JP7372396B2 - battery charger - Google Patents

Description

BACKGROUND OF THE INVENTION This invention relates generally to battery chargers for charging batteries, and more particularly to battery chargers for charging power tool batteries.

Cordless power tools are typically powered by portable battery packs. These battery packs vary in battery chemistry and nominal voltage and can be used to power numerous tools and electrical devices. Typically, the battery chemistry for power tool batteries is nickel cadmium ("NiCd") or nickel metal hydride ("NiMH"). The nominal voltage of a battery pack typically ranges from about 2.4V to about 24V.

Some battery chemistries (e.g., lithium (“Li”), lithium ion (“Li-ion”), and other lithium-based chemistries) require strict charging regimes with controlled discharge and Charging operation is required. Inadequate charging regimes and uncontrolled discharging regimes may result in excessive heat buildup, excessive overcharge conditions, and/or excessive overdischarge conditions. These conditions and accumulations can cause irreversible damage to the battery and can seriously impact battery capacity.

The present invention provides a system and method for charging a battery. In some configurations and in some aspects, the invention provides a battery charger that can fully charge a variety of battery packs with different battery chemistries. In some configurations and in some aspects, the invention provides a battery charger that can fully charge lithium-based batteries, such as lithium cobalt batteries, lithium manganese batteries, and spinel-type batteries. In some configurations and in some aspects, the invention provides a battery charger that can charge battery packs of lithium-based chemistries at or within different nominal voltage ranges. In some configurations and in some aspects, the invention provides a battery charger having various charging modules implemented based on different battery conditions. In some configurations and in some aspects, the invention provides methods and systems for charging lithium-based batteries by applying pulses of constant current. Depending on some battery characteristics, the time between pulses and the length of the pulses can be increased or decreased by the battery charger.

The unique features and advantages of the present invention will be apparent to those skilled in the art from consideration of the following detailed description, claims, and drawings.

It is a perspective view showing a battery. 2 is another perspective view of a battery, such as the battery shown in FIG. 1. FIG. 2 is a perspective view of a battery, such as the battery shown in FIG. 1, electrically and physically connected to a battery charger; FIG. 4 is a circuit diagram illustrating a battery electrically connected to a battery charger, such as the battery and battery charger shown in FIG. 3; FIG. 4 is a flowchart illustrating the operation of a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3. 4 is a flowchart illustrating the operation of a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3. 4 is a flowchart illustrating a first module that may be implemented in a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3; 4 is a flowchart illustrating a second module that may be implemented in a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3. 4 is a flowchart illustrating a third module that may be implemented in a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3; 4 is a flowchart illustrating a fourth module that may be implemented in a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3. 4 is a flowchart illustrating a fifth module that may be implemented in a battery charger embodying aspects of the present invention, such as the battery charger shown in FIG. 3. 4 is a flowchart illustrating a sixth module that may be implemented in a battery charger embodying aspects of the invention, such as the battery charger shown in FIG. 3; 4 is a flowchart illustrating a charging algorithm that may be implemented in a battery charger embodying aspects of the present invention, such as the battery charger shown in FIG. 3; FIG. 2 is a circuit diagram showing a battery electrically connected to a battery charger. It is a figure showing other compositions of a battery. It is a figure showing other compositions of a battery. 14A-B is a perspective view of a battery electrically and physically connected to a power tool, such as one of the batteries shown in FIGS. 1, 2, and 14A-B. FIG. 14A-B is a perspective view of a battery electrically and physically connected to a power tool, such as one of the batteries shown in FIGS. 1, 2, and 14A-B. FIG. FIG. 3 is a schematic diagram showing a charging current regarding a battery. FIG. 3 is another circuit diagram showing a battery. FIG. 3 is a perspective view showing an inversion device connected to a battery charger. 19 is a plan view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is a side view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is a top view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is another side view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is a rear view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is another perspective view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is yet another perspective view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is yet another perspective view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 19 is yet another perspective view of an inverter connected to a battery charger, such as the inverter of FIG. 18; FIG. 2 is a flowchart illustrating a charging operation module for a battery. 5 is a flowchart illustrating another charging operation module for batteries. 5 is a flowchart illustrating another charging operation module for batteries. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. 5 is a flowchart illustrating yet another charging operation module for a battery. FIG. 3 is a schematic diagram showing a charging current regarding a battery.

Before describing embodiments of the invention in detail, it should be noted that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description and illustrated in the following drawings. I want to be understood. The invention is capable of other embodiments and of being practiced or carried out in various ways. Similarly, it is to be understood that the terms and terms used herein are for descriptive purposes and should not be considered limiting. The use of "comprising," "comprising," or "having," and variations thereof, is intended to encompass not only the elements listed below and their equivalents, but also additional elements as well. .

A battery pack or battery 20 is shown in FIGS. 1 and 2. The battery 20 transfers power to and from one or more electrical devices, such as, for example, a power tool 25 (shown in FIGS. 15A-B) and/or a battery charger 30 (shown in FIGS. 3 and 4). is configured to receive. In some configurations and in some aspects, the battery 20 includes, for example, lead acid, nickel cadmium ("NiCd"), nickel metal hydride ("NiMH"), lithium ("Li"), lithium ion ("L-ion"), etc. ”), another lithium-based chemistry, or another rechargeable battery chemistry. In some configurations and in some aspects, battery 20 can provide large discharge currents to electrical devices with high current discharge rates, such as, for example, power tools. In an exemplary configuration, battery 20 is of lithium, lithium ion, or another lithium-based chemistry and provides an average discharge current of about 20 A or more. For example, in exemplary configurations, battery 20 can have a lithium cobalt ("Li-Co"), lithium manganese ("Li-Mn") spinel, or Li-Mn nickel chemistry.

In some configurations and in some aspects, battery 20 may have any nominal voltage, such as, for example, a nominal voltage ranging from about 9.6V to about 50V. In one configuration (see FIGS. 1-3), for example, battery 20 has a nominal voltage of about 21V. In another configuration (see FIG. 14), battery 20 has a nominal voltage of about 28V. It should be appreciated that in other configurations, battery 20 may have another nominal voltage within another nominal voltage range.

Battery 20 includes a housing 35 in which a terminal support 40 is provided. Battery 20 further includes one or more battery terminals supported by terminal support 40 and connectable to an electrical device such as power tool 25 and/or battery charger 30. In some configurations, such as the configuration illustrated in FIG. 4, battery 20 includes a positive battery terminal 45, a negative battery terminal 50, and a sense battery terminal 55. In some configurations, battery 20 includes more or fewer terminals than the illustrated configurations.

Battery 20 has one or more battery cells 60, each having a chemistry and a nominal voltage. In some configurations, battery 20 has a lithium ion battery chemistry, a nominal voltage of about 18V or 21V, and includes five battery cells. In some configurations, each battery cell 60 has a lithium ion chemistry and each battery cell 60 has the same nominal voltage, such as, for example, about 3.6V or about 4.2V.

In some configurations and in some aspects, battery 20 includes an identification circuit or element electrically connected to one or more terminals. In some configurations, an electrical device, such as, for example, battery charger 30 (shown in FIGS. 3 and 4), "reads" or otherwise reads this identification circuit or element to ascertain one or more battery characteristics. The input may be received based on an identification circuit or element. In some configurations, such battery characteristics may include, for example, the nominal voltage of battery 20, the temperature of battery 20, and/or the chemistry of battery 20.

In some configurations and in some aspects, battery 20 includes a controller, microcontroller, microprocessor, or controller electrically connected to one or more battery terminals. These controllers connect to an electrical device, such as a battery charger 30, and provide information to the device, such as the nominal voltage of the battery 20, the individual cell voltages, the temperature of the battery 20, and/or the chemistry of the battery 20. provides information regarding one or more battery characteristics or conditions of the battery. In some configurations, such as the configuration illustrated in FIG. 4, battery 20 includes an identification circuit 62 having a microprocessor or controller 64.

In some configurations and in some aspects, battery 20 includes a temperature sensing element or thermistor. The thermistor is constructed and positioned within the battery 20 to sense the temperature of one or more battery cells or the temperature of the battery 20 as a whole. In some configurations, such as the configuration illustrated in FIG. 4, battery 20 includes a thermistor 66. In the illustrated configuration, thermistor 66 is included within identification circuit 62.

As shown in FIGS. 3 and 4, battery 20 is also configured to connect to an electrical device, such as a battery charger 30. In some configurations, battery charger 30 includes a housing 70. This housing 70 is provided with a connecting portion 75 to which the battery 20 is connected. Connection 75 includes one or more electrical device terminals for electrically connecting battery 20 to battery charger 30 . Terminals included in the battery charger 30 are configured to pair with terminals included in the battery 20 to exchange power and information with the battery 20.

In some configurations, such as the configuration illustrated in FIG. 4, battery charger 30 includes a positive terminal 80, a negative terminal 85, and a detection terminal 90. In some configurations, positive terminal 80 of battery charger 30 is configured to mate with positive battery terminal 45. In some configurations, negative terminal 85 and sense terminal 90 of battery charger 30 are configured to mate with negative battery terminal 50 and sense battery terminal 55, respectively.

