Patent Application
20150318720
The present invention relates to a charging device, and particularly to a charging device suitable for charging a battery pack used as the power supply for a cordless power tool.
In recent years, a variety of battery packs housing lithium-ion batteries have been used to power cordless electrical equipment. Lithium-ion batteries are preferred for powering high-load equipment, such as power tools, and a variety of battery packs housing lithium-ion batteries are available for different type of power tools. For example, many of these battery packs can be classified according to output voltage, from low-output battery packs suitable for light work, owing to their light weight and compact size, to high-output, high-capacity battery packs used in power tools requiring more power. Other battery packs can be classified according to their internal structure, as some battery packs with the same output voltage have different internal configurations.
Having such a wide variety of battery packs is considerably inconvenient for users, since each battery pack must be charged using a special battery charger that has been specifically designed for that battery pack. In light of this problem, there has been proposed a charging device that is capable of supporting many types of battery packs (For example, refer to Japanese Patent Application Publication No. 2000-312440).
This conventional charging device can charge battery packs having different numbers of battery cells, as well as battery packs possessing the same number of battery cells but having different internal structures. However, since the conventional charging device cannot discern differences in the internal structures of battery packs, the device cannot be expected to charge battery packs at specifications adjusted for the differences in their internal structures. For example, the conventional charging device might drive its built-in cooling fan during the charging operation to cool the battery pack, even though the battery pack itself possesses a cooling function. Some battery packs have a built-in microcomputer for determining whether charging is feasible.
When determining that charging is not feasible, the microcomputer controls a shutdown circuit provided in the battery pack to interrupt the electric current supplied from the charging device in order to halt charging operations. However, since temperature data related to the battery is not transmitted to the charging device, a charging device with this configuration cannot implement optimum when charging becomes unfeasible solely due to the battery temperature temporarily rising too high, for example.
In view of the foregoing, it is an object of the present invention to provide a charging device capable of determining the type of a battery pack, accounting for structural differences in battery packs, and capable of optimally charging each of various battery packs based on the results of such determinations.
The present invention features a charging device. The charging device includes: a connection portion; charging means; and control means. A first type battery pack and a second type battery pack are connectable to the connection portion. The first type battery pack is configured to control charging itself to determine whether charging is feasible. The second type battery pack is configured to provide information to the charging device for determining whether charging is feasible and controlling a charging operation. The charging means supplies charging current to a secondary battery included in a battery pack connected to the connection portion. The control means is configured to control a charging condition based on a type of the battery pack connected to the connection portion.
With this construction, the charging device can appropriately control charging and ancillary to charging such as whether to drive a cooling fan to cool the battery both for the autonomous first battery pack that monitors charging itself to determine whether charging is feasible and the device-dependent second battery pack that provide information to the charging device for determining whether charging is feasible.
Preferably, the charging device further includes battery type discriminating means.
The battery type discriminating means discriminates between the first type battery pack and the second type battery pack.
With this construction, the control means can appropriately control charging and ancillary to charging based on results of the discrimination between the first type battery pack and the second type battery pack.
Preferably, the connection portion has a positive terminal and a negative terminal. The positive terminal and the negative terminal supply the charging current. The first type battery pack is connected to the connecting portion only via the positive terminal and the negative terminal.
With this construction, the charging device can optimally charge each of the first type battery pack and the second type battery pack correspondingly even though the internal data of the first type battery pack connected to the connection portion is not conveyed to the charging device.
Preferably, the control means infers an internal state of the battery pack connected to the connection portion and controls the charging condition based on an inference result, when the battery type discriminating means determines that the battery pack is the first type battery pack.
With this construction, the charging device can infer the internal state of the battery pack connected to the connection portion and control charging based on the inference result even though the internal data of the first type battery pack is not conveyed to the charging device. Consequently, the charging device can perform charging efficiently and economically.
Preferably, the control means controls a charging condition to enter a standby state without performing a charging operation during a prescribed interval, when inferring that the secondary battery in the battery pack is an unchargeable state.
