System and method for charging autonomously powered devices using variable power source
10483790 ยท 2019-11-19
Inventors
Cpc classification
Y02B20/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F21S9/043
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B47/11
ELECTRICITY
Y02E10/76
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02J7/00
ELECTRICITY
F21S9/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S8/086
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02J2300/40
ELECTRICITY
H02J7/00712
ELECTRICITY
International classification
H02J7/00
ELECTRICITY
Abstract
A solar or self-powered assembly includes a rechargeable battery and photo voltaic panel and/or wind turbine for supplying a battery charging current. A charge controller processor is controls charging current from the photovoltaic panel and/or wind turbine to maintain the battery in a substantially fully charged state of 80% or more state of charge over daily charge and discharge cycle charging is based on a projected target energy input based on the initial bulk energy charge, the level of discharge required to compensate for charging inefficiencies and the battery capacity factor representative of the projected natural charge in the battery over its lifespan.
Claims
1. A solar light or other autonomously powered device assembly comprising: solar light pole and/or other load bearing device including, a rechargeable battery, a light and/or load electrically connected to said battery, photovoltaic panel for supplying a charging current to said battery, and a charge controller operable to sense a level of a depth of discharge (DOD) and/or a state of charge (SOC) of said battery and regulate or control a flow of charging current from the photovoltaic panel to the battery, a processing assembly communicating with said charge controller and operable to receive input signals representative of said sensed level of DOD and/or SOC, and to output in response thereto controller control signals for controlling the flow of said charging current, the processing assembly including memory and program instructions, wherein, the memory periodically receiving initial input values representative of an estimated initial battery capacity factor F.sub.B[T] for said battery, and a preselected battery target voltage V.sub.AB[T] at a selected operating temperature (T.sub.OP), wherein as part of a daily charging and discharge cycle the program instructions being operable whereby, during an initial charge period: A. receiving into said memory an initial bulk energy charge (AH.sub.bulk) representative of cumulative charging current over time required to charge said battery to said preselected battery target voltage (V.sub.AB)[T]; B. calculate a target energy input (AH.sub.projected) selected as a projected required amperage per period of time for said battery to achieve a substantially 100% state of charge, wherein said target energy input (AH.sub.projected) is determined by the formula:
(AH.sub.project)=(AH.sub.bulk)(KF.sub.B[T]O.sub.c %1) wherein K is a constant selected at between about 1 and 2, F.sub.B[T] is selected at between 40% to 100%; and O.sub.c is a maximum overcharge capacity value selected at between 100% and 120%; C. following the initial charging period, the processing assembly outputting control signals to said charge controller to effect a second stage charging period and regulate the flow of said charging current into said battery as a first intermittent current flow, the first intermittent current flow characterized by sequential current charging periods selected to substantially maintain said battery at said preselected battery target voltage (V.sub.AB)[T] calculating and inputting into said memory an absorption energy charge (AH.sub.Ab) representative of cumulative charging energy into said battery; D. when the cumulative charging energy (AH.sub.Ab) equals the target energy input (AH.sub.projected), outputting control signals to said charge controller to regulate the flow of charging current to said battery as a second intermittent current flow, the second intermittent current characterized by sequential current charging periods selected to maintain said charge to said battery at a target voltage (V.sub.float) selected to substantially maintain the battery at a substantially 100% state of charge.
2. The assembly as claimed in claim 1, wherein the charging current comprises a variable current ranging between about 0 up to 30 amperes.
3. The assembly as claimed in claim 1, wherein the rechargeable battery comprises deep cycle lead acid battery comprising a plurality of cells.
4. The assembly as claimed in claim 1, wherein the estimated initial battery capacity factor is selected at from 50% to 100%.
5. The assembly as claimed in claim 1, wherein the preselected target battery voltage (V.sub.AB) is selected in the range of about 2.0 to 2.7.
6. The assembly as claimed in claim 1, wherein the first intermittent current flow comprises a pulsed current flow having charging pulse width frequency selected at between about 1 second and 10 seconds.
7. The assembly as claimed in claim 1, wherein during said second stage charging, the processing assembly dynamically selecting an adjusted battery target voltage (V.sub.AB[T]) per battery cell as a temperature compensated voltage in accordance with the formula:
V.sub.AB[T]=V.sub.ABS.sub.n+(C.sub.F).sub.1S.sub.n(T.sub.1T.sub.OP) where (C.sub.F).sub.1 is a compensating factor selected at between 0.001 to 0.01 where S.sub.n represent the number of cells in said battery.