In some configurations and in some aspects, battery charger 30 also includes charging circuitry 95. In some configurations, the charging circuit 95 includes a controller, microcontroller, microprocessor, or controller 100. Controller 100 controls the transmission of power between battery 20 and battery charger 30. In some configurations, controller 100 controls the communication of information between battery 20 and battery charger 30. In some configurations, controller 100 identifies and/or ascertains one or more characteristics or conditions of battery 20 based on the signal received from battery 20. Controller 100 may also control operation of charger 30 based on the identification characteristics of battery 20.

In some configurations and in some aspects, controller 100 may include timers, backup timers, counters, and/or perform various timing and counting functions. Timers, backup timers, and counters are used during various charging stages and/or modules and are controlled by controller 100. Timers, backup timers, and counters are discussed below.

In some configurations and in some aspects, battery charger 30 includes a display or indicator 110. This indicator 110 informs the user of the status of the battery charger 30. In some configurations, the indicator 110 can inform the user of the various charging stages, charging modes, or charging modules that are initiated and/or completed during operation. In some configurations, indicator 110 includes a first light emitting diode (“LED”) 115 and a second LED 120. In the example configuration, first LED 115 and second LED 120 are different colored LEDs. For example, the first LED 115 is a red LED and the second LED 120 is a green LED. In some configurations, controller 100 operates and controls indicator 110. In some configurations, indicator 110 is positioned on housing 70 or included within housing 70 such that indicator 110 is visible to a user. The display may also include an indicator that displays charge rate, time remaining, etc. In some configurations, the indicator or indicator 110 may include a fuel gauge on the battery 20.

Battery charger 30 is adapted to receive power input from power source 130 . In some configurations, power supply 130 is approximately a 120V AC, 60Hz signal. In other configurations, power supply 130 is an approximately 240V AC signal. In other configurations, power supply 130 is, for example, a constant current power supply. In these configurations, power source 130 may include a 12V DC signal, such as a DC signal received from a vehicle jack (eg, a vehicle battery).

In the exemplary configuration, battery charger 30 receives power input from an AC power source. For use with a DC power source, the user can connect the battery charger 30 to a power inverter 2140 shown in FIGS. 18-27. In these configurations, the inverter 2140 converts a first signal, such as a DC signal (i.e., a 12V DC signal from a vehicle DC outlet) into a second signal, such as an AC signal (i.e., a 120V AC signal). Convert.

As shown in FIGS. 18-26, the inverse transformer 2140 includes a housing 2145. In the example configuration, housing 2145 includes a first end 2146, a second end 2147, a first side 2148, and a second side 2149. Housing 2145 also includes a bottom surface 2152 and a top surface 2154. In other configurations, the housing 2145 may include more or fewer surfaces, sides, and edges than shown and described.

In one configuration, top surface 2154 can be an area for placing battery charger 30. In the illustrated configuration, top surface 2154 is substantially the same width and length as battery charger 30. In other configurations, top surface 2154 may be greater or less than the width and length of battery charger 30. In other configurations, top surface 2154 can include a securing mechanism (not shown) for securing battery charger 30 to inverter 2140. In yet other configurations, another portion of the housing 2145 can include a securing mechanism for securing the battery charger 30 to the inversion device 2140.

Inverter 2140 also includes an input terminal 2159 that receives a first power signal (ie, a DC power signal). In some configurations, input terminal 2159 includes cord 2160 and input connector 2165. In the exemplary configuration, input connector 2165 includes a 12V DC input plug for receiving a DC signal from a vehicle DC outlet.

Inversion device 2140 also includes a conversion output terminal 2170 for delivering a second power signal (ie, an AC power signal). In the example, conversion output terminal 2170 includes an AC outlet, such as a three-wire straight blade outlet 2170. As shown in Figure 18, outlet 2
170 is positioned on cord winding 2155.

In some configurations, the inverter 2140 can include a cord wrap 2155. This cord wrap 2155 can accommodate and secure the cord 2156 of the battery charger 30. In the illustrated configuration, groove 2158 in second end 2147 of housing 2145 forms cord wrap 2155 .

In some configurations, inverter 2140 can include a second output terminal 2180. In the example configuration, a second output terminal 2180 is positioned on the first end 2146 of the housing 2145 and is operable to output a second (converted) power signal. In other configurations, output terminal 2180 can deliver a first power signal (ie, a DC signal). In other configurations, the inverter 2140 can include an additional output terminal 2180 for delivering the first power signal or the second power signal. In yet other configurations, the inverter 2140 includes a combination of second outlets 2180, at least one outlet for delivering the first power signal and at least one other outlet for delivering the second power signal. I can do it.

In some configurations, inversion device 2140 can include a switch 2185 that controls the output of power via conversion output terminal 2170. The switch 2185 has an on position (when the inverter 2140 is receiving a first power signal) in which the inverter 2140 is operable to distribute power via the converter output terminal 2170 and an on position (when the inverter 2140 is receiving a first power signal); 2140 may include an off position in which it is not operable to dispense power via conversion output terminal 2170. The position of switch 2185 may be indicated to the user by one or more LEDs, such as, for example, first LED 2188 and second LED 2189 shown in FIGS. 23-26. In the example configuration, first LED 2188 and second LED 2189 are located on first end 2146 of housing 2145. In one configuration, the first LED 2188 is a red LED to indicate that the inverter 2140 is not operable to provide power via the conversion output terminal 2170 and the second LED 2189 is a green LED. , indicates that the inverter 2140 is operable to provide power via the transform output terminal 2170. In other configurations, switch 2185 can control the output of second output terminal 2180. In yet other configurations, the inverter 2140 includes a switch 2185 for each output terminal or outlet 2170, 2180.

In some configurations and in some aspects, battery charger 30 can charge a variety of rechargeable batteries having different battery chemistries and different nominal voltages, as described below. For example, in one typical implementation, battery charger 30 includes a first battery having a nickel cadmium battery chemistry and a nominal voltage of about 14.4V, a lithium ion battery chemistry and a nominal voltage of about 18V. and a third battery having a lithium ion battery chemistry and a nominal voltage of about 28V. In another exemplary implementation, battery charger 30 can charge a first lithium ion battery having a nominal voltage of about 21V and a second lithium ion battery having a nominal voltage of about 28V. In such a typical implementation, battery charger 30 identifies the nominal voltage of each battery 20 and scales some thresholds accordingly, or scales the nominal voltage of the battery, as discussed below. The voltage reading or measurement (measured during charging) can be changed accordingly.

In some configurations, battery charger 30 determines the nominal value of battery 20 by "reading" an identification element included in battery 20 or by receiving a signal from the battery's microprocessor or controller, for example. Voltage can be identified. In some configurations, battery charger 30 may include a range of acceptable nominal voltages for different batteries 20 that charger 30 is capable of identifying. In some configurations, the range of allowed nominal voltages may range from about 8V to about 50V. In other configurations, the range of acceptable nominal voltages may include a range from about 12V to about 28V. In other configurations, battery charger 30 is capable of identifying nominal voltages of about 12V or greater. Similarly, in other configurations, battery charger 30 may be capable of identifying nominal voltages of about 30V or less.

In other configurations, battery charger 30 may identify a range of values that includes the nominal voltage of battery 20. For example, rather than identifying that the first battery 20 has a nominal voltage of about 18V, the battery charger 30 may identify that the nominal voltage of the first battery 20 is, for example, from about 18V to about 22V, or from about 16V to about It can be identified that it is within a range of up to 24V. In other configurations, battery charger 30 may also identify other battery characteristics, such as, for example, number of battery cells, battery chemistry, and so on.

In other configurations, charger 30 can identify any nominal voltage of battery 20. In these configurations, the charger 30 is capable of charging a battery 20 of any nominal voltage by adjusting or scaling several thresholds according to the nominal voltage of the battery 20. These configurations also allow each battery 20 to receive approximately the same amplitude of charging current for approximately the same amount of time regardless of the nominal voltage (e.g., each battery 20 may be approximately fully discharged). ). The battery charger 30 is capable of threshold adjustment or scaling (discussed below) or measurement adjustment or scaling according to the nominal voltage of the battery 20 being charged.

For example, battery charger 30 may identify a first battery having a nominal voltage of approximately 21V and five battery cells. Throughout charging, battery charger 30 changes all measurements (eg, battery voltage) that it samples to obtain measurements per cell. That is, charger 30 divides all battery voltage measurements by five (eg, for five cells) to obtain the approximate average voltage of the cells. Therefore, all thresholds included in battery charger 30 may be correlated to measurements per cell. Battery charger 30 is also capable of identifying a second battery having a nominal voltage of approximately 28V and seven battery cells. Similar to operation with the first battery, battery charger 30 modifies all voltage measurements to obtain a per cell measurement. Again, all thresholds included in battery charger 30 may be correlated to measurements per cell. In this example, battery charger 30 is capable of monitoring and terminating charging to the first and second batteries using the same threshold, and battery charger 30 is capable of monitoring and terminating charging for the first and second batteries over a range of nominal voltages. Allows you to charge many batteries.

