modulator, state machine, and protection circuitry on a single chip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isolated converter is used for feedback information transfer, then galvanic isolation is achieved, but measurement precision deteriorates due to decreased accuracy of feedback information
Solution Approach 1:
The patent introduces a mediator (isolated converter) to transfer feedback information while maintaining galvanic isolation. The isolated converter acts as an intermediary component that enables communication between isolated circuits without direct electrical connection, thus preserving both isolation and information transfer capability.
2Adaptability or versatility
If PWM controller, isolated converter, sensing circuitry and MCU are used, then charging control functionality is achieved, but device complexity increases
Solution Approach 1:
The patent combines multiple discrete components (PWM controller, isolated converter, sensing circuitry, and MCU) into an integrated charging control system. By merging these functions into a unified controller architecture, the system achieves comprehensive charging control while reducing overall device complexity and component count.
Solution Approach 2:
The charging controller is designed with multi-functionality, integrating PWM control, isolated conversion, sensing, and microcontroller functions into a single universal device. This universal controller can perform multiple charging control tasks, eliminating the need for separate dedicated components for each function.
3Productivity
If conventional charging circuit is used, then charging operation is performed, but transformer saturation problem occurs
Solution Approach 1:
The patent implements a feedback mechanism where sensing circuitry continuously monitors charging parameters and feeds this information back to the PWM controller. This feedback loop enables real-time detection of transformer saturation conditions and allows the controller to adjust operating parameters to prevent saturation, ensuring reliable charging operation.
Solution Approach 2:
The patent incorporates preliminary protective actions by pre-configuring the state machine with predetermined battery statuses that indicate potential transformer saturation conditions. Before saturation actually occurs, the system detects these precursor statuses and takes preventive measures by adjusting charging parameters or triggering protection modes, thereby avoiding the harmful saturation effect.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution improves the accuracy of the charging system by direct sensing of charging signals and reduces costs through integration, effectively preventing transformer saturation by switching to a protection mode when predetermined statuses are met.
Implementation Method 1
The transformer is operable for receiving an input power and for providing a charging power according to a driving signal
Data Source
AI summary
A circuit for charging a battery pack includes a transformer and a charger controller. The transformer is operable for receiving an input power and for providing a charging power according to a driving signal to charge the battery pack. The charger controller is operable for monitoring a status of the battery pack, for selecting a charging mode from multiple charging modes according to the status, and for generating the driving signal according to the charging mode to adjust the charging power. The charger controller further executes a state machine that stores data indicating predetermined battery statuses that cause saturation of the transformer, and that selects a protection mode in which said charging power is restricted if the status of the battery pack matches to one of the predetermined battery statuses.