WO2000039907A1 - Systems for configuring and delivering power - Google Patents
Systems for configuring and delivering power Download PDFInfo
- Publication number
- WO2000039907A1 WO2000039907A1 PCT/US1999/031195 US9931195W WO0039907A1 WO 2000039907 A1 WO2000039907 A1 WO 2000039907A1 US 9931195 W US9931195 W US 9931195W WO 0039907 A1 WO0039907 A1 WO 0039907A1
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- WIPO (PCT)
- Prior art keywords
- power
- battery
- voltage
- powered device
- software
- Prior art date
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
- H02J7/0068—Battery or charger load switching, e.g. concurrent charging and load supply
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
- G01R31/3644—Constructional arrangements
- G01R31/3648—Constructional arrangements comprising digital calculation means, e.g. for performing an algorithm
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/36—Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
- G01R31/382—Arrangements for monitoring battery or accumulator variables, e.g. SoC
- G01R31/3835—Arrangements for monitoring battery or accumulator variables, e.g. SoC involving only voltage measurements
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
- H02J7/00047—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with provisions for charging different types of batteries
Definitions
- the invention relates to systems comprised of hardware and related software, specifically to systems in which hardware and software interact to configure an optimized power signal that is delivered to a powered device.
- a power source which may be embedded, or external
- These methods may be effected, for example, by a processor implementing a sequence of machine-readable instructions.
- These instructions may reside in various types of signal-bearing media.
- another embodiment of the present invention concerns a programmed product which includes a signal- bearing medium embodying a program of machine-readable instructions, executable by a digital processor to perform method steps to effect battery and power delivery procedures of the present invention.
- the signal-bearing media may include, for example, random access memory (RAM) provided within, or otherwise coupled to, the processor.
- the instructions may be contained in other signal-bearing media, such as one or more magnetic data storage diskettes, direct access data storage disks (e.g., a conventional hard drive or a RALD array), magnetic tape, alterable or non-alterable electronic read-only memory (e.g., EEPROM, ROM), flash memory, optical storage devices (e.g., CD-ROM or WORM), signal- bearing media including transmission media such as digital, analog, and communication links and wireless, and propagated signal media.
- the machine-readable instructions may constitute lines of compiled "C" language code or "C++" object-oriented code.
- the following Description has two major divisions: “Hardware,” and “Software.” The two divisions are meant to be read together, as information about software runs throughout the “Hardware” text, and vice versa.
- the hardware and software herein can be represented in a multiplicity of modalities, as illustrated in the various figures, and as discussed in the Description.
- This Overview is intended to describe the hardware and software in a basic way, in order to better indicate the inter-connectivity and inter-operability of the various major elements of the invention. Specific details of hardware elements and software processes are not within the scope of this overview. References to figures (and their related text in the Description) should be used to provide more details than are available in this simplified overview.
- Fig. 2B depicts an embedded power assembly 100.
- embedded indicates that assembly 100 is permanently located and non-transportable.
- a non-limiting example of such an embedded power assembly would be an assembly 100 mounted beneath a passenger seat on a commercial aircraft. Passengers can access a power assembly 100 in order to power various electronic devices they bring aboard the aircraft, such as laptop computers, personal video viewers, audio players, etc.
- Power assembly 100 provides an accessible power port 103 which, in the aircraft example, is typically a female receptacle mounted on (or in the vicinity of) the aircraft seat's armrest.
- passengers can bring abroad a variety of powered devices 136 in Fig. 2, ranging from laptop computers (which can require specific input voltages in the range of 12-24 VDC), to personal video viewers and hand-held video game players (which can operate at input voltages from 3-9 volts).
- powered devices 136 in Fig. 2 ranging from laptop computers (which can require specific input voltages in the range of 12-24 VDC), to personal video viewers and hand-held video game players (which can operate at input voltages from 3-9 volts).
- the embedded power unit in an aircraft seat has output a fixed voltage (15 VDC). Passengers accessing the embedded power unit were required to bring aboard an external DC/DC power adapter, which converted the fixed 15 -volt source at the seat to the correct voltage for a particular powered device.
- Embedded power assembly 100 solves the issue of a passenger being required to provide a suitable power adapter.
- Assembly 100 has a configurable power supply 122, which can be controlled by MCU 102 to output a voltage (in a range from 3-24-volts) compliant with a multiphcity of powered devices 136.
- a simple two-conductor power cord assembly 115 A can be used to deliver power from an embedded power assembly 100, to a variety of powered devices 100.
- a low-cost cord 115A can be provided by the airline, in the non- limiting example cited, thus eliminating the need for a passenger to carry a dedicated power adapter for every electronic (or electrical device).
- Powered devices 136 not only have particular input voltage requirements, but they also typically require a unique connector at their power ports 109 A. To date, over 40 power connector variants have been identified just for laptop computers. Often, similarly dimensioned connectors (e.g., a variety of connectors generically classified as "5 mm barrel connectors,” will mechanically 5 fit powered devices for which they were not intended. Both voltage mismatches, and/or reversed polarity, can result from this power connector inter-changeability.
- the invention employs a power connector 132 (Fig. 2B), which attaches to a powered device 136 at its battery pack 134, instead of at the traditional power-input port 109A found on today's
- a power assembly 100 can easily identify the correct voltage required by a particular powered device.
- One method of performing a voltage identification is for MCU 102 to sample — on powerlines 114 and 166 ⁇ the
- MCU 102 15 voltage of a battery 134.
- MCU 102's software 101 executes a process to acquire, and optimize, what becomes the output voltage requirement for configurable power supply 122.
- MCU 102 then uses that voltage information, sending a voltage-control signal along line 130B to configurable power supply 122.
- Power supply then outputs the correct voltage signal on conductors 118 and 120.
- MCU 102 closes powerline switches 112 A the power signal travels through connector
- Connector 132 is unique, in that by inserting it in one of its two positions, it creates an electrical path within battery pack 134 which bypasses the battery cells. This temporary bypass circuit reroutes the incoming power signal directly to the powered device 136.
- Powered device 136 recognizes the power as being delivered from its battery 134, while the actual power source is the embedded power supply 100.
- 25 power adapter assembly 400A is used in place of power cord assembly 115 A, powered device 134 gets its power from power box 400.
- a power connector interface in a battery pack also allows users to upgrade their equipment to be compliant with a power assembly 100 (Fig. 2B).
- Batteries, whether rechargeable or primary, 30 are virtually always user removable (or replaceable). Since batteries wear out and need replacing periodically, users need only replace a worn battery pack with a unit configured with a connector 132.
- a battery-based power connector is a convenient, and low-cost, way to upgrade almost any powered device.
- user costs are further reduced by eliminating the need to purchase the traditional external power adapter required to connect to embedded power systems on aircraft (or in an automobile, as the cigarette-lighter power port).
- safety is achieved by an embedded power assembly 100 being able to power a device 136 with the right voltage. Further safety is achieved by switches 112A changing the polarity on powerlines 114 and 116 (see Fig. 13 A and the related text for details).
- external power adapter assembly 400 A When external power adapter assembly 400 A is attached to embedded power supply 100, the two devices are capable of communicating with each other.
- One of the communications methods described herein is powerline modulation. This inter-device communication capability allows both assembly 100 and 400A to interact constructively (see Fig. 13 A, and related text).