In some configurations and in some aspects, battery charger 30 bases the charging scheme or method of charging battery 20 on the temperature of battery 20 . In one configuration, battery charger 30 provides charging current to battery 20 while periodically sensing or monitoring the temperature of battery 20. If battery 20 does not include a microprocessor or controller, battery charger 30 periodically measures the resistance of thermistor 66 after a predetermined period of time. If battery 20 includes a microprocessor or controller, such as controller 64, battery charger 30 may be used to: 1) periodically measure battery temperature and/or 2) periodically interrogate the controller 64 to determine whether it is outside the proper operating range; or 2) determine whether the battery temperature is outside the proper operating range from the controller 64, as discussed below. Wait to receive a signal indicating that it is present.

In some configurations and in some aspects, battery charger 30 bases the charging scheme or method of charging battery 20 on the current voltage of battery 20. In some configurations, battery charger 30 periodically detects or detects the battery voltage after a predetermined period of time when current is being supplied to battery 20 and/or after a predetermined period of time during which no current is being supplied to battery 20, as discussed below. A charging current is supplied to the battery 20 while being monitored. In some configurations, the battery charger 30 is such that the charging scheme or method for charging the battery 20 is based on both the temperature and voltage of the battery 20. Also, charging schemes can be based on individual cell voltages.

Once the battery temperature and/or battery voltage exceeds a predetermined threshold or is outside the proper operating range, battery charger 30 discontinues charging current. Battery charger 30 continues to periodically detect or monitor battery temperature/voltage or waits to receive a signal from controller 64 indicating that battery temperature/voltage is within proper operating ranges. When the battery temperature/voltage is within the proper operating range, battery charger 30 can resume supplying charging current to battery 20. The battery charger 30 continues to monitor battery temperature/voltage and continues to interrupt and resume charging current based on the detected battery temperature/voltage. In some configurations, battery charger 30 terminates charging after a predetermined period of time or when the battery capacity reaches a predetermined threshold. In other configurations, charging ends when battery 20 is removed from battery charger 30.

In some configurations and in some aspects, battery charger 30 includes an operating method for charging various batteries, such as battery 20, that have different chemistries and/or nominal voltages. An example of such a charging operation 200 is illustrated in Figures 5a and 5b. In some configurations and in some aspects, the battery charger 30 is compatible with lithium-based batteries, such as Li-Co chemistry, Li-Mn spinel chemistry, Li-Mn nickel chemistry, etc. including operating methods for charging. In some configurations and in some aspects, charging operation 200 includes various modules to perform different functions in response to different battery conditions and/or battery characteristics.

In some configurations and in some aspects, the method of charging operation 200 includes a module for suspending charging based on abnormal and/or normal battery conditions. In some configurations, the charging operation 200 may be performed on a defective pack module, such as a defective pack module illustrated in flowchart 205 of FIG. 6, and/or a temperature out module illustrated in flowchart 210 of FIG. of-range module). In some configurations, battery charger 30 enters bad pack module 205 to terminate charging based on abnormal battery voltage, abnormal cell voltage, and/or abnormal battery capacity. In some configurations, battery charger 30 enters temperature out-of-range module 210 to terminate charging based on an abnormal battery temperature and/or one or more abnormal battery cell temperatures. In some configurations, charging operation 200 includes more or less modules than those discussed above and below that terminate charging based on more or less battery conditions than those discussed above and below. Charging operations and other configurations of the charging module are shown in FIGS. 28 to 38.

In some configurations and in some aspects, charging operation 200 includes various modes or modules for charging battery 20 based on various battery conditions. In some configurations, the charging operation 200 may include a trickle charge module, such as a trickle charge module illustrated in flow diagram 215 of FIG. 8, a step charge module, such as a step charge module illustrated in flow diagram 220 of FIG. a staged charge module such as a fast charge module such as the fast charge module illustrated in flowchart 225 of FIG. 10, and/or flowchart 230 of FIG.
A maintenance charge module such as the maintenance module illustrated in FIG.

In some configurations and in some aspects, each charging module 215-230
is selected by controller 100 during charging operation 200 based on a certain battery temperature range, a certain battery voltage range, and/or a certain battery capacity range. In some configurations, each module 215-230 is selected by controller 100 based on the battery characteristics shown in Table 1. In some configurations, the term "battery temperature" or "battery temperature" refers to the temperature of the battery (i.e., battery cells, battery components, etc.) measured as a whole and/or measured individually or collectively. This can include the temperature of the battery cell. In some configurations, each charging module 215-230 may be based on the same basic charging scheme or charging algorithm, such as, for example, full charge current, as discussed below.

In some configurations and in some aspects, during trickle charging module 215, the charging current applied to battery 20 charges battery 20 to a full charging current (e.g., "I") and then suspending the full charging current for a second period, e.g., 50 seconds. In some configurations, the full charging current is a pulse of charging current at approximately a predetermined amplitude. In some configurations, battery charger 30 only enters trickle charge module 215 if the battery voltage is below a first predetermined voltage threshold V1.

In some configurations and in some aspects, during the fast charging module 225, the charging current applied to the battery 20 applies a full charging current to the battery 20 for a first period, e.g., 1 second, and then and suspending the full charging current for two periods, eg, 50 milliseconds. In some configurations, controller 100 sets the backup timer to a first predetermined time limit, such as about two hours. In these configurations, battery charger 30 does not run fast charge module 225 for a predetermined time limit to avoid damage to the battery. In other configurations, battery charger 30 terminates (eg, ceases charging) when the predetermined time limit expires.

In some configurations, the battery charger 30 is configured such that the battery voltage is within a range from a first voltage threshold V1 to a second predetermined voltage threshold V2, and the battery temperature is within a range from a second battery temperature threshold T2 to a second predetermined voltage threshold V2. If the battery temperature is within the range up to the battery temperature threshold T3 of 3, the battery temperature only enters the quick charging module 225. In some configurations, the second voltage threshold V2 is higher than the first voltage threshold V1 and the third temperature threshold T3 is higher than the second temperature threshold T2.

In some configurations and some aspects, during the staged charging module 220, the charging current applied to the battery 20 includes applying the charging current of a fast charging module 225 to the battery 20 for one minute. It has an operating cycle of charging ("on") and charging suspension for 1 minute ("off"). In some configurations, controller 100 sets the backup timer to a second predetermined time limit, such as, for example, about four hours. In these configurations, battery charger 30 does not perform staged charging module 220 for a predetermined time limit to avoid damage to the battery.

In some configurations, the battery charger 30 is configured such that the battery voltage is within a range from a first voltage threshold V1 to a second voltage threshold V2, and the battery temperature is within a range from a first temperature threshold T1 to a second temperature threshold T1. If it is within the range up to threshold T2, only the staged charging module 220 is entered. In some configurations, the second voltage threshold V2 is higher than the first voltage threshold V1 and the second temperature threshold T2 is higher than the first temperature threshold T1.

In some configurations and aspects, during maintenance module 230, the charging current applied to battery 20 applies a full charging current to battery 20 only when the battery voltage drops to a certain predetermined threshold. Including. In some configurations, this threshold is approximately 4.05V/cell (+/-1% per cell). In some configurations, the battery charger 30 is configured such that the battery voltage is within a range from a second voltage threshold V2 to a third voltage threshold V3, and the battery temperature is within a range from a first temperature threshold T1 to a third temperature threshold T1. If the temperature is within the range up to the temperature threshold T3, only the maintenance module 230 is entered.

In some configurations and in some aspects, controller 100 executes different charging modules 220-230 based on different battery conditions. In some configurations, each charging module 220-230 includes the same charging algorithm (eg, an algorithm for applying full charging current). However, each charging module 220-230 executes, iterates, or incorporates charging algorithms in a different manner. One example of a charging algorithm is the charging current algorithm illustrated in flowchart 250 of FIG. 12, as discussed below.

As illustrated in FIGS. 5a and 5b, charging operation 200 begins when a battery, such as battery 20, is inserted or electrically connected to battery charger 30 at step 305. At step 310, the controller 100 determines whether a stable input of power, eg, power source 130, is applied or connected to the battery charger 30. The same operation still applies if power is applied after battery 20 is electrically connected to battery charger 30 (ie, step 305 proceeds to step 310), as shown in FIG. 5a.

If the controller 100 confirms that a stable input of power is not applied, the controller 100 does not activate the indicator 110 and does not charge the battery 20 in step 315. In some configurations, battery charger 30 consumes a small amount of discharge current in step 315. In some configurations, such discharge current is less than about 0.1 mA.