8. The assembly as claimed in claim 1, wherein during charging of said battery with said second intermittent current, substantially outputting to said memory data representative of said battery voltage, temperature, and accumulated AH.
9. The assembly as claimed in claim 1, wherein during said first intermittent current flow, on detecting said pulsed current frequency being less than about 2 seconds, measuring minimum and maximum battery voltages, and outputting control signals indicative of a substantially 100% battery charge condition.
10. The assembly as claimed in claim 1, wherein the initial battery capacity factor (F.sub.B) is calculated in a direct linear relation to at least one of an age of the battery and a charging/discharge frequency of said battery.
11. The assembly as claimed in claim 10, wherein the battery capacity factor (F.sub.B) further is calculated on a historical discharge and recharge performance of said battery.
12. The assembly as claimed in claim 1, wherein said light pole and/or other load hearing device is disposed in a geographic location remote from said processing assembly, said light pole and/or other load bearing device further comprising a data transmission assembly electronically communicating with said charge controller, the data transmission assembly being operable to transmit said input signals to said processing assembly and for receiving said controller control signals therefrom.
13. The assembly as claimed in claim 12, wherein said data transmission assembly comprises a wireless transmission assembly.
14. The assembly as claimed in claim 4, wherein the light pole and/or other load bearing device further comprises a temperature sensor for sensing an approximate temperature of said battery, said data transmission assembly being operable to transmit data representative or said sensed temperature to said processing assembly.
15. An autonomously powered load or light assembly comprising: a plurality of loads and/or light poles disposed in an array at first geographic locations, each said load or light pole including, a rechargeable battery, a solar light or other load electrically communicating with said battery, a power generator including at least one of a photovoltaic cell and a wind turbine for supplying a charging current to said battery, said charging current comprising a variable current ranging between 0 and 30 amperes, a charge controller operable to sense a level of a depth of discharge (DOD) and/or state of charge (SOC) of said battery and regulate or control a flow of charging current from the power generator to the battery, a processing assembly communicating with said charge controller and operable to receive input signals representative of said sensed level of DOD and/or SOC, and to output in response thereto controller control signals for controlling the flow of said charging current, the processing assembly including memory and program instructions and wherein, the memory receiving initial input values representative of an estimated initial battery capacity factor F.sub.B for said battery, and a preselected battery target voltage V.sub.AB at a selected operating temperature (T.sub.OP), during a charge period, the processing assembly operable to: A. calculate an initial bulk energy charge (AH.sub.bulk) representative of cumulative charging current over time required to charge said battery to said preselected battery target voltage (V.sub.AB)[T]; B. calculate a target energy input (AH.sub.projected) selected as a projected required amperage per period of time for said battery to achieve a substantially 100% state of charge, wherein said target energy input (AH.sub.projected) is determined by the formula:
(AH.sub.projected)=(AH.sub.bulk)(KF.sub.B[T]O.sub.c %1) wherein K is a constant selected at between about 1 and 2, F.sub.B[T] is selected at between 40% to 100%, and O.sub.c is a maximum overcharge capacity value selected at between 100% and 120%; C. following the initial charging period, the processing assembly outputting control signals to said charge controller to effect a second stage charging period and regulate the flow of said charging current into said battery as a first intermittent current flow, the first intermittent current flow characterized by sequential current charging periods selected to substantially maintain said battery at said preselected battery target voltage (V.sub.AB)[T]calculating and inputting into said memory an absorption energy charge (AH.sub.ab) representative of cumulative charging energy into said battery.
16. The assembly as claimed in claim 15, wherein when the cumulative charging energy (AH.sub.Ab) equals the target energy input (AH.sub.projected), the processing assembly outputting control signals to said charge controller to regulate the flow of charging current to said battery as a second intermittent current flow, the second intermittent current characterized by sequential current charging periods selected to maintain said charge to said battery at a target float voltage (V.sub.float) selected to substantially maintain the battery at a substantially 100% state of charge.
17. The assembly as claimed in claim 15, wherein K is selected at between about 1.2 and 1.7.
18. The assembly as claimed in claim 15, wherein if during the initial charge period, AH.sub.projected is not reached, during said discharge period the processing assembly sending control signals to said load or light pole to activate said light or other load, and wherein the charge controller being operable to deactivate the light or other load on sensing a predetermined threshold maximum level of battery depth of discharge.