- the communications link between external adapter assembly 400 A also extends to communicating with a smart battery 134, so that the smart battery can communicate data such as the battery manufacturer's design voltage, remaining battery capacity, etc.
- Embedded power assembly 100 can power a powered device 136 using a simple power cord assembly 115 A comprised of a connector 103, power conductors 114 and 116, and a battery connector 132. But, as previously indicated, there are embedded power supplies which output a fixed voltage.
- Fixed- voltage power assemblies include the aircraft seat units already indicated, as well as a fixed- voltage car cigarette-lighter port (SAE spec J1211) indicates a design voltage for a cigarette lighter port as 9-16 VDC, but the typical nominal voltage delivered in most cars is in the 11-14 VDC range. Users of powered devices 1365 which are equipped with a battery pack 134 should be able to connect their powered devices to their cars, or to aircraft seats that deliver a fixed 15 -volt output.
- External power-conversion adapter assembly 400A (Fig. 2B) operates in most ways just like embedded power assembly 100.
- Power converter box 400 also has an MCU, a configurable power converter, powerline switches, and this hardware operates with software 800 (detailed drawings of a generic power box 400 appear as Fig 13 and software 800 is illustrated as flowchart 800 in Fig. 1 A).
- Power cords 505 and 507 are analogous to power cords 114 and 116 in cord assembly 115 A.
- Connector element 103 is interchangeable with that element of cord assembly 115 so that either simple power cord assembly 115A or power adapter assembly 400A can be connected to an embedded power assembly 100.
- External Power Adapter Variants As with an embedded power assembly 100 (Fig. 2B), so too with external power assembly 400A is there an implicit "Universal" power-delivery capability.
- One external adapter 400 that is capable of configuring its power output to match the various voltage input requirements of a multiplicity of powered devices 136, can replace a number of discrete, device-specific power adapters. The Description discusses a number of ways that a single external adapter 400 can replace the various variants of device-specific adapters commonly available.
- Today's electronics goods whether they be notebook computers, handheld video game machines, Personal Digital Assistants (PDAs), tape recorders, or any other type of battery-powered devices, usually ship with an AC ⁇ DC adapter.
- a separate DC/DC power adapter may be either available from the device manufacturer, or can be purchased in the aftermarket. Purchasing such optional external adapters from the manufacturer can be costly, or the manufacturer may not offer such a product (less than 50% of laptops even have an aircraft-style power adapter available at all, and few OEM laptop vendors offer such a product).
- Universal power adapters are available in the marketplace. Radio Shack, for example, stocks power adapters with delectable voltage dials, so that a user can manually set an output from as many as six voltages.
- Other adapter vendors such as Targus, and Nesco (Van Nuys, CA), offer so-called “universal” adapters that require a user to mate a particular connector tip (or power cord/tip assembly), in order to achieve a particular output voltage. While these devices may offer some slight cost savings over dedicated, device-specific power adapters, they can hardly be considered universal. Not all connector tips offered by Targus, for example, cover the over 250 models of laptop computers in the marketplace (Targus claims compatibility with only IBM, Toshiba and Compaq).
- Power adapter assembly 400A (Fig. 2B) solves these problems. Power box 400 automatically configures its output voltage, based on power requirements its MCU and software 800 acquire from a powered device's battery.
- Power box 400 can exist in several variants.
- a simple power module (see Fig. 11) connects between a user's fixed- voltage, device-specific external adapter and a powered device, in order to confirm that the output voltage of the fixed-voltage adapter is compatible with the powered device requirements.
- This intermediate module can also assist a user in setting the dial of a multi-voltage selectable power module to a correct voltage.
- a manually-selectable voltage adapter can have sufficient hardware and software from a power box 400 (Fig. 2B) incorporated so that a user receives a visual indicator — such as an LED ⁇ to indicate that a correct voltage has been matched on a voltage-indicator dial (see Fig. 13).
- the adapter in Fig. 13 also represents a data-enabled external adapter, which is capable of various data communications with an embedded power supply, or a powered device.
- the hardware and software of a power box 400 can even be integrated into a battery pack, as indicated in Fig. 10, which would result in either the ehmination of any external adapters at all, or in a battery pack providing an LED indicator when the correctly matched adapter is in the circuit.
- an external power-conversion adapter assembly 400A can replace (or enhance the proper operation of) a variety of commonly available power adapters, with a single "one-size-fits-all" adapter that is used with a multiplicity of powered devices.
- Fig. 1 illustrates in flowchart form the processes of software that primarily operates with embedded power hardware.
- Fig. 1 A depicts a flowchart of the software processes that primarily operate with external power hardware.
- Fig. 2 is a diagrammatic illustration of an embedded power supply and a powered device.
- Fig. 2B is a simplified overview drawing of the major elements which comprise both an embedded power supply, and an external power adapter.
- Fig. 3A shows the elements in a typical microcontroller unit (MCU).
- MCU microcontroller unit
- Fig. 3B depicts the architecture and port configurations of a typical microcontroller unit (MCU).
- MCU microcontroller unit
- Fig. 4 illustrates a schematic of a generic switching power supply configured to be controllable by a microcontroller, or other external processor.
- Fig. 5 shows a schematic of the microcontroller in Figs. 3 A and 3B, configured to control a switching power supply such as that shown in Fig. 4.
- Fig. 5 A depicts a circuit which can be added to the schematic in Fig. 5 to provide a means of inducing a load on the input powerline of an A/D converter.
- Figs. 6 to 6C illustrate a male connector, and (diagrammatically) its mating female receptacle with related circuits created when the male connector is inserted in two positions.
- Fig. 6D shows a detailed view of the male connector in Figs. 6-6C, with a removable cover that includes a resistive element.
- Fig. 6E to 6F-1 depict a variant of the connector assembly in Figs. 6-6C with two placements of a diode in the circuit.
- Fig. 7 illustrates a flexible connector interface that can be installed in battery-powered devices to redirect power to a battery, or to a powered device.
- Fig. 8 shows a multi-contact male connector (plug) which can be rotated to create different electrical paths to a battery, or a powered device.
- Figs. 9A to 9D depict wiring diagrams which either include or exclude a "smart" battery's electronics circuitry in a power delivery path between a power supply and a powered device.
- Fig. 10 illustrates two modalities of an external power-conversion adapter, one being an adapter with a selectable voltage dial, and the second being a battery, both having integrated power hardware and software that is used to power a powered device such as a laptop computer.
- Fig. 11 shows an external module inserted in the electrical path between a power-conversion adapter and a powered device's battery pack.
- Fig. 12 depicts a simplified function chart of the principles of operation of software.
- Fig. 13 illustrates the details of an external power adapter that has a manually-selectable output voltage, and wired and wireless data ports.
- Fig. 13 A shows a diagrammatic representation of the hardware elements of external power- conversion devices such as those in Figs. 10, 11, and 13.
- Fig. 14 depicts a representational instruction label, with LEDs to prompt a user to perform certain activities relevant to configuring hardware.
- Fig. 15 illustrates a look-up table in chart form which associates a battery's minimum and maximum voltages with individual cell voltages and the number of cells in a battery pack.