If the controller 100 determines in step 310 that a stable input of power is being applied to the battery charger 30, the operation 200 proceeds to step 320. At step 320, controller 100 checks whether the connections between battery terminals 45, 50, and 55 and battery charger terminals 80, 85, and 90 are all stable. At step 320, if the connection is not stable, controller 100 returns to step 315.

If the connection is stable at step 320, the controller 100 identifies the chemistry of the battery 20 via the sensing terminal 55 of the battery 20 at step 325. In some configurations, the resistive sensing lead from the battery 20, when detected by the controller 100, indicates that the battery 20 has a nickel cadmium or nickel hydride chemistry. In some configurations, the controller 100 measures the resistance of the resistive sensing leads to ascertain the chemistry of the battery 20. For example, in some configurations, if the resistance of the sensing leads is in the first range, then the battery 20 chemistry is nickel cadmium. If the resistance of the sensing leads is in the second range, then the battery 20 chemistry is nickel metal hydride.

In some configurations, nickel-cadmium and nickel-metal hydride batteries are charged by battery charger 30 using a single charging algorithm that is different from the charging algorithm performed for batteries with lithium-based chemistries. . In some configurations, such a single charge algorithm for nickel-cadmium and nickel-metal hydride batteries is, for example, an existing charging algorithm for nickel-cadmium/nickel-metal hydride batteries. In some configurations, battery charger 30 uses a single charge algorithm for charging nickel-cadmium and nickel-metal hydride batteries, but a different termination scheme than it uses to terminate charging for nickel-metal hydride batteries. According to the method, the charging process for the nickel cadmium battery is completed. In some configurations, battery charger 30 terminates charging the nickel cadmium battery when a negative change in battery voltage (eg, -ΔV) is detected by controller 100. In some configurations, battery charger 30 terminates charging the nickel metal hydride battery when the change in battery temperature over time (eg, ΔT/dt) reaches or exceeds a predetermined termination threshold.

In some configurations, nickel cadmium and/or nickel metal hydride batteries are charged using a constant current algorithm. For example, battery charger 30 may include the same charging circuit to charge different batteries with different chemistries such as nickel cadmium, nickel metal hydride, lithium ion, etc. In one typical configuration, charger 30 uses this charging circuit to apply the same full charge current to nickel cadmium and nickel metal hydride batteries as to lithium ion batteries using a constant current algorithm rather than pulse charging. I can do it. In another typical configuration, battery charger 30 can scale the full charge current with the charging circuit according to the battery chemistry.

In other configurations, controller 100 does not verify the exact chemistry of battery 20. Instead, controller 100 implements a charging module that can effectively charge both nickel cadmium and nickel metal hydride batteries.

In other configurations, the resistance of the sensing leads may indicate that the battery 20 has a lithium-based chemistry. For example, if the resistance of the sensing leads is within the third range, then the battery 20 chemistry is lithium-based.

In some configurations, the serial communication link between battery charger 30 and battery 20 established by sensing terminals 55 and 90 indicates that battery 20 has a lithium-based chemistry. Once a serial communication link is established in step 320, a microprocessor or controller, such as controller 64, in battery 20 sends information regarding battery 20 to controller 100 in battery charger 30. The information thus communicated between battery 20 and battery charger 30 includes battery chemistry, nominal battery voltage, battery capacity, battery temperature, individual cell voltages, number of charge cycles, number of discharge cycles. , the status of the protection circuit or circuitry (eg, operational, inoperable, operational, etc.).

At step 330, controller 100 determines whether the battery 20 chemistry is lithium-based. If, at step 330, the controller 100 determines that the battery 20 has a nickel-cadmium or nickel-metal hydride chemistry, the operation 200 proceeds to a nickel-cadmium/nickel-metal hydride charging algorithm at step 335.

If controller 100 determines at step 330 that battery 20 has a lithium-based chemistry, operation 200 proceeds to step 340. At step 340, controller 100 reconfigures any battery protection circuitry included within battery 20, such as a switch, and verifies the nominal voltage of battery 20 via the communication link. At step 345, controller 100 sets the charger's analog-to-digital converter ("A/D") to the appropriate level based on the nominal voltage.

At step 350, controller 100 measures the current voltage of battery 20. Once the measurements are taken, the controller 100 checks in step 355 whether the voltage of the battery 20 is greater than 4.3V/cell. At step 355, if the battery voltage is greater than 4.3V/cell, operation 200 proceeds to step 360, bad pack module 205. This bad pack module 205 will be discussed below.

If the battery voltage is below 4.3V/cell in step 355, the controller 100 measures the battery temperature in step 365, and further determines in step 370 whether the battery temperature is lower than -10°C or 65°C. Check if it is higher than At step 370, if the battery temperature is less than −10° C. or greater than 65° C., operation 200 proceeds to step 375, temperature out-of-range module 210. This temperature out-of-range module 210 is discussed below.

If the battery temperature is greater than or equal to -10°C and less than or equal to 65°C in step 370, the controller 100 determines whether the battery temperature is between -10°C and 0°C in step 380 (shown in Figure 5b). Check. At step 380, if the battery temperature is between −10° C. and 0° C., operation 200 proceeds to step 385. At step 385, controller 100 checks whether the battery voltage is less than 3.5V/cell. If the battery voltage is less than 3.5V/cell, operation 200 proceeds to trickle charge module 215 in step 390. This trickle charging module 215 is discussed below.

If the battery voltage is 3.5V/cell or higher in step 385, the controller 100 determines in step 395 whether the battery voltage is within a voltage range of 3.5V/cell to 4.1V/cell. Check. At step 395, if the battery voltage is not within the voltage range of 3.5V/cell to 4.1V/cell, operation 200 proceeds to maintenance module 230 at step 400. This maintenance module 230 is discussed below.

If the battery voltage is within the voltage range from 3.5V/cell to 4.1V/cell at step 395, controller 100 clears a counter, such as a charge counter, at step 405. . Once the charge counter is cleared in step 405, the controller 200 proceeds to the step charging module 220 in step 410. This stage charging module 220 and charge counter are discussed below.

Referring again to step 380, if the battery temperature is not within the range of -10°C and 0°C, the controller 100 checks in step 415 whether the battery voltage is less than 3.5V/cell. do. In step 415, if the battery voltage is less than 3.5V/cell, operation 20
0 proceeds to trickle charge module 215 in step 420.

If the battery voltage is 3.5V/cell or higher in step 415, the controller 100 determines whether the battery voltage is within the voltage range from 3.5V/cell to 4.1V/cell in step 425. Check. At step 425, if the battery voltage is not within the voltage range of 3.5V/cell to 4.1V/cell, operation 200 proceeds to maintenance module 230 at step 430.

If the battery voltage is within the voltage range from 3.5V/cell to 4.1V/cell at step 425, controller 100 clears a counter, such as a charge counter, at step 435. Once the charge counter is cleared in step 435, operation 200 proceeds to fast charge module 225 in step 440. This fast charging module 225 is discussed below.

FIG. 6 is a flowchart illustrating the operation of the bad pack module 205. Operation of module 205 begins when main charging operation 200 enters bad pack module 205 at step 460 . Controller 100 interrupts the charging current at step 465 and activates indicator 110, such as a first light emitting diode (LED), at step 470. In the exemplary configuration, controller 100 controls the first LED to flash at a rate of about 4 Hz. Once indicator 110 is activated in step 470, module 205 ends in step 475 and operation 200 also ends.

FIG. 7 is a flowchart illustrating the operation of the temperature out-of-range module 210. Operation of the module 210 begins when the main charging operation 200 enters the out-of-temperature module 210 at step 490 . Controller 100 interrupts the charging current at step 495 and activates indicator 110, such as a first LED, at step 500. In the exemplary configuration, controller 100 controls the first LED to blink at a rate of about 1 Hz to notify the user that battery charger 30 is currently in out-of-range module 210 . At step 500, once indicator 110 is activated, operation 200 exits module 210 and proceeds to suspend operation 200.

FIG. 8 is a flow diagram illustrating trickle charging module 215. Operation of trickle charging module 215 begins when main charging operation 200 enters trickle charging module 215 in step 520 . Controller 100 activates indicator 110, such as first LED 115, at step 525 to inform the user that battery charger 30 is currently charging battery 20. In the exemplary configuration, controller 100 operates to cause first LED 115 to be displayed as always on.

Once the indicator 110 is activated in step 525, the controller 100 initializes a counter, such as a trickle charge count counter, in step 530. In the exemplary configuration, the trickle charge count counter has a count limit of twenty.

In step 540, controller 100 applies ten one second ("1-s") full current pulses to battery 20 and then pauses charging for fifty seconds ("50-s"). In some configurations, there is a 50 millisecond time interval between 1-s pulses.

At step 545, controller 100 determines whether the battery voltage exceeds 4.6V/cell when charging current is applied to battery 20 (e.g., current-on-times). Measure the voltage. If the battery voltage exceeds 4.6V/cell during the current on time in step 545, module 215 will proceed to bad pack module 205 in step 550 and end in step 552. If the battery voltage does not exceed 4.6 V/cell during the current-on time in step 545, the controller 100 determines, in step 555, when no charging current is applied to the battery 20 (e.g., during the current-off time). Measure the battery temperature and battery voltage at the following times.

