Universal battery charger apparatus

[0002] The invention herein is related to my own vehicular battery charger U.S. Pat. No. 4,449,089 issued May 15, 1984 to Winkler, as well as to my own vehicular arc welder U.S. Pat. No. 4,705,934 issued Nov. 10, 1987 to Winkler. This present invention can take the place of my own prior art battery charger U.S. Pat. No. 4,449,089 and can be used with my arc welder prior art U.S. Pat. No. 4,705,934.

[0003] 1. Field of the Invention

[0004] This invention relates generally to a universal battery charger apparatus.

[0005] A. Provides a wide range of current limiting abilities.

[0006] B. Capable of charging a wide range of different voltage batteries.

[0007] C. Provides a 115 volt DC power supply.

[0008] D. Provides a DC arc welding system.

[0009] 2. Description of Prior Art

[0010] In general there are a good number of different battery chargers that use part of a vehicle's electrical system and add a switching system that pulls away from maintaining that vehicle's battery system, using said vehicle's alternator to charge external batteries and/or for arc welding. One such battery charger is in U.S. Pat. No. 4,449,089 issued May 15, 1984 to Winkler. In said patent, I used a potentiometer to get the different controlled output voltage levels for charging batteries. The problems with using a potentiometer is after it was used for awhile, said potentiometer would have blank spots and would break contact, causing the output voltage to go wild. Life of said potentiometer was on the short side. Also, I found said potentiometer was on the inconvenient side for adjusting for different output voltages. There are a good number of 115 volt AC and/or 230 volt AC generators on the market. I am not referring to the large ones, as their engines go as low as 2.5 HP and up. They are self-contained and portable. In general they produce AC power with quite limiting 12 volt battery charging abilities. There are a number of DC arc welders with a 115 volt power supply on the market, but, as far as I know they are not designed for charging external batteries. They are self-contained and portable, but they are big, bulky and heavy. There are also some battery powered arc welders, one such arc welder is in U.S. Pat. No. 5,250,786 issued Oct. 5, 1993 to Kiknchi, Tanuma and Suzuki of Japan. Said patent appears to have no battery charging ability other than its own 36 volt battery system.

[0011] For the summary of the invention see the Block Diagram in FIG. 1. It is an object of this invention to provide a universal battery charger apparatus, powered by a small gas engine in the range of 5 HP low and up to 10 HP high. Said engine to be equipped with a small 12 volt alternator with at least a 4 AMP output rating. Said alternator to be used with a regulator to maintain a small 12 volt battery, as well as supplying voltage to the input of the circuit of said battery charger. A standard vehicle's alternator is used, its field is powered and controlled by the circuit of said battery charger.

[0012] It is another object of this invention to provide a battery charger capable of producing a wide range of different controlled voltages for charging batteries.

[0013] It is still another object of this invention to provide a wide range of current limiting abilities independent of the voltage sensor.

[0014] It is another object of this invention to provide a battery charger capable of light duty arc welding, as well as combining its output energy at the workload in arc welding with a battery powered arc welder, as in prior art U.S. Pat. No. 4,705,934 issued Nov. 10, 1987 to Winkler, when said battery powered arc welder has no arc, its 36 volt battery system automatically recharges from said battery charger.

[0015] It is still another object of this invention to provide a 115 volt DC power supply, with no fuse nor circuit breaker needed in the output.

[0016] It is another object of this invention to provide a cold weather starting aid for motors with a 12 or 24 volt battery system; 1. by keeping the batteries charged; 2. When the starter of said motor engages, the battery charger will produce full output power up to the current limit setting, thus boosting the starting ability of the equipment or vehicle's motor; 3. Also, said charger can power block heaters.

[0017] It is a further object of this invention is to get away from the problems in prior art, for example, a battery charger, an arc welder, and/or a DC power supply being installed in a vehicle and in some cases, a second alternator is also installed, thus making their system portable. When said vehicle is tied up with repair work being done, or far worse yet, people trade off said vehicle. Keep in mind older vehicles had reasonable room under their hood and elsewhere for installing different equipment. As years have gone by, less space is left available for installing any added equipment in newer vehicles.

[0018] My invention solves the above problems in prior art by keeping the apparatus self-contained, light weight and portable. Battery powered arc welders can also be self-contained and portable.

[0019] FIG. 1 shows a Block Diagram of the method used in the universal battery charger apparatus.

[0020] FIG. 2 shows the circuit used in the universal battery charger apparatus. In said circuit, the lines - - - - - connects the Heavy Lead #49 to the Output+Terminal of the alternator.