- Fig. 16 shows a sub-routine of the software in Figs. 1, and IA, which is used extensively in various software processes and operations.
- Fig. 17 illustrates a chart listing the three positions of a connector in Figs. 6-6C.
- Fig. 18 depicts a screen display showing power-related information, such as voltage values, line- load values, connector insertion states, and other data relevant to the operations of hardware and software.
- Fig. 19 shows a template created from changes in load during a typical BIOS POST sequence of a laptop computer.
- Fig. 20 illustrates a look-up table used by software in Figs. 1 and 1 A which correlates line load values to various hardware states.
- a software program operates on a hardware platform comprised of a processor, memory (both volatile or non- volatile), controller, and at least one data-acquisition I/O port.
- a configurable power supply can be used, but such a device is not essential to the operation of the software.
- the elements can be combined as a single device (as a non-limiting example, a microcontroller), or as discrete sub-assemblies in a multiplicity of combinations. Some or all of the elements can be included in a configurable power supply. 5
- a device's power- requirement information can be acquired as an analog voltage signal from a battery pack 134, as is
- Battery voltage (and/or current) is converted at MCU 102 in hardware assembly 100 to a digital data signal.
- a digital signal is processed, as described in software 101 and 800, and sent as a voltage command to configurable power supply 122.
- Power supply 122 configures its output voltage based on information from a processor in MCU 102.
- powered device 136's correct voltage is properly delivered to it by power supply 122, along conductors 114 and
- Assembly 100 in Fig. 2 can also monitor the electrical load of powered device 136 (see U.S. Patent Application No. 09/193,790, and International Application No. PCT/US98/24403).
- Powered device's memory 104B (volatile or non-volatile) stores information, which is retrieved by resident software. Through a multiplicity of available data I/O ports at powered device 136, voltage information is delivered to an appropriate I/O port at hardware assembly 100 in Fig. 2.
- Prior art Figs. 3 A and B show a variety of data I/Os
- Synchronous, serial, and I 2 C data links can be created, as a non-limiting example of data I/Os.
- powered device 136 be capable of storing its voltage and load requirements as digital data, that data being communicated to hardware assembly 100 by a multiplicity of methods, including but not limited to, powerline modulation, and wireless infrared.
- Fig. 2 shows two conductors 114 and 116 that electrically connect hardware assembly 100 to powered device 136, via associated battery pack 134. These two conductors can function as data lines, as well as powerlines. This would be practical if battery pack 134 is a "smart" battery capable of data communications. Smart batteries, non-limiting examples of which are those defined in the SMBus specifications (available at www.sbs-forum.org), can be modified to include a modulator/demodulator for powerline modulation. Also, revisions to the SMBus specifications allow for battery and host data available on a standard PCI bus. Conductors 114 and 116 can be used for powerline modulation, or additional lines can be added (SMBus is a four-wire data bus, and Dallas 1-Wire only requires three).
- SMBus specifications available at www.sbs-forum.org
- two-wire analog data acquisition is achievable using powerline modulation.
- This shared two-wired power and data topology is viable because power supply 122 is controllable, so it can be shut down, or reconfigured to a compatible voltage with powerline modulation during periods of data acquisition.
- the 40 programmable I/Os 138, or serial I/O 154, in Fig. 3A can be used to create a digital data path.
- 40 programmable I/Os 138 can create a parallel port.
- Serial I/O 154 can be, as another non-limiting example, configured to drive an infrared or RF circuit for wireless data communications between hardware assembly 100 and powered device 136 in Fig. 2.
- I 2 C and SMBus capabilities of the Mitsubishi M37515 (which is compliant with I 2 C data protocols) simplify the functionality and implementation of this new digital I/O path.
- the M37515 (or equivalent) can be readily programmed to communicate with a "smart battery" 134 in Fig. 2 by using SMBus-compliant function control unit 144.
- Data communications between a powered device 136 (Fig. 2) and hardware assembly 100 is not restricted to hardwired connectivity.
- Wireless data communications for example using infrared (134C), RF, or acoustic arrays, can be created with appropriate communications devices in hardware assembly 100.
- Software 101 in Fig. 1 (and software 800 in Fig. 1 A) are not limited to any particular data communications method between powered device 136 and hardware assembly 100.
- the method of data acquisition by a hardware assembly 100 from powered device 136 or battery pack 134 is not limited to the analog methods described herein.
- Intermediate Hardware Fig. 2 shows an embodiment of hardware assembly 100, in which MCU 102 is indirectly connected to power supply 122.
- Intermediate device 126 is a computer with a display screen (see Fig. 18 for an example of a "Power Monitor” screen display). Data from MCU 102 is sent to computer/display 126 along data lines 130. Computer 126 also controls power supply 122 via data lines 124. Computer 126 is not essential to the operation of the invention's hardware and software. It serves a useful function in providing a display for acquired voltage and current-load values, as illustrated in the 'Tower Monitor" screen in Fig. 18. In some applications, a graphical user interface and display screen is indicated as user prompts in software 101 and 800 (Figs. 1 and 1 A). This is discussed later under "GUI Considerations.”
- Hardware assembly 375 in Fig. 5 eliminates data control lines 124, and relocates them between MCU 102 and power supply 122, so that MCU 102 directly controls the output voltage of power supply 122.
- MCU 102 in Fig. 2 is a Mitsubishi M37515 (Figs. 3A and B).
- MCU 102 has a plurality of I/O ports 138, at least one of which is an A/D port.
- Fig. 2A details three A/D I/O ports 106, 110, and 112. Each of these is used to acquire powerline voltage (or current), with I/O port 106 reading voltage under a load condition.
- the load is provided by a power resistor 108 (or equivalent) in powerline 107.
- I/O port 110 senses voltage as a no-load value at powerlines 114 and 116.
- I/O port 112 detects current at powerlines 113 and 114.
- Powerlines 107, and 113 are all tied to primary conductor 116, which is one of two conductors comprising cable 115. Additional circuits shown in Fig. 5 A can be implemented at the appropriate I/O ports for current and load- test states.
- Analog signals acquired by I/O ports 106, 110, and 112 in Fig. 2 A are converted to digital signals in A D converter 140 in Fig. 3A.
- some digital data values are stored in memory, either temporarily or permanently.
- data values are stored in ROM 148, or RAM 146.
- Processor 150 is used to calculate values, control data flow, time functions, etc.
- Timer construct 142, and/or clock generator 152, can be used for sequencing processes.
- Fig. 5 illustrates a reference-design test jig for the Mitsubishi M37515 (a non-limiting example of MCU 102 (Fig. 2), as well as MCUs 102A and 102D (Fig. 13A).
- MCU 102 in Fig. 3 A can output a digital signal on a reconfigured I/O port (not shown, but referenced in Figs. 3B and 5) created from 40 programmable I/Os 138. As a parallel port, not all 25 pins are allocated. MCU 102's programmable I Os 138 serve to communicate data to configurable power supply 122 in Fig. 2. In the modality of configurable power supply shown in Fig. 4, data input from MCU 102 is expressed as +0.5 VDC line voltage.
- Resistor ladder 160 in Fig. 4 can be configured in a plurality of output voltage combinations, based on voltage values at pins 2, 4, 6, 8, 10, and 12, which control the final output voltage of power supply 122.