At step 560, the controller 100 determines whether the battery temperature is below -10°C or above 65°C. If the battery temperature is less than −10° C. or greater than 65° C. at step 560, module 215 will proceed to temperature out of range module 210 at step 565 and end at step 570. If the battery temperature is greater than or equal to -10°C and less than or equal to 65°C in step 560, the controller 100 determines that the battery voltage is within the range of 3.5V/cell to 4.1V/cell in step 575. Check to see if it is.

If the battery voltage is within the range of 3.5V/cell to 4.1V/cell in step 575, the controller 100 determines in step 580 that the battery temperature is within the range of -10°C to 0°C. Check if it is included. If the battery temperature is within the range of −10° C. to 0° C. at step 580, module 215 proceeds to staged charging module 220 at step 585. At step 580, if the battery temperature is not within the range of −10° C. to 0° C., module 215 proceeds to fast charging module 225 at step 590.

If the battery voltage is not within the range of 3.5V/cell to 4.1V/cell at step 575, controller 100 increments a trickle charge counter at step 595. In step 600, the controller 100 determines whether the trickle charge count counter is equal to a limit value of the counter, such as twenty, for example. At step 600, if the counter is not equal to the count limit, module 215 proceeds to step 540. At step 600, if the counter is equal to the count limit, module 215 will proceed to bad pack module 205 at step 605 and end at step 610.

FIG. 9 is a flowchart illustrating staged charging module 220. Operation of module 220 begins when main charging operation 200 enters stage charging module 220 at step 630. Controller 100 activates indicator 110, such as first LED 115, at step 635 to inform the user that battery charger 30 is currently charging battery 20. In the exemplary configuration, the controller 100 operates to cause the first LED 115 to be displayed as always on.

At step 640, controller 100 starts a first timer or charge-on timer. In the example configuration, the charge-on timer counts down from one minute. At step 645, module 220 proceeds to charging current algorithm 250. Once the charging current algorithm 250 is executed, the controller 100 checks at step 650 whether the charging count is equal to a count limit, such as 7,200, for example. At step 650, if the charge count is equal to the count limit, module 220 proceeds to bad pack module 205 at step 655, and module 220 ends at step 660.

If the charge count is not equal to the count limit at step 650, the controller 100 determines at step 665 that the wait time between current pulses (discussed below) is greater than or equal to a first wait time threshold, such as, for example, 2 seconds. Check if there is. If the wait time is greater than or equal to the first wait time threshold at step 665, the controller 100 activates the indicator 110 at step 670, e.g., turns off the first LED 115 and turns off the second LED 120 at about 1 Hz. It works by flashing at a rapid rate. At step 665, if the wait time is less than a first wait time threshold, module 220 proceeds to step 690 (discussed below).

Once the indicator 110 is activated in step 670, the controller 100 determines in step 675 whether the wait time between current pulses is greater than or equal to a second wait time threshold, such as, for example, 15 seconds. do. At step 675, if the wait time is greater than or equal to the second wait time threshold, the controller 100 changes the indicator 110 at step 680, e.g., so that the second LED 120 is displayed as always on. Activate the LED 120. Module 220 then proceeds to maintenance module 230 at step 685.

If the standby time is less than the second standby time threshold in step 675, the controller 100 determines in step 690 whether the battery temperature is greater than 0°C. At step 690, if the battery temperature is greater than 0° C., module 220 proceeds to fast charging module 225 at step 695. If the battery temperature is below 0° C. in step 690, the controller 100 checks in step 700 whether the charge-on timer has expired.

At step 700, if the charge on timer has not expired, module 220 proceeds to charge current algorithm 250 at step 645. If the charge-on timer has expired in step 700, the controller 100 activates a second timer or charge-off timer to temporarily stop charging in step 705. At step 710, controller 100 determines whether the charge off timer has expired. At step 710, if the charge off timer has not expired, the controller 100 waits for a predetermined amount of time at step 715 and then proceeds to step 710. At step 710, if the charge off timer has expired, module 220 returns to step 640 to restart the charge on timer.

FIG. 10 is a flow diagram illustrating the quick charging module 225. Operation of module 225 begins when main charging operation 200 enters fast charging module 225 at step 730 . Controller 100 activates indicator 110 , such as first LED 115 , at step 735 to inform the user that battery charger 30 is currently charging battery 20 . In the example configuration, the controller 100 operates the first LED 115 so that it always appears on.

At step 740, module 225 proceeds to charging current algorithm 250. Once the charging current algorithm 250 is executed, the controller 100 checks at step 745 whether the charging count is equal to a count limit (eg, 7,200). At step 745, if the charge count is equal to the count limit, module 225 proceeds to step 750, bad pack module 205, and module 225 ends at step 755.

If the charge count is not equal to the count limit at step 745, the controller 100 determines whether the wait time between current pulses is greater than or equal to a first wait time threshold (e.g., 2 seconds) at step 760. . At step 760, if the wait time is greater than or equal to the first wait time threshold, the controller 100 activates the indicator 110 at step 765, e.g., turns off the first LED 115 and turns off the second LED 120 at a rate of about 1 Hz. It operates in such a way that it blinks. At step 760, if the wait time is less than a first wait time threshold, module 225 proceeds to step 785 (discussed below).

Once the indicator 110 is activated in step 765, the controller 100 determines in step 770 whether the wait time between current pulses is greater than or equal to a second wait time threshold (eg, 15 seconds). If the wait time is greater than or equal to the second wait time threshold in step 770, the controller 100 changes the indicator 110 in step 775, e.g., energizes the second LED 120 such that the second LED 120 is always on. As shown in the status. Module 225 then proceeds to maintenance module 230 at step 780 .

If the standby time is less than the second standby time threshold in step 770, the controller 100 checks in step 785 whether the battery temperature is within a range of -20°C to 0°C. At step 785, if the battery temperature is within this range, module 225 proceeds to step 790, step charging module 220. At step 785, if the battery temperature is not within this range, module 225 returns to charging current algorithm 250 at step 740.

FIG. 11 is a flow diagram illustrating maintenance module 230. As shown in FIG. Operation of module 230 begins when main charging operation 200 enters maintenance module 230 at step 800 . At step 805, the controller 100 checks whether the battery voltage is within the range of 3.5V/cell to 4.05V/cell. If the battery voltage is not within this range at step 805, the controller 100 continues to remain at step 805 until the battery voltage is within the range. Once the battery voltage is within this range at step 805, controller 100 starts a maintenance timer at step 810. In some configurations, the sustain timer counts down from 30 minutes.

At step 815, the controller 100 checks whether the battery temperature is below -20°C or above 65°C. At step 815, if the battery temperature is below -20°C or above 65°C, module 230 proceeds to step 820, temperature out of range module 210, and the module ends at step 825. At step 815, if the battery temperature is greater than or equal to −20° C. and less than or equal to 65° C., module 230 proceeds to charging current algorithm 250 at step 830.

Once the charging current algorithm 250 is executed at step 830, the controller 100 checks at step 835 whether the sustain timer has expired. If the maintenance timer has expired, module 230 proceeds to bad pack module 205 in step 840 and module 230 ends in step 845. If the sustain timer has not expired in step 835, the controller 100 determines in step 850 whether the wait time between current pulses is greater than or equal to a first predetermined sustain wait period, such as, for example, 15 seconds.

At step 850, if the wait time is longer than the first predetermined maintenance wait period, module 230 proceeds to step 805. At step 850, if the wait time is less than a first predetermined maintenance wait period, module 230 proceeds to charging current algorithm 250 at step 830. In some configurations, battery charger 30 remains in maintenance module 230 until battery pack (batteries) 20 is removed from battery charger 30.

FIG. 12 is a flowchart illustrating a basic charging scheme or charging current algorithm 250. Operation of module 250 begins when other modules 220 - 230 or main charging operation 200 enter charging current algorithm 250 at step 870 . At step 875, controller 100 applies a full current pulse for approximately 1 second. At step 880, controller 100 checks if the battery voltage is greater than 4.6V/cell while applying current to battery 20.

At step 880, if the battery voltage is greater than 4.6 V/cell, algorithm 250 will proceed to bad pack module 205 at step 885, and algorithm 250 will end at step 890. If the battery voltage is less than or equal to 4.6V/cell at step 880, the controller 100 interrupts the charging current, increments a counter, such as a charging current counter, and stores the count value at step 895. do.

In step 900, the controller 100 determines whether the battery temperature is below -20°C or 65°C.
Check whether it exceeds. In step 900, if the battery temperature is less than -20°C or greater than 65°C, algorithm 250 proceeds to temperature out of range module 210 in step 905, and algorithm 250 ends in step 910. If the battery temperature is greater than or equal to -20° C. or less than or equal to 65° C. in step 900, then in step 915 the controller 100 measures the battery voltage while no charging current is being applied to the battery 20.