With this construction, the battery pack keeps its chargeable state with limitation. Consequently, the charging device can perform charging efficiently and economically.
Preferably, the charging device further includes cooling means. The cooling means cools the battery pack connected to the connection portion. The control means infers that the battery pack possesses a battery temperature control function and controls a charging condition to supply a charging current by the charging means without driving the cooling means, when the battery type discriminating means determines that the battery pack is the first type battery pack.
With this construction, the charging device can appropriately determine whether to drive the cooling means.
Preferably, the control means infers that the battery pack connected to the connection portion does not possess a battery temperature control function and controls a charging condition to supply charging current by the charging means with driving the cooling means, when the battery type discriminating means determines that the battery pack is the second type battery pack.
With this construction, the charging device can appropriately determine whether to drive the cooling means.
Preferably, the battery type discriminating means discriminates between a battery pack that is connected to the connection portion through an adapter and a battery pack that is connected directly to the connection portion without using the adapter.
With this construction, the charging device can determines whether the battery pack is connected to the connection portion through the adapter.
Preferably, the battery type discriminating means discriminates between the first type battery pack configured of three or more battery units connected in parallel and the second type battery pack configured of one battery unit or two battery units connected in parallel. The battery unit includes a plurality of battery cells connected in series.
With this construction, the charging device can discriminate between two types of battery packs according to those connection connected to the connection portion of the charging device.
Preferably, the battery type discriminating means discriminates between the first type battery pack that is connected to a power tool through an electric power supply cable and the second type battery pack that is connected directly to the power tool.
With this construction, the charging device can discriminate between two types of battery packs according to those mounting mounted to the power tool.
Preferably, the charging device further includes a charging current detecting unit. The charging current detecting unit is configured to detect the charging current. The control means infers an internal state of the battery pack connected to the connection portion based on a detection result of the charging current detecting unit and controls the charging conditions based on an inference result, when the battery type discriminating means determines that the battery pack is the first type battery pack.
With this construction, the charging device infers the internal state of the first type battery pack based on the charging current. Consequently, the charging device can control reasonable charging by rule of thumb.
Preferably, the connection portion has only a positive terminal and a negative terminal. The positive terminal and the negative terminal supply the charging current. The control means infers that the secondary battery in the battery pack is an unchargeable state and controls a charging condition to enter a standby state without performing a charging operation during a prescribed interval, when the charging current detecting means does not detect a charging current.
Preferably, the control means infers that the secondary battery is a chargeable state and controls a charging condition to cancel the standby state and perform a charging operation, when the charging current detecting means detects a current.
Preferably, the control means infers that the secondary battery is the chargeable state and controls a charging condition to halt supplying the charging current based on an inference result, when the charging current detected by the charging current detecting means is less than a prescribed value after the control means canceled the standby state and performed the charging operation.
Preferably, the charging device further includes display means. The display means displays a battery state of the battery pack connected to the connecting portion. The battery state includes a standby state, a charging state, and a charging completed state.
Preferably, the charging device further includes: battery type discriminating means; and cooling means. The battery type discriminating means discriminates a battery type of the battery pack connected to the connection portion. The cooling means cools the battery pack. The control means controls a charging condition to supply the charging current by the charging means without driving the cooling means, when inferring that the battery pack possesses a battery temperature control function based on a discrimination result of the battery type discriminating means.
Preferably, the charging device further includes: battery type discriminating means; and cooling means. The battery type discriminating means discriminates a battery type of the battery pack connected to the connection portion. The cooling means cools the battery pack. The control means drives the cooling means at least during supplying the charging current by the charging means, when inferring that the battery pack does not possess a battery temperature control function based on a discrimination result of the battery type discriminating means.
Preferably, the battery type discriminating means discriminates between a battery pack that is connected to the connection portion through an adapter and a battery pack that is connected directly to the connection portion without using the adapter. The control means infers that the battery pack that is connected to the connection portion through the adapter possesses the battery temperature control function and the battery pack that is connected directly to the connection portion without using the adapter does not possess the battery temperature control function.