19. The assembly as claimed in claim 15, wherein following said second stage charging, the control processing unit being operable to send control signals to the charge controller to effect monitoring of battery amp-hour discharge (AH.sub.discharge) up to a next said initial charging period.
20. The assembly as claimed in claim 15, wherein the charge controller being operable to output to the processing assembly, the total said amp-hour discharge (AH.sub.discharge), the processing assembly operable to calculate a next total energy input (AH.sub.projected-next) in accordance with:
AH.sub.projected-next=AH.sub.dischargeO.sub.c %AH.sub.bulk.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Reference may now be had to the following detailed description, taken together with accompanying drawings in which:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
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(12) As will be described, the CPU 14 is provided with memory together with software and/or stored program instructions for receiving operational data signals from and providing control signals to the light pole array 12 and/or data storage repository 16. The light pole array 12 is typically located in a geographic location which is remote from, and which for example may be several kilometers to several thousand kilometers away from the central processing unit 14. The light pole array 12, central processing unit 14 and data storage repository 16 are provided in electronic communication with each other, and most preferably electronically communicating by one or more of the Internet, cellular WiFi, or other ZigBee communication networks 18.
(13) In the embodiment shown, the light pole array 12 is illustrated as consisting of a number of autonomously powered light poles 20. The light poles 20 forming each array 12 may optionally include at least one telecommunications aggregator pole, together with a number of conventional poles.
(14) The column 22 is used to mount above the ground, at least one LED light 30 as an electric load, as well as a low current (typically less than 100 amps) power generation assembly 34 which is used to generate and supply charging electric current to the battery 28. In one preferred construction, the power generation assembly 34 preferably includes both at least one solar or photovoltaic panel 36, and a top mounted wind turbine generator 38. In a conventional light pole application, the power generation assembly 34 is configured to output a maximum peak charging current of approximately 10 to 40 amps, preferably 15 to 30 amps, and most preferably 20 amps, with a minimum duration of 1 second. It is to be appreciated that because of the variable nature of input solar and wind energy, in use, the power generation assembly 34 will typically generate and output charging electric current as a variable current supply.
(15) The battery 28 is configured to receive and store charging electric current which is generated by the power generation assembly 34, and supplies a discharge electric current to the LED lights 30a,30b.
(16) At least one charge controller 40 is provided in either direct electrical communication with the battery 28, or in the case where the battery 28 has an internal battery management system wired or wireless communication. As will be described, the charge controller 40 is operable to sense the level of the depth of electric discharge (DOD) and/or the state of electric charge (SOC) of the battery 28, and further to regulate the flow of charging current from the power generation assembly 34 to the battery 28.
(17) It is to be appreciated, that given the variable nature of input household solar and/or wind energy operating, the power generation assembly 34 typically outputs a charging current to the battery 28 as a variable current. In particular, as a result of changing wind speeds and solar cover, charging current output by the power generation assembly 34 may vary over time ranging from 0 to 30 amps, depending on cloud cover and wind speed. Reference may be had to
(18) Optionally, a battery temperature sensor 44 may be housed within the interior battery storage compartment 26, and which is operable to provide data as to the temperature of the battery 28 and/or compartment 26, and as well ambient temperature.
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(20) Most preferably, the data transmission assembly 48 further continuously receives from the battery temperature sensor 44 data indicating the ongoing temperature of the battery 28 and/or compartment 26. The data transmission assembly 48 most preferably substantially continuously or periodically transmits temperature as well as DOD and/or SOC signals to the CPU 14 for input and/or storage in memory.
(21) Reference may be had to
(22) In operation of the system 10, initial input baseline values are stored in the CPU memory which are representative of a selected individual light pole battery 28 parameters. Initial input baseline values most preferably include an initial battery capacity factor (F.sub.B) for the selected light pole battery 28. The estimated initial battery factor F.sub.B is selected as a value ranging from 50% and 120%, wherein a lowest value of 50% represents a battery chosen as of about the end of its projected working lifespan, with a value of 100% representing a newly installed battery 28 with an anticipated 100% storage capacity. In one simplified calculation, the initial battery capacity factor (F.sub.B) is selected as a value in direct linear relationship to the age of the battery having regard to a manufacture's warranted or projected battery lifespan at a target operating temperature. More preferably, a historically observed battery capacity factor (F.sub.B) is determined based on the historical temperature, discharge and/or recharge performance of the specific or similar batteries at a particular geographic location.