At step 920, controller 100 checks whether the battery voltage is less than 4.2V/cell. At step 920, if the battery voltage is less than 4.2V/cell, algorithm 250 proceeds to step 875. If, in step 920, the battery voltage is greater than or equal to 4.2V/cell, then in step 925, controller 100 waits until the battery voltage equals approximately 4.2V/cell. In step 925, controller 100 also stores its wait time. Algorithm 250 ends at step 930.

In some configurations and in some aspects, battery charger 30 may include alternative methods of operation for charging various batteries having different chemistries and/or nominal voltages, such as battery 20. . An example of such a charging operation is illustrated in FIGS. 28-38. In some configurations and in some aspects, the battery charger 30 is a lithium-based battery, such as a battery having a Li-Co chemistry, a Li-Mn spinel chemistry, a Li-Mn nickel chemistry, etc. Includes operating methods for charging batteries. In some configurations and aspects, charging operation 200 includes various modules to perform different functions in response to different battery conditions and/or battery characteristics.

In some configurations and aspects, the method of charging operation includes a module for suspending charging based on abnormal and/or normal battery conditions. In some configurations, the charging operation includes a defective pack module and/or an out-of-temperature module, such as the out-of-range module illustrated in flowchart 2235 of FIG. In some configurations, battery charger 30 enters a bad pack module to terminate charging based on abnormal battery voltage, abnormal cell voltage, and/or abnormal battery capacity. In some configurations, battery charger 30 enters temperature out of range module 2235 to terminate charging based on an abnormal battery temperature and/or one or more abnormal battery cell temperatures. In some configurations, the charging operation includes more or less modules than those discussed above and below that terminate charging based on more or less than the conditions discussed above and below.

In some configurations and aspects, charging operations include different modes or modules for charging battery 20 based on different conditions or stages of operation. In some configurations, charging operations include a trickle (limited) charge module, such as a trickle (limited) charge module, illustrated in flow diagram 2225 of FIG. 34, a trickle (limited) charge module, illustrated in flow diagram 2220 of FIG. step) module (trickle)
(step module), a fast charging module such as the fast charging module illustrated in flowchart 2215 of FIG. 32, and/or a maintenance charging module such as the maintenance module illustrated in flowchart 2230 of FIG. A flatpack wake-up module illustrated in flowchart 2210, a charging module and a packinsert module 2200 illustrated in flowchart 2205 of FIGS. 29 and 30 and flowchart 2200 of FIG. 28, respectively.
Other modules such as (start charging) are also included. Charging operations also include charging current algorithms, such as the algorithm illustrated in flowchart 2240 of FIGS. 37 and 38, that other modules execute in various ways.

An example of some of the charging operations is listed with respect to FIGS. 28-30. For example, the charging operation begins with the pack insertion module 2200, as shown in FIG. The operation begins with power being supplied to the battery charger 30 (step 2305), and the battery charger 30 determines whether the input voltage V input is within proper operating parameters (e.g., 80V < V input < 140V). (Step 2310). If the input voltage V input is not within this operating parameter range, battery charger 30 prevents charging (step 2315). Battery charger 30 also informs the user whether the proper input voltage V input is being provided (step 2315).

If the battery charger 30 is receiving the proper input voltage V input, the battery pack 20 is connected to the charger (step 2325) and the charger 30 is connected to the charger 30 if the proper connections (e.g., terminal-to-terminal connections) are made. (step 2330). If proper connections are not made, charger 30 will not illuminate any LEDs (step 2335) and the charging operation will end (step 2340). If the connection is made, charger 30 detects the presence of battery 20 by voltage to controller 100 (step 2345), and controller 100 measures the voltage V pack of battery 20 (step 2350).

Charger 30 checks whether the battery voltage V-pack is lower than 5V (step 2355). If the battery voltage V-pack is less than 5V, the charging operation proceeds to the flat-pack activation module 2210 (step 2360). If the battery voltage V-pack is greater than or equal to 5V, charger 30 attempts to establish a connection with battery 20 (step 2365) and checks whether a connection is established (step 2370). If a connection is not established, charger 30 does not light any indicators (step 2375) and ends the charging operation (step 2380). Once the connection is established, charging operations proceed to charging module 2205 (step 2385).

Charging module 2205 is illustrated in FIGS. 29 and 30. The charging module 2205 begins with the charger 30 identifying the pack nominal voltage and setting the appropriate metering parameters (step 2405), then interrogating the cell voltage of the battery 20 (step 2410), and at any time. Check whether the cell voltage is greater than an upper threshold (eg, 4.35V) (2415). If any cell is greater than the upper threshold, charger 30 does not activate any LEDs (step 2420) and ends the charging operation (step 2425). If none of the cells exceeds the upper threshold, charger 30 measures the battery voltage across the terminals of charger 30 (step 2430) and then queries the battery voltage V-pack measured by battery 20. (Step 2435), and confirm whether the measured values match (Step 2440). If the measurements do not match, charger 30 does not activate any LEDs (step 2445) and the charging operation ends (step 2450).

If the measured values match, charger 30 queries battery 20 regarding battery temperature (step 2455) and determines whether the battery temperature is within the operating range (step 2460). If the battery voltage is not within the desired operating range, operation proceeds to out-of-range module 2235 (step 2465), and charger 30 returns battery 20 to the battery temperature once the charging operation exits out-of-range module 2235. Information can be queried (2455).

If the battery temperature is within the desired operating range, charger 30 determines whether the battery voltage V-pack is greater than a maintenance threshold (e.g., 4.1V per cell) (step 470) and determines whether the battery voltage V-pack is greater than a maintenance threshold (e.g., 4.1V per cell) If is greater than the maintenance threshold, the charging operation proceeds to maintenance module 2230 (step 2475). Otherwise, charger 30 checks whether the battery voltage V-pack is less than a trickle threshold (e.g., 3.5V per cell) (step 2480), and if the battery voltage V-pack is less than the trickle threshold. , the charging operation proceeds to trickle (limit) module 2225 (step 2485). If the battery voltage is above the trickle threshold, charger 30 determines whether the battery temperature is within the trickle range (step 2490). If the temperature is within the trickle range, operation proceeds to the trickle (stage) module 2220 (step 2495), and if the temperature is not within the trickle range, operation proceeds to the fast charge module 2215 (step 2505). Charging operations can continue as shown with other modules illustrated in FIGS. 31-38.

During charging operations illustrated in FIGS. 28-38, battery charger 30 powers battery 20 using a pulse charging method. In one configuration, battery charger 30 provides pulses to battery 20 each time having the same pulse width, but with different times between pulses. This is called the "full charge current" or "full charge pulse." In other configurations, such as the configurations shown in FIGS. 16 and 39, the full charge current or full charge pulse applied by battery charger 30 can be scaled according to the individual cell voltages in battery 20. Such an implementation is described with respect to FIGS. 4, 16, and 39.

As shown in FIG. 4, controller 100 in battery charger 30 can receive information from and communicate information to microcontroller 64 in battery 20. In some configurations, microcontroller 64 monitors various battery characteristics during charging, including the voltage or current state of charge of each battery cell 60, automatically or in response to commands from battery charger 30. can do. Microcontroller 64 may monitor several battery characteristics and process or average measurements during charging current T on (ie, "current on" time periods). In some configurations, the current on period may be about 1 second ("1-s"). During periods of no charging current Toff (i.e., "currentoff" time periods), information regarding some battery characteristics (e.g., cell voltage or state of charge of the cell) is removed from the battery 20. It can be transmitted to the charger 30. In some configurations, the current off period Toff is approximately 50 milliseconds. The battery charger 30 can process the information sent from the battery 20 and change the current on period T on accordingly. For example, if one or more battery cells 60 have a higher current state of charge than the remaining battery cells 60, battery charger 30 avoids overcharging these one or more higher battery cells 60. Therefore, the subsequent current-on period T-on can be shortened.

In some configurations, battery charger 30 may compare each individual cell voltage to an average cell voltage such that the difference between the individual cell voltage and the average cell voltage exceeds a predetermined threshold (e.g., an imbalance). (imbalancethreshold), charger 30 can identify the cell as a higher state of charge cell. The battery charger 30 can change the current on period Ton. In other configurations, the battery charger 30 determines the state of charge for a particular battery cell (the battery cell identified to be a higher voltage cell) during the current on period based on information received from the battery 20. can be evaluated. In these configurations, the battery charger 30 can change the duration of the current on period T on when the current state of charge estimate for the cell exceeds a threshold.