[0021] An explanation of the universal battery charger's circuit is based with a 12 volt battery #36 installed, with the 12 volt+power switch #39 turned ON. A diode #38 is wired across one end of a fuse #37 and to the ground. Said diode is poled to blow said fuse in the event of reverse polarity. As seen in FIG. 2, transistors #2,3,4 and 6 are PNP type, with their emitters connected to the 12 volt+lead #40. Transistors #1,5,7,8 and 9 are NPN type, with their emitters connected to ground. As seen in FIG. 2, the collectors of both power transistors are connected to the field terminal of the alternator #34. Said output power transistors #3 and #4 are a matched pair and are wired to produce full output voltage to said field of said alternator #34 until said transistors receive a different command from either the voltage sensor or the current limiter. A resistor #31 with one end connected to ground, the other end connected to the bases of said power transistors #3 and #4, thus making a negative bias for said power transistors. Two diodes #32 and #33 with anode ends connected to ground and cathodes connected to the collector's of said power transistors #3 and #4. Said diodes are used to protect said power transistors from inductive spikes caused by the field windings of said alternator #34.

[0022] A voltage divider network is used to control said alternator's output voltage and I feel the way the voltage is divided in said voltage divider network it needs no explanation to a person skilled in the field. A resistor #25 is connected across the output of said voltage divider network and to ground, Lead #43 is connected from said voltage divider network output in series with a resistor #26, a zener diode #27, with anode connected to the base of transistor #1 and to ground. A resistor #30 is connected from the collector of said transistor #1 to the base of a regulator transistor #2. A resistor #29 is connected from said collector of said transistor #1 to the emitter of said transistor #2.

[0023] Going back to the voltage divider network, when the output voltage rises to a significant voltage level, said Zener diode #27 will break down, passing the voltage on to the base of said transistor #1. When a significant voltage level is reached, said Transistor #1 will switch on, thus creating a negative bias at the base of said regulator transistor #2 and when a significant voltage level is reached, said transistor #2 will switch ON, thus creating a positive voltage at the bases of the power transistors #3 and #4. When a significant voltage level is reached said power transistors will switch OFF, thus cutting off the alternator's #34 field voltage. By using said voltage divider network and a Zener diode, the universal battery charger's circuit works to maintain the voltage level that said selector switches are set for, by switching the output voltage OFF and On. With this switching action, the two output power transistors #3 and #4 operate more cool because they are more fully ON and OFF. Also, their total power producing ability is increased. By using said two PNP type (matched pair) power transistors, the output voltage to said field of said alternator will be very close to the supply voltage when working at maximum power.

[0024] Again, going back to the voltage divider network, a 12-position rotary switch #45 shorting type is used as a selector switch for different voltages. For example, 6, 12, 18, 24, 30, 32, 36, 36, 42 and 48 volts, all with a 0.4 volt per cell built-in charge level for battery charging. Also, said voltage selector switch #45 has one setting for a 115 volt DC power supply. Eleven resistors are wired across eleven of the terminals of said switch #45, leaving one said switch terminal blank allowing for a twelfth resistor to be added at a later date for a special voltage. In the meantime, when said selector switch #45 is in the twelfth position, said alternator will operate on (uncontrolled) full output voltage without said twelfth resistor.

[0025] A 12-position rotary switch #46 shorting type is used as a selector switch for a fine tuner for subtracting from the output voltage up to 2.5 volts, or adding to the output voltage up to 3 volts in ½ volt jumps. Twelve resistors are wired across the terminals of said fine tuner switch #46 in said voltage divider network.

[0026] As seen in FIG. 2, a jumper wire #44 connects said eleven resistors to said twelve resistors in said voltage divider network. I feel the voltage divider network needs no explanation on the resistors values in ohms.

[0027] As seen in FIG. 2, a 12-position rotary switch #57 shorting type is used as a selector switch for current limiting controls, for example, 10, 15, 20, 30, 40, 50, 60, 70, 75, 80, 90 and 100 amps. Twelve resistors are wired across the terminals of said selector switch #57. Said resistors work as a multiplier, for example, if the alternator's output heavy lead #49 has 10 amps current going through it and a voltage drop of 5 millivolts, said 5 millivolts (if multiplied by 250) the output would be 1.25 volts. Another example, if said alternator's output heavy lead #49 has 50 amps current going through it, the voltage drop would be 25 millivolts (if multiplied by 50) the output would be 1.25 volts, assuming the current limit control point is 1.25 volts.

[0028] An explanation how the current limit works, said alternator's output heavy lead #49 (having a small voltage drop within it) which has both a positive and a negative voltage. Said negative voltage is connected to a lead #52 and on through a resistor #58 to terminal 2 of said op-amp #59. Said positive voltage goes to terminal 3 of said op-amp #59.