(23) In addition to the estimated initial battery capacity factor (F.sub.B) a preselected battery target voltage (V.sub.AB), at a given operating temperature (T.sub.OP) is further input into memory. The battery target voltage (V.sub.AB) is typically chosen as the manufacturer recommended charging voltage for the individual battery 28, and which is selected to optimize battery performance. It is envisioned that periodically, users update the input baseline values, as for example, to provide a revised battery capacity factor (F.sub.B) which reflects battery wear and/or usage, and/or to provide an updated battery target voltage (V.sub.AB) following battery replacement. Typically, updates to the baseline input values would be effected on a monthly or yearly basis. In a preferred embodiment, updates to such values could be automated by the CPU 14 on a preset time schedule basis.
(24) During daily charging operation of light pole array 12, with the battery 28 installed, an initial battery charging period (100) is undertaken. Typically, primary initial charging occurs with sunrise wherein the CPU 14 is operated to input into memory an initial bulk energy charge (AH.sub.bulk). The input initial bulk energy charge (AH.sub.bulk) is selected as representative of the cumulative charging current over time which is required to charge the battery 28 to the preselected battery target voltage (V.sub.AB).
(25) The CPU 14 next calculates a target energy input (AH.sub.projected). The target energy input (AH.sub.projected) is selected as the required charging amperage per period of time for the battery 28 to achieve a 100% state of charge, and wherein the target energy input (AH.sub.projected) is determined in accordance with the formula:
(AH.sub.projected)=(AH.sub.bulk) (KF.sub.B[T]O.sub.c %1) wherein K is a constant which is selected at between about 1 and 2, and most preferably about 1.5. F.sub.B[T] represents the originally input estimated initial battery capacity factor, and O.sub.c % selected as a maximum overcharge capacity value.
The O.sub.C % is typically selected at between 100% of total battery charging capacity (with overcharge capacity being nil) and 115% of total battery charging capacity (with overcharge capacity being +15% beyond 100% capacity).
(26) As shown in
(27) Once V.sub.BAT is found to equal [V.sub.AB]T, second stage charging commences.
(28) During second stage charging, the CPU 14 processor calculates and inputs into memory, an absorption energy charge (AH.sub.Ab), calculated as the cumulative charging energy input into the battery 28 up to the point where AH.sub.projected is reached
(29) When the calculated absorption charge (AH.sub.Ab) is further determined as equaling the target energy input (AH.sub.projected), the CPU 14 outputs further control signals to the charge controller 40 to modify the flow of charging current from the power generation assembly 34 to the battery 28 into a second intermittent current flow as shown in
(30) In one preferred embodiment, during second stage charging, the intermittent current flow is provided as a pulsed current flow having a charging pulse frequency selected at between about second and 10 seconds, and typically 1 to 5 seconds. More preferably, during second stage charging, the CPU 14 is operable to dynamically adjust the battery target voltage (V.sub.AB) to an adjusted battery target voltage (V.sub.AB)[T] as a temperature compensated voltage per battery cell in accordance with the formula:
V.sub.AB[T]=V.sub.AB+(C.sub.F).sub.1(T.sub.1T.sub.OP)
wherein C.sub.F is a compensating factor which is selected at between 0.001 to 0.1 and most preferably at about 0.004, and T.sub.1 Represents selected temperature for the initial target voltage V.sub.AB.
(31) It is to be appreciated that by reason of the variable nature of input solar and/or wind energy, during battery charging operations, it is conceivable that on overcast and/or calm days, the power generation assembly 34 may fail to provide sufficient energy input into the battery to reach either target energy input (AH.sub.projected) 100% state of charge during initial charging and/or calculated absorption charge (AH.sub.ab). In such case, at the end of the charging cycle and which typically occurs at dusk or sunset, the CPU 14 continues to provide output signals to the charge controller 40 to activate the light pole light 30 as an electric load. The charge controller 40 continues during the discharge period to sense the level of the depth of battery discharge (DOD) the charge controller 40 preferably continues to output to the CPU 14 signals representative of the state of battery charging and/or discharge, with the CPU 14 monitoring the amp-hour discharge hour (AH.sub.discharge) up until the commencement of the next charging period occurring at the next sunrise.