- Serial I/O port 154 in Fig. 3 A can be used for communication outputs, such as control and command functions to the circuitry of a power supply 122 in Fig. 4.
- an LTC1329A- 50 from Linear Technologies (Milpitas, CA) can be used (via a serial port) to drive the LT 1339 shown in Fig. 4.
- the LTC1329A-50 is tied to the LT1339 at pin 12 (Sense) and pin 9 (Vfb).
- the Linear Technologies' LT1339 requires a modification to perform proper shutdown, as indicated in the chip's data sheets.
- Vout is measured at header PIN 20, which is jumpered directly to the positive output terminal block #1 at TBl.
- a diode is included in the positive output powerline, but not ahead of the jumper that feeds Vout information to PIN 20.
- GUI Considerations Fig. 2 indicates an external processor with a screen display 126.
- Software 101 and 800 Figs. 1 and 1 A) use various screen prompts to assist the user in manipulating connector 132.
- Elements of software 101 (or 800) relevant to displaying information can reside on appropriate storage media, such as CD-ROMs, DVDs, diskettes, etc., as freestanding software applications, or the software can be "burned" into hardware chips (for example, EPROMS, and EEPROMs) for use with embedded systems which provide a display interface.
- An appropriate display can also be integral with hardware assembly 100, or independent as shown in Fig. 2.
- a screen display can be, as a non-limiting example, an LCD character display (or equivalent), mounted to an enclosure within which resides hardware assembly 100.
- Display screen technologies are not, however, essential to the proper operation of software 101 and 800 (Figs. 1 and 1 A).
- Other methodologies to guide a user through the simple configuration steps include, but are not limited to, LEDs that are linked to a text-based information panel or card, as shown in Fig. 14.
- MCU 102 in Fig. 2 controls status LEDs 420, 422, 424, and 426, using available programmable I/Os 138 to actuate the appropriate LED.
- Error states determined by user compliance to a requested action, can be shown by blinking the appropriate LED, for example 420, if a required user action has not been performed.
- Display screens or LEDs are only two modalities of alerting a user to perform a specific action, or to confirm the appropriateness of the results of such actions, and are illustrated here as non- limiting examples only. Any method that will prompt a user is acceptable for the proper operation of software processes defined in software 101 and 800.
- Software 101 and 800 (Figs. 1 and IA) is not specific to a particular configurable power supply.
- a switching power supply design 122 in Fig. 4, that configures itself to a correct output voltage, is typical of a hardware configuration supported by software 101 and 800.
- Software 101 and 800 can operate with a plurality of power supply design modalities.
- a power supply which has a method of manually adjusting or configuring its output voltage can function according to the processes defined in software 101 and 800. Instead of the calculated output voltage available from MCU 102 in Fig. 2 being forwarded to a configurable power supply 122, the resultant voltage can be displayed on a screen. The user, seeing such voltage information on the screen uses this data to manually select the matching voltage. Because software 101 is capable of verifying that user-selected power supply 122's output voltage is correctly matched to the input voltage requirements of powered device 136, the user has validation and confirmation of the correctness of the selected voltage.
- Software 800 in Fig. 1 A comprises a method of verifying a manually-set output voltage by using a simple reference-voltage comparator circuit, or by acquiring and calculating battery output voltage.
- Power supply device 400 in Fig. 13 and 13A includes an LED 402 that is capable of blinking, and also holding a continuous LED ON condition. When Vout and Vout 2 are the same, LED 402 goes from a blinking state to a continuous ON state. A continuously ON LED 402 indicates to a user that an accurate voltage match has occurred. This eliminates any mismatched voltage from a power supply 400 which could damage a powered device. With this LED confirmation, a power supply 400 need not have any voltage values demarcated on manually- adjustable voltage selector 337.
- Selector 337 in Fig. 13 A uses changes in impedance across its rotating manual selector switch to define incremental voltage values.
- Each selector setting 416 (Fig. 13) has a known resistance value.
- These individually unique Ohm values are plotted in a look-up table (not shown) that equates an Ohm value to an output voltage value.
- LED 402 goes from a blinking state to a continuous ON state. Users cannot mistakenly select a mismatched voltage, which provides a high degree of safety to power box 400. Should a user rotate selector dial 504 at any time after Vout has been executed, MCU 102 A ignores the selector.
- FIGs. 13 and 13 A illustrate non-limiting examples of a self-confirming power adapter 335 that is comprised of at least one signaling indicator that can be an LED 402. LED 402 is wired so that it blinks during voltage selection, then lights solid ON when a voltage match is achieved. This indicates to a user that a powered device's voltage, determined by software 800 in Fig. 1 A is the same as the selected output voltage of adapter 400 at voltage selector 337.
- the tool used to rotate selector indicator 504 is a male "key" connector 404.
- Connector 404 in Fig. 13 is shown in Fig. 6D as connector 540.
- MCU 102 A has an input 506 (based on 13 selectable output voltages) from selector 337.
- Selector 337 is a rotary switch with four lines. Each switch position represents a unique binary value that is expressed on four-conductor-line 506 to MCU 102 A.
- MCU 102 A is thus able to know, by combinations of these binary values, each specific voltage setting that is 10 selected. MCU 102 A interprets these binary values as voltage selections.
- power adapter 400 in Fig. 13A is capable of reading a voltage value from an external powered device 508C (item 136 in Fig. 2).
- Data acquisition at signal lines 523 and 524 is configured to read voltage from an external source, such as battery
- MCU 102 A holds power switches 526 and 526A open while reading an external voltage from battery 508B.
- Software 800 (Fig. IA) stores voltage values in MCU 102A's memory 518A. MCU 102A then looks to binary inputs from manual voltage selector 337 at data-input line 506. When a user selects a voltage by rotating selector dial 504 that matches the voltage value stored in MCU 102A's memory, MCU 102 A turns on LED 402. This indicates to the user to stop rotation
- power adapter 400 (Fig. 13 A) can determine the output voltage of its power converter 122A by acquiring voltage information from an attached battery 508B.
- 25 519 and 527 provide A/D converter inputs to MCU 102 A.
- Line voltage from main powerlines 523 and 524 is acquired using A/D lines 525 and 527.
- Line load values are acquired at conductors 522A (with its resistor 517), and/or conductor 519 (with its resistor 521). Further information on how software 101 and 800 use these various A/D I/Os to determine the optimum output voltage of a power converter 122 A is described in the sections "Conductors and Insulators," and
- An adjusted voltage value defined by software 800 (Fig. 1 A) is sent form MCU 102 A in Fig. 13A to power supply 122 A along multi-conductor control line 510.
- Power converter 122A's resistor ladder (indicated in Fig. 4 as assembly 160) corresponds to binary values expressed by selector 337.
- A/D lines 525 and 527 read power supply 122A's Vout.
- Software 800 (Fig. 1 A) and MCU 102A then apply a resistive load 517 to power supply 122A's output, top test the integrity of the power settings. If monitored Vout shows negligible voltage sag under load, and having confirmed that power supply' s Vout matches the desired voltage value stored in memory 518 MCU 102 A then closes switches 526 and 526A allowing power to flow along powerlines 523 and 524 to connector 132, and into battery 508B.