[0029] As seen in FIG. 2, said op-amp is powered by the output of a 12 volt DC-DC isolated converter #62. The 12 volt+output terminal of said converter #62 is connected to terminal 7 of said op-amp #59. The 0-volt output terminal of said converter #62) is connected to terminal 4 of said op-amp #59. Also, terminal 4 of said op-amp #59 is connected to the center terminal of a potentiometer #60. One end of said potentiometer #60 is connected to terminal 1 of said op-amp #59, the opposite end of said potentiometer #60 is connected to terminal 5 of said op-amp #59. Said potentiometer is used to adjust the output of terminal 6 of said op-amp to zero volts at the time the unit is produced. A resistor #64 is connected in series from terminal 6 of said op-amp #59 to anode terminal of the input of a photo transistor #63. Two resistors #65 and #66 are connected in series across the output terminals of said converter #62, thus making a split-voltage supply. The output+terminal of said alternator #34 is connected to lead #54.

[0030] Also, said lead #54 is connected to terminal 3 of said op-amp #59, said lead #54 is connected in between said two resistors #65 and #66, said lead #54 is connected to cathode terminal of the input of said photo transistor #63. One end of a heavy lead #49 is connected to the output+terminal of said alternator #34, the other end of said heavy lead #49 is connected to a taper lock jack #50. Note, the heavy lead #49 is designed to drop 50 millivolts with a 100-amp load on said lead #49.

[0031] A shunt type DC amp-meter can be wired across said lead #49, thus cutting costs by eliminating the need for a 50 millivolt shunt. A second taper lock jack #53 is connected to ground. The output of terminal 6 of said op-amp #59 has a feedback line #61 that the energy goes through one of the 12 current limit resistors and on to terminal 2 of said op-amp #59, thus making available 12 different current limit settings on the current limit selector switch #57. One end of said 12 resistors are wired together on said selector switch #57 and connected to terminal 2 of said op-amp #59. The other end of said 12 resistors on said selector switch selects one resistor at a time for 12 different current levels. As seen in FIG. 2, all current limiting controls up to and including the input terminals of said photo transistor #63 are isolated from the battery charger circuit's ground. From the output of said photo transistor #63 everything goes back to the battery charger circuit's ground. A resistor #70 is connected from the collector of transistor #6 and to the ground. A resistor #69 is connected from the base of said transistor #6 and to the emitter of said transistor #6. A resistor #67 connects across the emitter of said photo transistor #63 and to the ground. When the input of said photo transistor #63 receives a significant voltage from said current limiter, said photo transistor will switch ON passing the energy on through a resistor #68 and to the base of transistor #5. When a significant voltage level is reached said transistor #5 will switch ON, thus creating a negative voltage at the base of said transistor #6, when a significant voltage level is reached said transistor #6 will switch ON, thus creating a positive voltage which is passed on through a resistor #71, in series to the base of transistor #7, when a significant voltage level is reached said transistor #7 will switch ON, thus creating a negative voltage that is passed on through a resistor #72, in series to the base of said regulator transistor #2, when a significant voltage level is reached said transistor #2 will switch ON, thus creating a positive voltage at the bases of said power transistors #3 and #4, when a significant voltage level is reached said power transistors will switch OFF, thus cutting off the field voltage of said alternator #34. Said current limiter works not to exceed the current limit that said selector switch #57 is set for by the continuous OFF/ON switching action in the circuit of the universal battery charger.

[0032] As seen in FIG. 2, said regulator transistor #2 is controlled by either the voltage sensor or the current limiter. Thus, in a sense said current limiter operates independently of the voltage sensor. For example, if you were using the 115 volt DC power supply, the current limit is set at 15 amps and you put a 20 amp load on said power supply, said battery charger's circuit would cut down the alternator's output volts to the point where 15 amps is consumed. Thus, neither a circuit breaker nor a fuse is needed in said charger's output. Also, on said power supply, you can dead short the alternator's output and the field voltage drops down to 2.2 volts on the 10 amp setting, or 2.7 volts on the 15 amp setting.

[0033] Going back to the voltage selector switch #45, a voltage sensor lead #55 is connected to the input of said voltage selector switch #45, to the center terminal of the first relay #56. As seen in FIG. 2, when said selector switch #45 is set for (Batt. 36v. Weld), voltage from said selector switch #45 is to lead #48, in series through a resistor #74, a Zener diode #75, to the base of transistor #8 NPN. The collector of said transistor #8 is connected to one end of a first relay's #56 coil, the other end of said coil is connected to the 12 volt+lead #40, thus switching said first relay ON, thus changing the voltage sensor from said alternator's #34 output+terminal over to the +terminal of a 36 volt battery system of a battery powered arc welder. Said selector switch setting (Batt. 36V. weld) is used in some battery powered arc welders, however, other battery powered arc welders would use the regular 24 or 36 volt setting on said voltage selector switch. I am not claiming a battery powered arc welder, nor an improvement to a battery powered arc welder, so none is shown in the drawings.