Preferably, the battery type discriminating means discriminates between a battery pack configured of three or more battery units connected in parallel and a battery pack configured of one battery unit or two battery units connected in parallel. The battery unit includes a plurality of battery cells connected in series. The control means infers that the battery pack configured of three or more battery units connected in parallel possesses the battery temperature control function and the battery pack configured of one battery unit or two battery units connected in parallel does not possess the battery temperature control function.
Preferably, the battery type discriminating means discriminates between a battery pack that is connected to a power tool through an electric power supply cable and a battery pack that is connected directly to the power tool. The control means infers that the battery pack that is connected to the power tool through the electric power supply cable possesses the battery temperature control function and the battery pack that is connected directly to the power tool does not possess the battery temperature control function.
The charging device according to the present invention determines whether the battery pack being charged is an autonomous first battery pack that monitors charging itself to determine whether charging is feasible, or a device-dependent second battery pack that provides information to the charging device for determining whether charging is feasible, whereby the charging device controls charging while determining whether charging is feasible. In this way, the charging device of the present invention can perform charging efficiently and economically based on results of the determinations.
Next, a charging device 100 according to a preferred embodiment of the invention, and a battery pack mounted on the charging device 100 will be described while referring to
The charging device 100 according to the preferred embodiment has a function for classifying a wide variety of battery packs as battery packs that are either dependent on battery chargers or battery packs that are autonomous. A battery pack dependent on the charging device (hereinafter called a “device-dependent battery pack”) denotes a battery pack configured to provide data, such as battery temperature data, to the charging device for determining charging feasibility, while an autonomous battery pack denotes a battery pack having a function for determining charging feasibility itself and for controlling whether charging is executed based on the determination results. When a device-dependent battery pack is mounted on the charging device, the charging device can read data related to the internal battery cells of the battery pack and can set charging conditions including charging feasibility. With an autonomous battery pack, the charging device cannot read data related to the target battery cells and, hence, cannot set optimal charging conditions.
Here, charging conditions regulate at least one of (1) charge control at the start of charging, during charging, or at the end of charging, and (2) control ancillary to charging performed by the charging device. For example, control operations for driving a cooling fan to cool the battery or control operations for not driving the cooling fan constitute one charging condition. Similarly, control operations for initiating charging after determining that it is possible to begin charging, or control operations for immediately entering a standby state without performing charging constitute one charging condition. Similarly, control operations for setting the timing to end charging constitute a charging condition.
The method of distinguishing between a device-dependent battery pack and an autonomous battery pack does not depend on the number of built-in battery cells or the number of cells connected in series. For example, a battery pack having ten cells connected in series for outputting 36 volts may be classified as either a device-dependent battery pack or an autonomous battery pack. Further, some battery packs have a plurality of battery units connected in parallel, wherein each battery unit has a plurality of battery cells connected in series and the battery units are connected in parallel by connecting corresponding battery cells in each battery unit. Depending on the relationship of this battery pack to the charging device, the charging device may classify the battery pack as either a device-dependent battery pack or an autonomous battery pack. However, most device-dependent battery packs do not possess battery units connected in parallel and, at most, have two battery units connected in parallel. In addition, most device-dependent battery packs are small in size and have connection terminals formed on the battery pack itself. The device-dependent battery pack is generally mounted on the body of a power tool by sliding the battery pack onto the body of the power tool or inserting the battery pack into the body of the power tool and is used integrally with the power tool. A typical autonomous battery pack is a relatively large power supply, such as a backpack-type battery pack having a large battery capacity or a waist belt battery pack worn around the waist. Battery cells accommodated in the backpack are housed in a plurality of cell units. Each cell unit has a plurality of battery cells connected in series, and the cell units are connected in parallel by connecting corresponding battery cells of each cell unit. Normally, three or more cell units are connected in parallel. In addition, the autonomous battery pack may be connected to charging device through a special adapter or may be mounted directly on the charging device without the use of an adapter.