For example, as shown in FIGS. 16 and 39, battery charger 30 may instruct battery 20 to average cell voltage measurements taken during the next current on time T on 1. Such a command can be sent during the first current off period Toff1. Thus, during the first current on time T on 1, the microcontroller 64 measures and averages the cell voltage and other battery parameters. During the next current off time Toff2, battery 20 may send the averaged measurement to battery charger 30. In some configurations, the battery 20 may send eight average measurements, such as an average pack state of charge measurement and an average individual cell state of charge for each of the seven battery cells 60. For example, battery 20 can send the following information: That is, cell 114%, cell 2 14%, cell 3 15%, cell 4
14%, cell 5 16%, cell 614%, cell 7 14%, and pack (eg, cells 1-7) voltage 29.96V. In such an example, battery charger 30 identifies cell 5 as the higher battery cell. Charger 30 also records the battery voltage measured by both battery microcontroller 64 and battery charger 30. In such an example, battery charger 30 measures the battery voltage at approximately 30.07V. The battery charger 30 calculates the difference in battery voltage measurements (eg, 110 mV) and confirms that the voltage drop across the terminal and lead wire is approximately 110 mV.

During the subsequent current-on period Ton2, the battery charger 30 "estimates" the voltage of the cell 5. For example, battery charger 30 samples the voltage measurements of battery 20 and evaluates the state of charge for cell 5 for each battery voltage measurement according to the following equation.
(V battery/charging - V terminal) *V cell In the above formula, V battery/charging is the voltage of the battery 20 as measured by the charger 30, and the V terminal is the voltage drop across the terminal (for example, 110 mV). , and V cell is the voltage of the cell rated as a percentage of the battery voltage. If the evaluated value of the voltage of the cell 5 exceeds a threshold (“reduction threshold”), the battery charger 30 can change the subsequent current on period T on 3. In this example, the battery charger 30 stores the point in time when the estimated value (or calculated value) of the voltage of the cell 5 reaches the reduction threshold (which is approximately 800 milliseconds). As shown in FIG. 39, charger 30 identifies and calculates cell 5 as a high battery cell and further sets the subsequent current on period T on 3 to a duration stored by charger 30 (e.g., 800 milliseconds). Therefore, the length T2 of the current on period Ton3 is shorter than the length T1 of the preceding current on periods Ton1 and Ton2.

In some configurations, charger 30 continues to set subsequent current-on periods (e.g., T-on 4-5) to approximately the length T2 (e.g., 800 milliseconds) of the preceding current-on period, T-on 3. . If cell 5 (or another cell) is still identified as the high cell, charger 30 reduces the length of the subsequent current on period (e.g., T on 6) to length T2 (e.g., approximately 800 milliseconds) to T3 (eg, approximately 600 milliseconds) if, for example, the voltage of cell 5 continues to reach the reduced threshold (eg, 600 milliseconds).

In other configurations, if the charger 30 determines that the battery cells are not receiving sufficient current, the charger 30 increases the subsequent current on period (e.g., T on 5) to approximately the length of T1. It can also be reversed (thus increasing the on-time after reducing the on-time). For example, the battery charger 30 may cause the battery charger 30 to charge a current The on period can be increased. In these configurations, the battery charger 30 continues to vary the length of the current pulse (e.g., on-period) in consideration of the battery cell voltage to optimize the amount of charge the cell receives before overcharging. I can do it. In some configurations, battery charger 30 cannot increase this current on time to be longer than the initial current on period, eg, period T on 1.

Another circuit diagram of the battery 20' is schematically illustrated in FIG. Battery 20' is similar to battery 20, and common elements are identified by the same reference numerals with a ''.

In some configurations, circuit 62' includes an electrical element, such as an identification resistor 950, which may have a collective resistance. In other configurations, the electrical device may be a capacitor, a coil, a transistor, a semiconductor device, an electrical circuit, or another device that has resistance or is capable of transmitting electrical signals, such as a microprocessor, digital logic device, etc. ). In the exemplary configuration, the resistance value of identification resistor 950 is selectable based on characteristics of battery 20', such as the nominal voltage and chemistry of battery cell 60'. Detection terminal 55' is electrically connectable to identification resistor 950.

The battery 20' shown schematically in FIG. 13 is electrically connectable to an electrical device such as a battery charger 960 (also shown schematically). Battery charger 960 can include a positive terminal 964, a negative terminal 968, and a sense terminal 972. Each terminal 964, 968, 972 of battery charger 960 is electrically connectable to a corresponding terminal 45', 50', 55' (respectively) of battery 20'. The battery charger 960 includes electrical components such as a first resistor 976, a second resistor 980, a solid state electronic device or semiconductor 984, a comparator 988, and a processor, microcontroller, or controller (not shown). It can also include a circuit with. In some configurations, semiconductor 984 is operable in saturation or an “ON” state and operable in a cut-off or “OFF” state. A transistor may be included. In some configurations, comparator 988 may be a dedicated voltage monitor, microprocessor, or processing unit. In other configurations, comparator 988 may be included within a controller (not shown).

In some configurations, a controller (not shown) is programmable to identify the resistance value of an electrical element (such as identification resistor 950) in battery 20'. The controller is also programmable to ascertain one or more characteristics of the battery 20', such as the battery chemistry and nominal voltage of the battery 20'. As previously discussed, the resistance value of identification resistor 950 can correspond to a dedicated value associated with one or more certain battery characteristics. For example, the resistance value of identification resistor 950 may fall within a range of resistance values that correspond to the chemistry and nominal voltage of battery 20'.

In some configurations, the controller is programmable to recognize multiple resistance value ranges for identification resistor 950. In these configurations, each range corresponds to one battery chemistry, eg, nickel cadmium, nickel metal hydride, lithium ion, etc. In some configurations, the controller can recognize additional resistance value ranges, each corresponding to a different battery chemistry or different battery characteristics.

In some configurations, the controller is programmable to recognize multiple voltage ranges. The voltages included within these voltage ranges can depend on or correspond to the resistance value of identification resistor 950 such that the controller can ascertain the value of resistor 950 based on the measured voltage.

In some configurations, the resistance value of identification resistor 950 is further selectable to be unique for each possible nominal voltage of battery 20'. For example, in one range of resistance values, a first dedicated resistance value can support a nominal voltage of 21V, a second dedicated resistance value can support a nominal voltage of 16.8V, and a third dedicated resistance value can support a nominal voltage of 16.8V. The dedicated resistance value can support a nominal voltage of 12.6V. In some configurations, there may be more or fewer dedicated resistance values, each corresponding to another possible nominal voltage of the battery 20' associated with that resistance value range.

In one exemplary implementation, battery 20' is electrically connected to battery charger 960. To identify the first battery characteristic, semiconductor 984 is switched to an "on" state under the control of additional circuitry (not shown). When semiconductor 984 is in the "on" state, identification resistor 950 and resistors 976, 980 are connected to a voltage divider network.
make. This network establishes a voltage VA at a first reference point 992. If the resistance of resistor 980 is significantly lower than the resistance of resistor 976, voltage VA will depend on the resistances of identification resistor 950 and resistor 980. In such implementations, voltage VA is within the range determined by the resistance value of identification resistor 950. A controller (not shown) measures the voltage VA at the first reference point 992 and checks the resistance value of the identification resistor 950 based on this VA. In some configurations, the controller compares voltage VA to multiple voltage ranges to ascertain battery characteristics.

In some configurations, the first battery characteristic to be identified includes battery chemistry. For example, any resistance value below 150 kilohms indicates that the battery 20' has a nickel cadmium or nickel metal hydride chemistry, and any resistance value greater than about 150 kilohms indicates that the battery 20' has a lithium or lithium ion chemistry. It can be shown that it has the chemical properties of Once the controller verifies and identifies the battery 20' chemistry, an appropriate charging algorithm or method can be selected. In other configurations, there are more resistance ranges than in the example above, each corresponding to a different battery chemistry.

Continuing with this exemplary implementation, to identify the second battery characteristic, semiconductor 984 is switched to an "off" state under the control of additional circuitry. When semiconductor 984 switches to the "off" state, identification resistor 950 and resistor 976 create a voltage divider network. The voltage VA at the first reference point 992 is now ascertained by the resistance values of the identification resistor 950 and the resistor 976. The resistance value of the identification resistor 950 is such that when the voltage V battery at the second reference point 1012 is substantially equal to the nominal voltage of the battery 20', the voltage VA at the first reference point 992 is equal to the voltage at the third reference point 996. The voltage V is selected to be substantially equal to the V reference. If the voltage VA at the first reference point 992 exceeds the fixed voltage V reference at the third reference point 996, the output V output of the comparator 988 changes state. In some configurations, it may serve as an indicator to terminate charging or initiate additional functions such as maintenance routines, equalization routines, discharge functions, additional charging schemes, etc. The output V output can be used for In some configurations, the voltage V reference may be a fixed reference voltage.