- the sections "Power Connector,” “Connector Operations,” and “Diode UPS” explain how a connector 132 reroutes power-delivery lines within battery 508B to bypass the internal battery cell(s), and deliver power to a powered device 508C.
- Power switches 526 and 526 a can be controlled by MCU 102 A at control lines 520 to operate as polarity-reversing switches.
- MCU 102 A along with software 800, determines the polarity of the acquired power signal from battery 508B using techniques similar to that of a volt meter. Once the polarity of the battery on powerlines 523 and 524 is known, MCU 102 A configures switch 526 to either close the circuit to powerline 524C, or powerline 523. Switch 526A can be directed to either powerline 523C, or 524.
- Power box 400 (Fig. 13 A) diagrammatically represents the powered devices shown as power adapter 335 in Fig. 10, power module integrated into a battery 347 in Fig. 10, power module 357 in Fig. 11, and power adapter 335B in Fig. 13. As discussed elsewhere, each of these power devices can communicate with other such devices, with data-enabled "smart" batteries, and even with powered devices such as the laptop 249 in Figs. 10 and 11.
- Fig. 13 A depicts three forms of inter-device communications:
- Powerline modulation is used between a battery 508B which has a Modulator/Demodulator (MD/DM) 508D and a processor such as MCU 102D.
- the corresponding Modulator/Demodulator 508E in power box 400 is controlled by MCU 102 A to allow communications along the primary powerlines 523 and 524, which are connected to MD/DM 508E with conductors 524A and 523 A.
- MCU 102A uses lines 511 A and 51 IB as data lines to and from MD/DM 508E.
- a corresponding scheme is employed within battery 508B to configure its MCU 102D and MD/DM 508D.
- MCU 102 in power box 400 controls power switches 526 and 526A to be open during a powerline modulation session.
- the power signal on the primary powerlines is from battery 508B, although the powerlines can be configured through switches 526 and 526A to allow power converter 122 A to be the source of power during a powerline session.
- MCU 102A in power box 400 can acquire data from analog signals (voltage and current) at powerlines 523 and 524, or digital data using powerline modulation can be used by MCU 102 A to acquire relevant data from battery 508B.
- digital data typically includes the battery manufacturer's pack "design" voltage, the present state of charge (fuel gauge values), and other values only available by using a true communications link between power box 400 and smart battery 508B.
- Data port 406A in power box 400 (Fig. 13A) is used to connect a power box 400 to a powered device 508C.
- Figs. 13 and 10 depict a power adapter that has a data I/O port 406, which attaches to a mating data port on a powered device, shown in a non-limiting example as a laptop computer 349.
- This data link allows a communications-enabled external power adapter/module 335, 335B, or 347 (integrated into a battery) to access a powered device 508C's data storage, memory, and software applications, or even the operating system to either acquire power-related information from the powered device, or to share information acquired by the adapter/module with the various hardware/software within the powered device.
- elements of software 101 and 800 relevant to inter-device or network communications can be stored on diskettes, CD-ROMs, DVDs, etc., as appropriate for use with powered devices, servers, embedded LAN nodes, and the like.
- a non-limiting example of a use for this external adapter/module-to-powered-device comm link can be to indicate with a screen prompt on the powered device that selector dial 504 is incorrectly positioned (this assumes that the powered device is turned ON and operating from battery power).
- Infrared data I/O 412D (Fig. 13A) is depicted in Fig. 13, as infrared-compliant upper shell 412 of external power adapter 335B.
- Infrared emitters 412A and collectors 412B are positioned to allow a diffusely-radiated pattern of light over which data can be bi-directionally communicated. While infrared is shown here as a mode of wireless communications, RF and acoustic arrays are also viable, depending on the intended function of the data link, and the availabiUty of compatible devices in the communications environment. Further information about a wireless Ir data link is available in the section "Modules That Open Closed Data Systems. "
- Software flowchart 800 does not include detailed descriptions of the steps in software for a communications session.
- the wide variety of communications protocols, and selection of specific hardware, cannot be adequately in a series of communications steps in flowchart 800. Since such communications methodologies as powerline communications, wireless (infrared, RF, etc.), and cabled links are so widely known by those skilled in these various arts, the requisite software sequences to read from and write to a comm port can be readily implemented.
- Information on the data protocols for "smart" batteries is available from the Smart Battery Systems (SMBus) web site (www.sbs-forum.org).
- Power box 400 (Fig. 13 A) is representative of various hardware found in external power adapters and modules such as power adapter 335 in Fig. 10, power module integrated into a battery 347 in Fig. 10, power module 357 in Fig. 11, and power adapter 335B in Fig. 13. All of these external power units requires a power input from a compatible power source.
- the power source can be either DC, or AC.
- Fig. 13 A depicts hardware by which a power box 400 (and related software 800 I Fig. 1 A) can communicate with a power source connected at input power lines 505 and 507.
- Such a communications-enabled power source can be, for example, an embedded power module 100 in Fig. 2, which will be used herein to describe the various communications capabilities.
- power box 400 provides for a powerline communications link between its MCU 102 A and a power source 100 in Fig. 2.
- power source 100 operates under software 101 (Fig. 1)
- power box 400 operates under
- Power box 400 and its associated powerlines and connectors is illustrated as assembly 400 A in Fig. 2 for purposes of illustration.
- Assembly 400 replaces the two-conductor cord 115 and its associated connectors 103 and 132, so that assembly 400 is interposed between a connector 103 of power source 100, and a battery pack 134.
- the sequence of events which occur prior to establishing a communications link between a power box 400 and power source 100 are:
- Power box 400 (Fig. 13A), as part of assembly 400A in Fig. 2, receives power source 100's 5- volt power signal along conductors 522 and 522B, which deliver the power to voltage regulator 505 A.
- the regulator outputs a voltage compatible with the power requirements of an MCU 102 A along continued lines 522 and 522B, to MCU 102 A. This voltage activates and turns ON MCU 25 102A.
- MCU 102 can be turned on with power flowing along lines 523D and 523E to voltage regulator 505B, with the power then flowing 30 along conductors 522C and 522D, which are tied into the primary power input lines 522B and 522 to MCU 102 A. If a voltage regulator has sufficiently broad input voltage range capabilities, a single regulator can replace the two 505 A and 505B. 3) Once MCU 102 A is powered by either of the two power sources in step 2 above, the MCU uses A D lines 529 and 528 to sample the voltage on input powerlines 505 and 507. Note that MCU 102 A closes switch 516, using control line 515A, to allow power to flow between input
- Software 800's steps 801 through 806 indicate the software branches related to determining to what type of input power source power box 400 is connected. If a 5-volt signal is acquired (software step 803) along lines 529 and 528, power box 400 is connected to a power source 100 (Fig. 2). If the line voltage is 14-16 VDC (software step 804), power box 400 is connected to an aircraft's In-Seat Power (ISP) outlet, which typically has
- ISP In-Seat Power
- MCU 102A in power box 400 assumes that it is connected to an automotive power source, such as a car cigarette lighter adapter outlet. This process of identifying a power source is important, because the connector 103 (Fig. 2) used to attach a power box 400 to a power source can, in some situations, be common to several of the types of power sources indicated.
- MCU 102A (Fig. 13 A) can initiate a powerline modulation communications session.