[0034] I am claiming a universal battery charger apparatus that can be used with some of the battery powered arc welders. Two single conductor taper lock jacks are used for taking the energy from the output of the universal battery charger's alternator 434, for either battery charging and/or arc welding. Said first taper lock #50 is connected to the far end of the heavy lead #49 from said alternator's #34 output+terminal. Said second taper lock jack #53 is connected to ground. Two taper lock jacks means for transferring electrical energy from said first and said second taper lock jacks #50 and #53 to the workload in arc welding. Means electrically connecting in parallel said universal battery charger's arc welder with a battery powered arc welder at said workload in arc welding. Said battery charger's arc welder provides a first portion of energy at said workload in welding and said battery powered arc welder provides a second portion of energy at said workload in welding. Said battery charger provides a charging means for said battery powered arc welder's batteries during time when an arc is not generated. Also, said battery charger;s arc welder can be used direct for light duty arc welding by selecting the desired voltage and current.

[0035] As seen in FIG. 2, when the voltage selector switch #45 is set for (115 V. DC power), voltage from said selector switch #45 is connected to lead #47 in series through a resistor #77, a Zener diode #78, to the base of transistor #9 NPN. The collector of said transistor #9 is connected to one end of the second relay's #80 coil, the other end of said coil is connected to the 12 volt+lead #40, thus switching said second relay #80 ON. Said second relay is used for coupling two electrolytic capacitors to the alternator for doubling the output voltage, as well as filtering the output voltage.

[0036] As seen in FIG. 2, the positive end of the first capacitor #81 is connected in series through a first set of points of said second relay #80, onto the output+terminal of said alternator #34. The positive end of the second capacitor #82 is connected in series through a second set of points of said second relay #80, onto the negative end of said first capacitor #81 and onto the stator terminal of said alternator #34. The negative end of said second capacitor #82 is connected to ground. A receptacle #51 has three terminals. The positive terminal is connected to said first taper lock jack #50, the remaining two negative terminals are connected to ground. Said receptacle is used for taking the 115 volt DC power from the universal battery charger.

[0037] A pilot light #41 is connected to the OFF/ON switch #39 and ground. A 15 volt-meter #35 is connected to the field terminal of said alternator #34 and to ground. A 0-199.9 digital volt-meter #73 is connected to the output+terminal of said alternator #34 and to ground. A 0-100 amp-meter #42 is connected from the output+terminal of said alternator #34 to first taper lock jack #50.

[0038] Said pilot light, said 15 volt-meter, said 0-199.9 digital volt-meter and said 0-100 amp-meter are used as a guide for the operator. It will be understood that said amp-meter may go to a higher amp rating. Also, the 100 amp alternator may go to a higher output rating. Note, the two zener diodes #75 and #78 are used to prevent the first and second relay from switching until a higher voltage is selected. Both diodes #76 and #79 are connected, one each across said first and second relay's coils, protecting the two switching transistors #8 and #9 from the inductive spikes. A resistor #28 is connected between said base of transistor #1 and ground. Said 12 volt+lead #40 connects to the input+terminal of said converter #62. The input negative terminal of said converter #62 is connected to ground. Said 12 volt+lead #40 connects to the collector of said photo transistor #63.

[0039] I've built a test model of the universal battery charger apparatus using the same system as seen in FIG. 1, as well as said charger's circuit, as seen in FIG. 2. I used a Honda 5.5 gas engine with a built-in 100 watt 12 volt alternator. An individual regulator and rectifier system are used for controlling said alternator's output volts. I used a sealed lead-acid 12 volt battery, 5 lb. weight.

[0040] I used a large case alternator for Ford, a 90 amp, as well as a 100 amp alternator. Both work good. In order to produce the 115 volt DC power supply, I had to add a voltage doubler to the alternator. Also, I had to increase said alternator's RPM to 4500 to produce the 15 amp's current for said power supply. Said Honda engine runs at 36 RPM, full throttle (standard). I increased the drive ratio by 25% to get the 4500 RPM.

[0041] Tests have shown it is very important to have a good current limiter to prevent overloading a small engine. A 5.5 HP engine driving an alternator will produce 1700 to 1800 watts without overloading said engine. Naturally, as the engine's horse-power is increased, so is the watts rating. When working within any given voltage range, you can calculate where to set the current limit to avoid overloading said engine.

[0042] Various changes may be made in the details of construction without departing from the spirit and scope of my invention as defined by the appended claims.