The device-dependent battery pack 20 shown in
The battery 20a shown in
The battery type discrimination element 16 is configured of resistors having resistance values that correspond to types of battery packs. These resistance values can reveal information, such as the number of battery cells directly connected to the charging device. The battery type discrimination element 16 will be described later with reference to
The autonomous battery pack 40A shown in
As with the device-dependent battery pack 20 in
The regulator 40f regulates the power supplied from the battery 40a to power the microcomputer 40e. The overcharge detection unit 40d detects an alert signal outputted from the protection IC 40b when the voltage of battery cells in the battery 40a exceeds the threshold voltage defining a full charge and conveys this signal to the microcomputer 40e. The battery temperature detection unit 40g detects the temperature of the battery 40a using a thermistor and conveys the detected temperature data to the microcomputer 40e. The battery voltage detection unit 40h detects the voltage of the battery 40a and transmits the detected battery voltage data to the microcomputer 40e. The FET 40c is connected to the output port of the microcomputer 40e and is turned on and off by the microcomputer 40e. When the FET 40c is off, a charging current from the charging device 100 is interrupted so that the battery 40a is not charged. Conversely, when the FET 40c is on, the battery 40a is charged by the charging current. The microcomputer 40e turns the FET 40c on and off based on data, including overcharge data received from the overcharge detection unit 40d, temperature data received from the battery temperature detection unit 40g, and battery voltage data received from the battery voltage detection unit 40h. Thus, the autonomous battery pack 40A itself determines whether charging is feasible and allows charging when determining that charging is feasible, but does not allow charging when determining that the state of the battery 40a is unsuitable for charging.
More specifically, the microcomputer 40e in the autonomous battery pack 40A shown in
Next, the charging device 100 according to the preferred embodiment will be described. The charging device 100 has the same structure in
The charging device 100 is a computer-controlled charging device housing a microcomputer 8 and differs from a specialized device that can charge only specific battery packs. The charging device 100 includes power supplies, the microcomputer 8, various detection circuits connected to the A/D input port of the microcomputer 8, and various controlled components connected to the output port of the microcomputer 8.
The power supplies include a main power supply 3, and an auxiliary power supply 4. The main power supply 3 supplies the charging power for charging a battery pack. The main power supply 3 in turn is powered by an AC power supply 1. The AC power supply 1 supplies an AC current that is rectified by a rectifying circuit 2 to produce DC power. The rectifying circuit 2 then feeds this DC power to the main supply 3. The main power supply 3 is primarily configured of a switching IC 3a, and a switching FET 3b. The switching IC 3a and switching FET 3b perform power width modulation (PWM) control based on feedback from the secondary side of a high-frequency transformer TR1 in order to supply a prescribed current/voltage to the charge line on the secondary side of the high-frequency transformer TR1. A rectifying circuit 9 for rectifying the output of the main power supply 3 is connected to the secondary side of the high-frequency transformer TR1.
The auxiliary power supply 4 is a power supply circuit on the primary side for control system of the microcomputer 8 and the switching IC 3a. As with the main power supply 3, the auxiliary power supply 4 is configured of a switching IC, switching FET, and the like and supplies a prescribed power through PWM control. The auxiliary power supply 4 is connected to the primary winding of a high-frequency transformer TR2. A power supply 5 is connected to the secondary winding of the high-frequency transformer TR2, while power supply 6 is connected to the tertiary winding. The power supply 5 is configured of a rectifying circuit, a constant voltage circuit, and the like and supplies power to the switching IC 3a. The power supply 6 is configured of a rectifying circuit and the like and supplies a voltage to the microcomputer 8 and the like. A regulator 7 is provided for regulating the output voltage of the power supply 6 at a prescribed constant voltage. In the preferred embodiment, the regulator 7 outputs a constant voltage of 5 V to the microcomputer 8 and the like.
The microcomputer 8 controls charging operations based on battery type data acquired from the battery type discrimination element 16, temperature data acquired from the thermistor 17, and current data acquired from a current detection circuit 13. The microcomputer 8 also controls the operations of a cooling fan 14, and a display unit 18.