- Modulator/demodulator (MD/DM) 528E is accessed by MCU 102 A along send/receive lines 528 A and 528B. The modulated signal then travels along lines 528C and
- Power source 100 also has powerline switches 112 which are equivalent to switches 526 and 526A in Fig. 13 A. These switches allow for floating powerlines 505 and 507 during a communications session, as well as providing a means of reversing polarity when a cord assembly
- 25 115 is used, instead of a power box assembly 400A in Fig. 2.
- power switch 516A remains open, so that power converter 122 A remains unaffected by a communications session. Power converter 122 A is not capable of operating efficiently from a 5 VDC input, so it is not practical to keep the power converter 122 A in the powerline. Later, power 30 source 100 (Fig. 2) will reconfigure its Vout to 28 volts, at the time when power converter 122 A (Fig. 13A) is about to be configured to power device 508C. 5) Powerline communications continue during the entirety of the software sequences defined in flowchart 800 (Fig. IA). Power box 400, and power source 100 (Figs. 13A and 2, respectively) communicate information, for example, about available alternative communications hardware in each device.
- Power source 100 can be a node in a network of such power sources, all linked by a wireless LAN.
- Power box 400 communicates to its networked power source 100 information about any wireless comm link hardware it has.
- Diagrammatic generic power box 400 (Fig. 13 A) can, in this non-limiting example, be representative of an actually external power adapter 335B in Fig. 13.
- Power adapter 335B includes wireless infrared capabilities, so it is important that a power source 100 know that there is a wireless link available, since power source 100 also has a compatible Ir port 134C (Fig. 2).
- the secondary Ir comm link enables power box 400 and power source 100 to continue to communicate via Ir, after powerlines 505 and 507 have been reconfigured to 28 VDC.
- power box 400 communicates to power source 100, requesting a change in powerline voltage from the present 5-volts, to 28-volts. This call can occur via powerline communications, as described.
- resistor array 509 is used as a simple means to communicate the requisite voltage change.
- MCU 102 and software 101 (Fig. 1) in power source 100 (Fig. 2) uses its A/D converter functions to determine whether or not a power box 400 is requesting a voltage change at its power supply 122.
- Software 101 describes monitoring both powerline voltage and current. In particular, software 101 is looking for changes to the line load which indicate that MCU 102 A in power box 400 has activated resistor array 509 (Fig. 13 A).
- the resistive values that resistor array 509 are capable of creating on powerlines 505 and 507 are pre-determined, and are thus known to both software 800 and 101.
- Control line 130C is for MCU 102 to configure the variable Vout of power supply 122, and is not associated with control line 130B, which is specific to the control of bypass switch 112B.
- Lines 120B and 118B are powerlines along which power supply 122 delivers a compatible power signal with which to power MCU 102 A (this assumes that power supply 122 has two outputs, one of which delivers a fixed voltage for powering MCU 102, and the other is a controllable and configurable output which is controlled by MCU 102.
- Software 800 in power box 400 detects the input voltage change to 28- volts along MCU 102A's A D lines 528 and 529 (MCU 102 A has closed switch 516 in line 528). MCU 102 A in power box 400 then closes switch 516A, which allows the 28-volt power signal to flow into power converter 122 A. Power converter 122A's output is then configured by MCU 102 A to be the optimized voltage previously determined by software 800.
- Fig. IA software flowcharts 800 (Fig. IA), nor 101 (Fig. 1) defines specific inter-device communications sessions, because each type of data communications - - whether it be wireless infrared, or powerline modulation — requires specific protocols and hardware interactions (calls, read/writes to various ports, etc.). Since the communications methodologies discussed here are widely known and so readily implemented by those skilled in the art, the description herein of hardware interaction, and the non-limiting examples of communications functions cited, are sufficient to allow one skilled in the art to implement the software coding required to create a communications session.
- Software 800 (Fig. IA) monitors output voltage and powerline load during power delivery.
- SmartAdapter is a type of manually-configurable power supply.
- a DC/DC adapter module which can deliver a range of voltages, is the central hardware device on which the "SmartAdapter” is based.
- a user selects an appropriate "SmartCord” that matches the input voltage requirements of a powered device.
- Each SmartCord has a specific resistor value that is pre-matched to an associated powered device.
- the correct SmartCord is attached to the SmartAdapter power module to configure a correct output voltage.
- SmartCords But a user must have ready access to SmartCords. Selecting an appropriate SmartCord requires pre-knowledge of power details of the intended powered device, perhaps from users who do not understand the proper reading of product labels that explain input and output voltage requirements. Also, the sheer number of powered devices suggests hundreds, if not thousands of SmartCords, each dedicated to a specific power product. These 12" cords are also easily lost, or confused with each other.
- Power adapter 400 in Fig. 13 and 13 A eliminates the need for interchangeable SmartCords. Voltage requirements are not determined by users who may make mistakes; instead a reliable computer process accurately defines voltage requirements. This adds safety, convenience and reliability to products like the Nesco SmartAdapter.
- Configurable power supplies are not limited to auto-configurable, or selector-controlled manually-configurable modahties, as described above.
- User configuration can include a function as simple as choosing the appropriate power supply from a number available.
- a corporate Manager of Information Systems (MIS) may, for example, need to confirm that the one of a number of identical-looking power supplies available in a spares bin is the correct voltage match for a particular powered device.
- Software 800 in Fig. 1 A operates to confirm the proper voltage required, and can also, with a hardware device 335 or 357 in Fig. 11, interface with a pre- manufactured, fixed-output-voltage power adapter.
- a separate module 357 in Fig. 11 can interface between a powered device's battery pack and an independent power supply.
- the function of this module is to acquire a battery 355's voltage, using software 800 in Fig. 1 and to compare the acquired voltage information from battery 355 to configure the fixed-output voltage of a power supply 335.
- Module 357 cannot use software 800, but can employ a simple hardware voltage comparator.
- Module 357 can also be a more versatile data acquisition device that stores at least two voltage values in memory, each from a different source, and determines if they are a match.
- Simple indicators a non-limiting example of which is a bi-colored red/green LED 338, is used to indicate whether or not there is a valid voltage match between 335' s battery voltage and that of a power supply 337. Only power supply devices that create a valid green LED indicator when attached to module 357 can be safely attached to a powered device's battery interface.
- Automatically-configurable power supplies include embedded or in-line corded power modules that rely on pre-determined computer-readable values which equate to output voltage matches.
- a U.S. Patent # 5,570,002 by Castleman describes a self-configuring power supply system that relies on computer chips or other hardware/software. This hardware essentially pre-identifies an appropriate output voltage of a powered device to an embedded, multi-point power supply system. This approach is very similar to the Nesco "SmartCord" defined above. But, instead Castleman relies on manufacturers of powered devices to pre-install a chip indicating each device's correct input voltage. Castleman does not address the availabiUty of a battery pack interface, but only addresses the primary power jack or port of a powered device.
- Software 101 and 800 (Figs. 1 and 1 A) and related hardware, provide power device users a battery pack modified as indicated schematically in Figs. 6-6E.
