Hybrid battery charger
A hybrid battery charger is disclosed that includes a linear charger circuit for providing vehicle starting current and battery charging and a high frequency battery charging circuit that provides battery charging current. The linear charger circuit and the high frequency battery charging circuits are selectively enabled to provide vehicle starting current, maximum charging current and optimum efficiency.
1. A hybrid battery charger comprising:
a housing;
a set of output terminals configured to electrically couple with a battery;
a linear charger circuit positioned within said housing and configured to supply a first current to the battery via said set of output terminals during a first mode of operation;
a high frequency charger circuit positioned within said housing and configured to supply a second current to the battery via said set of output terminals during a second mode of operation,
wherein the linear charger circuit is electrically connected in parallel with the high frequency charger circuit between a power source and the set of output terminals via one or more switches;
a variable frequency drive circuit positioned within said housing and configured to control a frequency of the high frequency charger circuit between 20 kHz and 100 kHz; and
a microcontroller to selectively control said linear charger circuit and said high frequency charger circuit via the one or more switches during a charging cycle of the battery,
wherein the microcontroller is configured to switch the hybrid battery charger from the first mode of operation to the second mode of operation during the charging cycle when a battery voltage of the battery measured across the set of output terminals is above a voltage threshold, and
wherein the microcontroller is configured to switch the hybrid battery charger from the second mode of operation to the first mode of operation during the charging cycle when the battery voltage is not above the voltage threshold.
2. The hybrid battery charger of claim 1 , wherein the variable frequency drive circuit is configured to control the frequency as a function of a load current at the set of output terminals.
3. The hybrid battery charger of claim 2 , wherein the variable frequency drive circuit is configured to increase the frequency as the load current at the set of output terminals increases.
4. The hybrid battery charger of claim 1 , wherein the high frequency charger circuit and the linear charger circuit supply the first current and the second current to the battery simultaneously via said set of output terminals during a third mode of operation.
5. The hybrid battery charger of claim 1 , wherein the first mode of operation is either an engine-starting mode of operation or a charging mode of operation, and the second mode of operation is a maintenance mode of operation.
6. The hybrid battery charger of claim 1 , wherein said high frequency charger circuit includes a flyback transformer to provide power to said microcontroller during a low voltage condition.
7. The hybrid battery charger of claim 1 , wherein the high frequency charger circuit and the linear charger circuit supply the first current and the second current to the battery simultaneously via said set of output terminals when a desired charging current exceeds a maximum limit of the first current.
8. The hybrid battery charger of claim 1 , wherein the one or more switches comprises a first switch operatively coupled to said microcontroller to selectively couple said linear charger circuit to the power source.
9. The hybrid battery charger of claim 8 , wherein the one or more switches further comprises a second switch operatively coupled to said microcontroller to selectively couple said high frequency charger circuit to said set of output terminals.
10. The hybrid battery charger of claim 1 , wherein the variable frequency drive circuit is configured to skip one or more switching cycles when a load current at the set of output terminals is (i) zero or (ii) not detected.
11. The hybrid battery charger of claim 8 , wherein the microcontroller opens said first switch when said linear charger circuit is not charging the battery, thereby prohibiting supply of power from the power source to the linear charger circuit.
12. The hybrid battery charger of claim 1 , wherein the microcontroller is configured to enter a sleep mode during a maintenance mode of operation.
13. The hybrid battery charger of claim 12 , wherein the high frequency charger circuit is configured to regulate its output voltage to a predetermined maintenance voltage in response to an analog signal.
14. The hybrid battery charger of claim 12 , wherein the microcontroller is configured to exit the sleep mode when the battery is disconnected from the set of output terminals.
15. The hybrid battery charger of claim 1 , wherein said high frequency charger circuit includes a flyback transformer and said microcontroller includes a set of bias windings on a primary and a secondary of said transformer configured to provide power to a pulse-width modulation (PWM) controller and the microcontroller during a low voltage condition.
16. A hybrid battery charger for charging a battery, the hybrid battery charger comprising:
a housing having a display device positioned thereon, wherein the display device is configured to indicate a status of the battery;
a set of output terminals configured to electrically couple with the battery;
a linear charger circuit positioned within said housing to supply a first current to the battery via said set of output terminals during a charging mode of operation;
a high frequency charger circuit positioned within said housing to supply a second current to the battery via said set of output terminals during a maintenance mode of operation, wherein said high frequency charger circuit includes a flyback transformer, wherein the linear charger circuit is electrically connected in parallel with the high frequency charger circuit between a power source and the set of output terminals via one or more switches; and
a microcontroller to selectively control said linear charger circuit and said high frequency charger circuit in accordance with said charging mode of operation or said maintenance mode of operation during a charging cycle;
wherein the microcontroller is configured to switch the hybrid battery charger from the charging mode of operation to the maintenance mode of operation via the one or more switches during the charging cycle of the battery when a battery voltage of the battery measured across the set of output terminals is above a voltage threshold, and
wherein the microcontroller is configured to enter a sleep mode during a maintenance mode of operation and to exit the sleep mode when the battery is disconnected from the set of output terminals.
17. The hybrid battery charger of claim 16 , further comprising a variable frequency drive circuit positioned within said housing and configured to control a frequency of the high frequency charger circuit.
18. The hybrid battery charger of claim 16 , wherein the microcontroller is configured to control the high frequency charger circuit and the linear charger circuit to supply the first current and the second current to the battery simultaneously via said set of output terminals.
19. The hybrid battery charger of claim 16 , wherein the display device is configured to indicate a charge percentage of the battery.
20. A hybrid battery charger comprising:
a housing;
a set of output terminals configured to electrically couple with a battery;
a linear charger circuit positioned within said housing and configured to supply a first current to the battery via said set of output terminals during a first mode of operation;
a high frequency charger circuit positioned within said housing and configured to supply a second current to the battery via said set of output terminals during a second mode of operation,
wherein the linear charger circuit is electrically connected in parallel with the high frequency charger circuit between a power source and the set of output terminals via one or more switches;
a variable frequency drive circuit positioned within said housing and configured to control a frequency of the high frequency charger circuit; and
a microcontroller to selectively control said linear charger circuit and said high frequency charger circuit via the one or more switches during a charging cycle of the battery,
wherein the one or more switches comprises a first switch configured to electrically couple said linear charger circuit to the power source and a second switch configured to electrically couple said high frequency charger circuit to said set of output terminal, and
wherein the microcontroller is configured to switch the hybrid battery charger from the first mode of operation to the second mode of operation during the charging cycle when a charging current into the battery drops below a current threshold.
21. A hybrid battery charger comprising:
a housing;
a set of output terminals configured to electrically couple with a battery;
a linear charger circuit positioned within said housing and configured to supply a first current to the battery via said set of output terminals during a first mode of operation;
a high frequency charger circuit positioned within said housing and configured to supply a second current to the battery via said set of output terminals during a second mode of operation,
wherein the linear charger circuit is electrically connected in parallel with the high frequency charger circuit between a power source and the set of output terminals via one or more switches;
a variable frequency drive circuit positioned within said housing and configured to control the high frequency charger circuit at a frequency that is greater than 20 kHz, wherein the variable frequency drive circuit is configured to skip one or more switching cycles when a load current at the set of output terminals is (i) zero or (ii) not detected; and
a microcontroller to selectively control said linear charger circuit and said high frequency charger circuit via the one or more switches during a charging cycle of the battery,
wherein the microcontroller is configured to switch the hybrid battery charger from the first mode of operation to the second mode of operation during the charging cycle when a battery voltage of the battery measured across the set of output terminals is above a voltage threshold.