The charging device 100 also includes a feedback circuit 10 for providing data indicating the voltage and current on the secondary side of the high-frequency transformer TR1 to the primary side; and a voltage control circuit 11 and a current control circuit 12 for detecting the voltage data and current data, respectively, and for conveying this data to the feedback circuit 10. The current detection circuit 13 detects the charging current. The cooling fan 14 functions to cool the battery 20a. For a small battery pack (e.g., the device-dependent battery pack 20) that can be mounted directly on the power tool, the cooling fan 14 is provided in a suitable position for cooling the battery 20a built into the device-dependent battery pack 20. However, when the autonomous battery pack 40A is connected to the power tool through the adapter 30, as shown in
The display unit 18 notifies the user of the charging state. Charging states may include “pre-charging,” “charging,” “charging complete,” and “charging suspended.” The charging device 100 may enter the latter state when the battery temperature exceeds the prescribed value.
In S304 the charging device 100 determines whether the mounted battery pack is an autonomous battery pack or a device-dependent battery pack based on results of detecting the value of the battery type discrimination element 16 provided in the device-dependent battery pack 20, autonomous battery pack 40B, or adapter 30. Here, the method of distinguishing between the device-dependent battery pack 20 and the autonomous battery packs 40A and 40B will be described with reference to
The battery type discrimination element 16 housed in the device-dependent battery pack 20, the battery type discrimination terminal housed in the adapter 30 used together with the autonomous battery pack 40A, and the battery type discrimination element 16 housed in the autonomous battery pack 40B shown in
The conventional battery type identification element has a similar configuration to that shown in
For example, let's assume that the resistance values of resistors Ra, Rb, and Rc are a, b, and c, respectively. In the conventional circuit, the switching element SW1 is turned on when a high-level signal is outputted from the output port of the microcomputer 8. At this time, the voltage applied to the A/D input port of the microcomputer 8 is found by multiplying the 5-V reference voltage by b/(a+b). However, this voltage value is the same for both device-dependent battery packs and autonomous battery packs whose batteries are configured of ten cells connected in series, for example. Thus, while the conventional circuit can determine that the battery has ten cells, the circuit cannot distinguish between a device-dependent battery pack and an autonomous battery pack.
With the circuit according to the preferred embodiment shown in
Returning to the flowchart in
However, if the charging device 100 determines in S307 that the battery temperature does not exceed the prescribed value (S307: NO), indicating that the current battery temperature poses no problems to the charging operation, in S308 the charging device 100 displays data on the display unit 18 indicating that charging is underway by lighting the LED in orange, as described in S311, and in S312 begins charging.
Once charging is initiated in S312, in S313 the charging device 100 determines whether the battery pack is device-dependent based on the determination results in S304. If the battery pack is not device-dependent (i.e., if an autonomous battery pack is mounted on the charging device 100; S313: NO), in S314 the charging device 100 determines whether the charging current detected by the current detection circuit 13 exceeds a prescribed value a. As described above, when the battery temperature of the autonomous battery packs 40A and 40B becomes too high, the microcomputer 40e interrupts the charging current by switching off the current shutdown FET 40c provided in the battery pack. Since a charging current is not flowing in this case, in S314 the charging device 100 determines that the charging current does not exceed the prescribed value a. Thus, even though the charging device 100 can recognize that a charging current is not flowing when the autonomous battery packs 40A and 40B is connected to the charging device 100, the charging device 100 cannot determine the state of the battery 40a housed in the autonomous battery packs 40A and 40B from this information. There are various possible reasons for the charging current being interrupted, including a cell in the battery 40a being defective, the battery 40a being in a fully charged state, or the battery temperature being too high. Generally, the most likely of these reasons is that the battery temperature has become too high to be suitable for charging and that charging has been temporarily suspended. Accordingly, when the charging device 100 determines that the charging current is less than the prescribed value a, the charging device 100 infers that charging of the battery 40a is temporarily not feasible.