- a battery pack modified with connector system 212 or 212 A (Figs. 6-6E), together with intermediate voltage-acquisition hardware as in Figs. 2, 10, 11 and 13, can yield a valid voltage value which can be used by Castleman's power system. Since battery packs are usually removable and replaceable, non- Castleman-compUant devices can be upgraded to store a voltage value required by Castleman.
- a "smart" battery can communicate its design voltage value as a digital value to a data-enabled intermediate module 357 in Fig. 11.
- Battery-housing-shaped module 347 in Fig. 10 contains electronics equivalent to that shown in Fig. 13A (no power converter 122 is present, since the power converter is in power adapter 335).
- Modules 357 or 347 "translates" a voltage value, using software 101 or software 800 (Figs. 1 and IA), to a data signal compliant with Castleman's voltage-identifier system.
- software 101 and 800 enable Castleman's closed-loop system to access voltage values at the battery pack interface, instead of the limiting primary power port of a powered device.
- the software can also translate analog or digital voltage- specific information into readable data that is compliant with Castleman's schema.
- Battery-pack-shaped module 347 in Fig. 10 can be comprised of any, or all, of the various elements that comprise hardware assembly 100 in Fig. 2. As configured in Fig. 10, the presence of a power converter module 335 indicates that a power supply 122 or equivalent in Fig. 2 is not needed in module 347. However, MCU 102, memory 104B, a controller (considered here as integral to MCU 102 in Fig. 2), and perhaps one of the wired (e.g., powerline modulation as Modulator/Demodulator 134B), or wireless communications (e.g., Infrared port 134C) modalities described herein can be incorporated into a battery-pack module 347 in Fig. 10.
- wired e.g., powerline modulation as Modulator/Demodulator 134B
- wireless communications e.g., Infrared port 134C
- capabilities not already built into a power module 335 can be added, without modifying the pre-manufactured power module 335.
- Module 347 (Fig. 10) or 357 (Fig. 11) can be a smart battery emulator, the function of which is to "trick" laptop 349' s battery-related circuitry into believing that there is a smart battery present, (instead of a plastic battery housing fuU of electronics).
- Such battery emulators are available from 10 a number of sources, including David Simm (Bethesda, MD). Such emulators are used to test smart battery bus communications hardware and software. If battery charging is to be avoided, the emulator is configured not to request charging activities. Also, since there is no source of power at laptop 349' s primary power port, powered device's internal battery charger will not turn on.
- Power adapter 335 in Figs. 10 and 11 can be only a basic non-configurable AC/DC (or DC/DC) power converter. Although both figures indicate a manual voltage selector 337, in some modahties there may be no ability to communicate with, control, or otherwise configure a power adapter 335. However, module 347 can confirm the output voltage of power adapter 335, and allow power to pass through module 347 and into laptop 349, only if the input voltage at module 347
- module 347 serves a vital safety function in protecting laptop 349 from external power adapters like 335 that can output a mis-matched voltage.
- battery voltage data for powered device 349 — acquired at module 347 — is transferable to laptop 349, via communications-enabled power adapter 335.
- data communications need not be any more sophisticated than powerline modulation.
- a scant amount of data needs to be transferred — only a binary hex, or other equivalent of a two-digit voltage value, for example.
- a robust, high-speed data link is not required.
- power adapter 335B has a data port 406.
- Data connector 406 is shown as a parallel port interface, but it can be a USB, serial or any other data I/O port. This port connector gives access for power-related data to software within laptop 349 in Fig. 10.
- voltage data acquired at a battery 355 (Fig. 11) by module 357 (or, in the alternative, at a battery-pack configured module 347 (Fig. 10)) is communicated over powerline 336 (using powerline modulation) to a data-enabled power adapter 335.
- Power adapter 335B (Fig. 13) has a data port 5 406 that connects to a powered device 349 (Fig. 10).
- Voltage data previously discussed as acquired from a battery module 347 in Fig. 10 (or external module 357 in Fig. 11) is communicated from module 335B, via data connector 406, to powered device 349.
- Software resident on powered device 349 captures voltage data from power adapter 335B and stores it in non-volatile memory (or writes it to a storage media such as a hard drive).
- An external module 10 357 (Fig. 11) can also have a data I/O equivalent to a port 406 shown in Fig. 10.
- powered device 349 has its voltage values in memory, the device can communicate that information to any compatible power adapter or other device.
- This movement of voltage data from a battery to its host device is via an assembly of hardware and software devices which enable 15 not only compliant power adapters, but also provide power apparatus such as Castleman's, a way to place data in an accessible location specified in his U.S. Patent 5,570,002.
- Fig. 13 is also capable of communicating data wirelessly.
- Top shell 412 of power adapter 335B is fabricated of translucent plastic, tinted to be compatible with infrared light.
- Below the tinted Ir 0 cover is a matrix of infrared LEDs (emitters) 412A and collectors 412B, typical of "diffuse” (i.e., non-directional) infrared.
- the emitters and collectors are arranged so as to disseminate light along various 30 x 120-degree paths.
- Collectors are physically isolated from emitters by partitions 412C, so that the collectors are not “blinded” by the emitters.
- the number of emitters and collectors can vary, according to the requirements of various diffuse infrared vendors.
- IBM Markham, Ontario, 5 Canada
- Siemens Siemens (Bonn, Germany)
- Spectrix Moundelein, IL
- the entire top surface, and some portion of the sides of the top shell 412, of 0 power adapter 335B disseminate infrared light into the local environment where, as a non-Umiting example, the data within the non-columnated light beams can be captured by a host device 349 (Fig. 10).
- This wireless capability eliminates the need for a data I/O connector 406 on power adapter 335B in Fig. 13, allowing the device to positioned anywhere in proximity (typically diffuse infrared operates within a range of 10 meters) to its powered device.
- Such diffuse infrared capabilities also enable a number of power adapters 335B (Fig. 13) to be wirelessly linked to a compatible local area network.
- a non-limiting example of such a LAN can be an aircraft cabin configured with diffuse Ir receptors (transceivers) that transmit and receive data over the infrared network, so that power adapters such as 335B can communicate power- related activities at each node on the LAN to a server.
- the server thereby can monitor overall power consumption in the environment, report on the possible misuse of any power adapter 335Bs by airUne passengers, report on a failing module that requires a service call ⁇ or to monitor the amount of time an adapter is used, so that an airline can charge a passenger for power usage.
- a wirelessly networked power grid of power adapters empowers a number of practical solutions which benefit users and providers of power equipment such as power adapter 335B (or equivalents).
- Smart battery topologies treat battery communications as a closed system. Not only are software applications resident on a powered device unable to access smart battery bus communications, but even the operating system has firewalls between it and the battery data bus. Until recently, this closed system approach made sense. Smart battery technology brought a reasonable level of safety to charging highly-volatile Lithium-Ion (Li-Ion) battery cells. But, commercial airlines are now adverse to even the slight risk that an onboard laptop could cause a dangerous situation by charging its battery while in flight. The involatile closed battery bus now needs outside intervention, so that battery charging activities within laptops can be temporarily disrupted during flight, but resumed when those laptops are on the ground.
- Li-Ion Lithium-Ion
- a system that allows smart battery bus data to be transferred bi-directionally to/from a powered device's application or operating system levels can be created using elements described in the section "Modules That Open Closed Data Systems."
- Such a data system has a battery pack interface.