In some configurations, the second battery characteristic to be identified can include the nominal voltage of battery 20'. For example, a general formula for calculating the resistance value for identification resistor 950 may be:

In the above equation, R100 is the resistance of identification resistor 950, R135 is the resistance of resistor 976, V battery is the nominal voltage of battery 20', and V reference is, for example, about 2.5V. It is a fixed voltage such as. For example, within the range of resistance values for lithium ion chemistry (discussed above), a resistance value of approximately 150 kilohms for identification resistor 950 corresponds to a nominal voltage of approximately 21V, and a resistance value of approximately 194 kilohms corresponds to a nominal voltage of approximately Corresponding to a nominal voltage of 16.8V, a resistance value of approximately 274.7 kilohms may correspond to a nominal voltage of approximately 12.6V. In other configurations, more or fewer dedicated resistance values can accommodate additional or different battery pack nominal voltage values.

In an example configuration, both identification resistor 950 and third reference point 996 may be located on the "high" side of current sensing resistor 1000. Positioning identification resistor 950 and third reference point 996 in this manner may reduce any relative voltage variation between VA and V references when charging current is present. If identification resistor 950 and third reference point 996 are referenced to ground 1004 and charging current is applied to battery 20', voltage fluctuations may appear in voltage VA.

In some configurations, battery charger 960 may also include charger control functionality. As discussed above, when the voltage VA is substantially equal to the voltage V reference (indicating that the voltage V battery is equal to the nominal voltage of battery 20'), the output V output of comparator 988 changes state. In some configurations, when the output V output of comparator 988 changes state, charging current is no longer provided to battery 20'. Once the charging current is interrupted, the battery voltage V battery begins to decrease. When the voltage V battery reaches the low threshold, the output V output of comparator 988 changes state again. In some configurations, the low threshold of the voltage V battery is determined by the resistance value of hysteresis resistor 1008. Once the output V output of comparator 988 changes state again, charging current is reestablished. In some configurations, such cycles are repeated for a predetermined amount of time determined by the controller or repeated for a fixed amount of statechanges performed by comparator 988. be done. In some configurations, such cycles are repeated until battery 20' is removed from battery charger 960.

In some configurations and in some aspects, a battery, such as battery 20 shown in FIG. It can be. As shown in FIG. 17, the battery 20 can include one or more battery cells 60, a positive terminal 1105, a negative terminal 1110, and one or more sensing terminals 1120a, 1120b (see FIG. 17). As shown, the second sensing terminal or drive terminal 120b may or may not be included within the battery 20). Battery 20 may also include circuitry 1130 that includes a microcontroller 1140.

As shown in FIG. 17, circuit 1130 controls the discharge current when circuit 1130 (e.g., microprocessor 1140) identifies or detects a condition above or below a predetermined threshold (i.e., an "abnormal battery condition"). A solid state switch 1180 may be included for blocking. In some configurations, switch 1180 includes an interruption condition in which current flowing into and out of battery 20 is interrupted, and an allowance condition in which current flowing in and out of battery 20 is allowed. In some configurations, abnormal battery conditions include, for example, high or low battery cell temperature, high or low battery state of charge, high or low battery cell state of charge, high or low discharge current, high or low charge current, etc. It can be done. In an exemplary configuration, switch 1180 includes a power FET (field effect transistor) or a metal oxide semiconductor FET (“MOSFET”). In other configurations, circuit 1130 may include two switches 1180. In these configurations, switches 1180 are arranged in parallel. Parallel switch 1180 may be included in a battery pack (eg, battery 20 that powers a circular saw, driver drill, etc.) that provides a large average discharge current.

In some configurations, once switch 1180 becomes non-conductive, switch 1180 cannot be reset even if the abnormal condition is no longer detected. In some configurations, circuit 1130 (e.g., microprocessor 1140) resets switch 1180 only if an electrical device, such as battery charger 30, instructs microprocessor 1140 to reset. I can do it. As previously discussed, battery 20 may be discharged to such an extent that battery cells 60 may not have sufficient voltage to power microprocessor 1140 and communicate with battery charger 30.

In some configurations, if battery 20 is unable to establish a connection with charger 30, battery charger 30 provides a small charging current through body diode 1210 of switch 1180 to gradually charge battery cell 60. can be charged to. Once cell 60 receives sufficient charge to power microprocessor 1140, microprocessor 1140 can change the state of switch 1180. That is, battery 20 can be charged even when switch 1180 is in a non-conductive state. As shown in FIG. 17, switch 1180 can include a body diode 1210 that is integrated with MOSFETs and other transistors in some configurations. In other configurations, diode 1210 can be electrically connected in parallel with switch 1180.

In some configurations, if the battery 20 is unable to establish a connection with the charger 30, the battery charger 30 provides a small average current through a sensing lead, e.g., sensing lead 120a or dedicated drive terminal 120b. can do. This current can charge capacitor 1150, which in turn can provide sufficient voltage to enable microprocessor 1140.

The configurations described above and illustrated in the figures are presented by way of example only and are not intended as limitations on the ideas and principles of the invention. Accordingly, those skilled in the art will appreciate that changes may be made in the elements and their configuration and arrangement without departing from the spirit and scope of the invention.

20 Battery 30 Battery charger 45 Positive battery terminal 50 Negative battery terminal 55 Detection battery terminal 60 Battery cell 62 Identification circuit 64 Controller 66 Thermistor 80 Positive terminal 85 Negative terminal 90 Detection terminal 95 Charging circuit 100 Controller 110 Instructions device 115 first light emitting diode 120 second light emitting diode 130 power supply

Claims (14)

A battery charger,
housing and
at least two terminals including a battery terminal and a detection terminal, electrically connected to a power tool battery pack supported by the housing;
a controller;
Equipped with
The power tool battery pack includes a plurality of lithium-based battery cells, each of the plurality of battery cells having an individual state of charge;
The controller is
supplying charging current to the power tool battery pack via the battery terminal;
receiving an individual state of charge of at least one battery cell among the plurality of battery cells via the detection terminal;
determining the charging current being provided to the power tool battery pack based at least in part on a comparison of an individual state of charge of at least one battery cell of the plurality of battery cells to at least one state of charge threshold; control,
A plurality of pulses, each of the plurality of pulses having a first period during which the charging current is supplied to the power tool battery pack with a predetermined amplitude and a second period during which the supply of the charging current is interrupted. controlling the charging current supplied to the power tool battery pack by controlling the battery charger to supply a charging current of
controlling the charging current supplied to the power tool battery pack by changing the first period based on the comparison and controlling the second period to be constant;
It is possible to operate as
the at least one state of charge threshold includes an average cell voltage of the plurality of battery cells;
A battery charger characterized by: The battery charger of claim 1, wherein the controller is operable to change the first time period by shortening the first time period. The battery charger of claim 1, wherein the controller is operable to receive an individual state of charge of each of the plurality of battery cells via the sensing terminal. The controller includes a first charging module and a second charging module, the first charging module is operable to supply a first charging current to the power tool battery pack, and the first charging module is operable to supply a first charging current to the power tool battery pack. 2. The battery charger of claim 1, wherein the second charging module is operable to supply a second charging current to the power tool battery pack. 5. The battery charger of claim 4, wherein the first charging current and the second charging current differ in one of average current amplitude and duty cycle. The battery charger of claim 5, wherein the first charging module includes a quick charging module. 7. The battery charger of claim 6, wherein the fast charging module is operable to provide fast charging current to a power tool battery pack. A method for operating a battery charger, the method comprising:
The battery charger includes a housing, a controller, and at least two terminals including a battery terminal and a detection terminal that electrically connect to a battery pack for a power tool supported by the housing, and a battery pack for use in a vehicle includes a plurality of lithium-based battery cells, each of the plurality of battery cells having an individual state of charge;
The method includes:
supplying charging current to the power tool battery pack via the battery terminal;
receiving, by the controller, an individual state of charge of at least one battery cell of the plurality of battery cells via the detection terminal;
charge being provided to the battery pack by the controller based at least in part on a comparison of an individual state of charge of at least one battery cell of the plurality of battery cells to at least one state of charge threshold; controlling the current;
The controller causes each of the plurality of pulses to define a first period in which the charging current is supplied to the power tool battery pack with a predetermined amplitude and a second period in which the supply of the charging current is interrupted. controlling the charging current being supplied to the power tool battery pack by controlling the battery charger to supply a plurality of pulsed charging currents;
controlling, by the controller, the charging current supplied to the power tool battery pack by changing the first period based on the comparison and controlling the second period to be constant;
including;
the at least one state of charge threshold includes an average cell voltage of the plurality of battery cells;
A method characterized by: 9. The method of claim 8, further comprising modifying the first time period by shortening the first time period with the controller. 9. The method of claim 8, further comprising receiving by the controller an individual state of charge of each of the plurality of battery cells via the sensing terminal. executing a first charging module operable by the controller to supply a first charging current to the power tool battery pack;
executing a second charging module operable by the controller to supply a second charging current to the power tool battery pack;
9. The method of claim 8, further comprising: 12. The method of claim 11, wherein the first charging current and the second charging current differ in one of average current amplitude and duty cycle. 13. The method of claim 12, wherein the first charging module includes a fast charging module. 14. The method of claim 13, wherein the fast charging module is operable to provide fast charging current to a power tool battery pack.

Images