Hence, in S315 the charging device 100 notifies the user through the display unit 18 that charging has been temporarily suspended. For example, the charging device 100 controls the display unit 18 to flash the LED in red for a fixed interval. Next, the charging device 100 determines intermittently over a prescribed interval in S316 and S318 whether the charging current exceeds the prescribed value a. As described above, the charging device infers that the battery is in a temporary unchargeable state when the charging current is less than the prescribed value a. However, the charging device 100 infers that the temporary unchargeable state has been canceled when the charging current exceeds the prescribed value a (S316: YES) before the prescribed interval has elapsed (S318: NO). This change may occur when the battery temperature, initially found to be in a high-temperature state, drops below a prescribed temperature, for example. Note that if the FET 40c is shut down due to a defective battery cell or other abnormality that is not temporary, the FET 40c will remain shut down, and the charging current will remain below the prescribed value a.
Hence, when the charging current is found to exceed the prescribed value a (S316: YES), the charging device 100 resumes charging and in S317 displays data through the display unit 18 informing the user that charging has begun. For example, the charging device 100 controls the display unit 18 to light the LED in orange. As described above, the process to determine the level of the charging current implemented in S314 and S316 is a process of inferring the internal state of the battery pack.
If the charging suspension continues for a prescribed time (five hours, for example; S318: NO), in S321 the charging device 100 aborts the operation to supply a charging current.
When the charging device 100 determines during the charging process that the electric current detected by the current detection circuit 13 is less than the prescribed value a (S319: YES), the charging device 100 infers that the battery has reached a full charge. In other words, if the charging device 100 determines in S319 that the charging current is less than the prescribed value a, the charging device 100 infers that the FET 40c has been turned off because the batter is fully charged. Accordingly, in S320 the charging device 100 controls the display unit 18 to light the LED in green to inform the user that the battery is fully charged, and in S321 ends the charging operation. As in S314 and S316 described above, the process in S319 is performed to infer the internal state of the battery pack.
Thereafter, the charging device 100 repeatedly determines in S322 whether the battery pack has been removed from the charging device 100. When the battery pack has been removed (S322: YES), the charging device 100 returns to S301. The process for determining whether the battery pack has been removed is similar to the process in S302 for determining whether the battery pack has been mounted. For example, the charging device 100 makes this determination by detecting the value of the battery type discrimination element 16 provided in the device-dependent battery pack 20, autonomous battery pack 40B or adapter 30.
On the other hand, if the charging device 100 determines in S313 that the battery pack is device-dependent (S313: YES), the charging device 100 of the preferred embodiment skips the determination in S314 and begins charging the battery pack at a constant current/voltage according to a common charging method for charging lithium-ion batteries in S323. According to this charging method, the charging device 100 charges the battery pack through constant current control from the initial stage of charging, and subsequently switches to constant voltage control when the battery voltage reaches a prescribed value. Here, the battery voltage rises during the charging process, and the electric current decreases after the charging operation enters constant voltage control. When the current drops below the prescribed value a (S319: YES), the charging device 100 determines that the device-dependent battery pack is fully charged and performs the process from step S320 described above.
As described above, the charging device according to the preferred embodiment determines whether the battery pack connected to the charging device is a device-dependent battery pack of an autonomous battery pack. When the charging device determines that the battery pack is autonomous battery pack, the charging device can suitably infer the state of the battery, even though internal data for the battery pack is not conveyed to the charging device, and can set appropriate charging conditions based on the results of this inference, such as whether to drive the cooling fan. The process described in S314 and S316 of the preferred embodiment serves to infer the internal state of an autonomous battery pack.
While the invention has been described in detail with reference to specific embodiments thereof, it would be apparent to those skilled in the art that many modifications and variations may be made therein without departing from the spirit of the invention, the scope of which is defined by the attached claims. For example, the process in S314 and S316 for determining whether the charging current exceeds the prescribed value a may be achieved by determining whether a charging current is being supplied. Further, the display unit 18 may be configured of an LCD for notifying the user about the charging process through text displays and the like.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-268854 | Dec 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/007239 | 12/9/2013 | WO | 00 |