(32) The charge controller 40 is most preferably operable to output to the CPU 14 signals which permit the determination of the total amp-hour discharge (AH.sub.discharge). The CPU 14 may thus store the amp-hour discharge data in memory, and calculate a next required total energy input (AH.sub.projected-next) required to either replace the energy discharge from the battery discharge period, or more preferably, where AH.sub.projected or AH.sub.bulk has not been reached, the total energy input required to achieve a substantially 100% state of battery charge in accordance with the formula:
AH.sub.projected-next=AH.sub.dischargeOc %AH.sub.bulk
(33) In an alternate mode of operation, during second stage charging of the battery 28, the controller 40 is further operated to verify circuit impedance for integrity and/or degradation. Preferably the controller 40 measures the charging current and whole network voltage measured during on-charging intervals and compares the measured voltage with the battery voltage (V.sub.BAT) during off-charging intervals according to
(34)
wherein I.sub.CHARGE represents the current input into the battery 28 during the on-charging interval.
(35) The R value thus represents a connection/wire loss valve for the individual light pole 20. The R value may be then compared against preselected threshold loss values representative of one or more pre-identified fault conditions.
(36) As a further possible embodiment, the system may be operable to sense battery temperatures at discharge or other points of time as a further compensating factor for temperature dependent battery charging capacity charges.
(37) Although the detailed description describes a preferred installation 10 which incorporates an array of solar powered light poles 12 as discrete autonomously powered devices, the invention is not so limited. It is to be appreciated that the present system may equally be applied to a number of different types of autonomously powered devices which incorporate a rechargeable battery and solar and/or wind turbine generator which in use, provide a variable charging power source. By way of non-limiting example, the present system could be used in autonomously powered security/video monitoring stations, weather and/or environmental monitoring stations, highway and/or traffic signs, bike rental installations, parking meters, and telecommunications installations such as cellular power or the like.
(38) While the preferred embodiment of the invention describes the CPU 14 as being located in a region which is geographically remote from the array 12, the invention is not so limited. In an alternate configuration, each of the light poles 20 could be provided with an internally housed, dedicated central processing unit which is adapted to receive either remotely or directly input data representative of the rechargeable battery age. In an alternate construction, the central processor unit could be provided with program instructions to automatically calculate and/or update the battery age following either initial activation of the light pole, or following any battery replacement or substitution.
(39) While the detailed description describes the preferred aspect of the invention as residing in a solar light installation 10, the invention is not so limited. It is to be recognized that the charge controller and method described herein may be used with a number of different types of autonomously powered devices or loads.
(40) In addition, while the preferred aspect describes the charged controller as used to regulate a limited or low current charging flow to battery 28, the present invention is not so limited. It is envisioned that the charge controller and method disclosed herein may also be used to regulate higher current intermittent charging to larger battery storage arrays, which for example are used for whole home off-grid household energy supply or large scale industrial energy storage for use with commercial solar or industrial wind turbine energy production.
(41) Although the detailed description describes and illustrates various preferred embodiments, the invention is not so limited to the best mode which is described. Modifications and variations will now occur to a person skilled in the art. For a definition of the invention, reference may be had to the appended claims.
(42) TABLE-US-00001 V.sub.ABis the target absorption voltage for a selected operating temp T.sub.1 V.sub.floatis the target float voltage for a selected operating temp-T.sub.2 C.sub.Fis the charge factor that adjusts battery voltage according to its operating temperature T.sub.OPis the actual battery operating temp being read via the temperature probe Absorption Voltage V.sub.AB[T]is used to trigger transition from Stage 1 Bulk Charge to Stage 2 Absorption Charge V.sub.AB[T] = V.sub.AB + CF.sub.1(T.sub.1 T.sub.OP) Float Voltage V.sub.F[T]is the target battery voltage that the batter is regulated to in the Float Stage #3 V.sub.float[T] = V.sub.float + CF.sub.2(T.sub.2 T.sub.OP) AHthe accumulated battery energy measured by using real time 1 second avg battery current 1 second/60 V.sub.ABis a selected value to control the reconnect of the input source to charge the batter in the absorption stage Kis a selected constant that will be adjusted based on battery chemistry and assumed normal daily discharge F.sub.Bis battery capacity factor that reflects the natural change in actual battery capacity during its useful life at a selected operating temperature F.sub.B[T]is calculated each day by taking F.sub.B and adjusting it for the daily operating temperature conditions O.sub.c %defines the level of overcharge energy required to compensate for battery charge inefficiency V.sub.floatis a selected value to control the reconnect of the input source to charge the battery in the float stage AH.sub.dischargeis the amount of energy removed from a fully charged battery during the discharge phase of a daily cycle Flagis an indicator in the logic to define when the charge algorithm has detected a full battery V.sub.BAToperates to sense and detect the actual battery voltage as the specific interval I.sub.CHARGE is the current input into the battery during the on-charging interval