- Male connector 290 in Fig. 8 provides sufficient data lines 292, 294, 296, 298, and 299 to redirect all battery bus communications to an external system. These five conductors of a connector 290 can be directed to a hardware assembly 100 in Fig. 2.
- MCU 102 is a Mitsubishi M37515
- the I 2 C/SMBus data port can provide a compatible I/O for the smart battery bus data.
- Microcontroller 102 is capable of translating the J C data protocol to RS 232 data, which can be output at an I/O port.
- This data port can be the existing serial port 154 in Fig. 3 as a non- limiting example, or a created parallel port constructed from the 40 programmable I/Os 138.
- the above description is not Umiting to those particular elements referenced here by example, but can be any combination of elements that perform equivalent functions to create the system so described.
- Software 101, and 800 can be integrated into an MCU, or equivalent processor or controller chips. Since elements of both software 101 and 800 relate to functions or operations not necessarily specific to software embedded into a chip, or processor, some software routines or sub-routines discussed herein can be distributed on media such as diskettes, flash, ROM (CD or DVD, for example), or equivalents. This distributed software can be an application purchased by an end user, and loaded onto a powered device such as a laptop computer, for non- limiting features such as a "Power Monitor" display.
- Data port 406 in Fig. 13 provides power adapter 335B a means of sending/receiving data acquired from a smart battery bus, as described above, and transferring such data to software running on a powered device, such as a laptop. Linking these various elements together provides a data loop that starts at the otherwise closed smart battery bus in a powered device, rerouted through an external device, then into an available data port on the powered device. Software on the powered device can thereby monitor battery bus activity. If charging occurs, for example, monitoring software 101 (Fig. 1) or 800 (Fig. IA) can send a command to the data-enabled external power adapter to shut down.
- SMBus specifications include smart battery bus "extensions" that, to a limited degree, allow other hardware sub-systems in a powered device access to a previously-closed data bus. Extensions to the PCI bus aUow the CPU, BIOS and other devices to have limited input and outputs on the smart battery bus.
- external devices such as power adapters, can potentiaUy access battery and charger data. While no provisions currently exist for an external device to manipulate a powered device 349's charger control, a power adapter 335, 335A or 335B (Figs. 10, 11, 13) (and schematically 400 in Fig. 13 A) is capable of monitoring battery and charger activities.
- One means of controlhng charging from an external device 335 is by disabling power to a powered device (assuming that an external adapter is delivering power to a device's primary power port 343 (Figs. 10 and 11), instead of utiUzing the battery bypass shown in Figs. 6-6E). Although an aggressive approach, discontinuing external power delivery can be rendered a harmless event.
- An external device such as module 335 (Fig. 11) that can monitor a battery data bus to confirm that a battery pack 355 has sufficient remaining capacity to power its host device. This eliminates any risk of a possible hardware crash caused by lack of battery power when shutting down external power in order to prevent battery charging..
- power adapters 335 or equivalents shown in Figs. 10, 11, 13, and 13A are enhanced by data port 406 in Fig. 13.
- data port 406 As specifications for smart battery bus extensions open up powered devices' parallel, serial, PC Card, USB and infrared data ports, power adapters such as the variants of 335 are capable of participating in bus communications.
- the bi-directional data system described above can serve as a precursor to the power apparatus described by Castleman.
- Castleman describes an embedded power and data bus, but does not allow for data access to a battery port.
- ⁇ by powerline modulation the minimal power information (consisting of the voltage and current values required by Castleman) from a battery pack to an external device such as a power adapter (335B in Fig. 13); then, secondly, transmitting the power information now captive in the power adapter to its available data port (connector 406, or infrared port 412) where, finally, the power information is now stored in the powered device's ROM, RAM, or written to a storage medium.
- the power information which originated at a battery has now been transferred to the battery's associated powered device.
- the power information is stored within the powered device until the powered device is attached to the Castleman apparatus.
- One of Castleman's data cables can then extract the stored power information from the powered device, and use it to configure the output of their embedded power system.
- Castleman can also access the battery port via a connector 290 in Fig. 8, for example, used in conjunction with a module 347 in Fig. 10.
- Module 347 is needed because Castleman addresses common data ports, and not ports that support SMBus (or Dallas 1-Wire) data protocols. Therefore, module 347 is needed to translate smart battery bus data to a format readable by Castleman's apparatus.
- software 800 in Fig. 1 A is already resident either on a powered device (and/or embedded in a powered adapter 335 or a module 347), a Castleman- compliant cord with an embedded Dallas chip can be connected, and the chip can be written-to from a modified version of software 800. Thereafter, the cord can be used according to Castleman's apparatus.
- the Dallas Semiconductor "I-Button" series of writeable data chips can be written-to using a 0.5-volt power signal at a parallel port, as a method of creating a Castleman- readable chip.
- the modality of power adapter 335B with a connector port 406 as shown in Fig. 13 also gains an additional safety feature.
- Adapter cords especially when used on an airplane, can become disconnected from the powered device. This can occur simply by the weight of the adapter, dangling from a passenger seat's food service tray causes a connector to become disconnected. That problem is resolved by attaching data connector 406, or an equivalent, to a powered device, as shown in Fig. 10.
- This arrangement makes for a clean implementation without dangling cords, and has the adapter firmly anchored to its powered device. This arrangement also minimizes cord fatigue, thus extending the life of the power adapter assembly.
- Fig. 11 shows an intermediate data acquisition module 357 to which a plurality of power supply types and battery packs can be connected.
- This module is not restricted to the form-factor of an in-line device. It can be expressed, as a non-Umiting example, as a PC Card (previously PCMCIA card). It can be a module that communicates with a powered device by attaching to a data port, or that wirelessly sends voltage and other information from software 101 or 800 in Fig. 1 and 1 A to a powered device.
- software 101 and 800 can operate without a power supply, per se. by using a module 357 to acquire data at a battery, then to convey it to a powered device through any available data port, so as to render such data accessible to software.
- the commonality of the hardware assemblies in Figs. 10, 11, 13, and schematically 13A is that they are all closed-loop systems.
- a powered device accesses its own battery via an external module in order to identify the power device's electrical characteristics, in particular voltage (and perhaps load current). Once acquired, this power-related data can be stored in a powered device's internal memory, written to a hard drive, or otherwise logged in an accessible location. By placing battery information at the application level within a powered device, for example a laptop, this data can be accessed by a plurality of power-specific devices.
- software that relates to power management can, when assisted by a hardware assembly 400 in Fig. 13 A, monitor battery capacity by updating changes in voltage (and/or) real-time current loads that are indicators of remaining capacity.
- Adapter Voltages Don't Match Battery Pack Voltages Users of powered devices have specific needs for battery information that are addressed by one or more of the modalities of software 101 and 800 in Figs. 1 and IA. Non-Umiting examples of these needs have already been defined as not charging batteries on aircraft, or to access an embedded power system by creating a "smart cord.” Users are connecting an external power system to a powered device at its battery I/O, and not to the usual power input port. A powered device's battery port typically does not accept the same voltage as would the power adapter input jack located elsewhere on the powered device. A powered device that operates on a 12 VDC battery wiU typically require a higher voltage at its external power port. This is usually dictated by the need to charge the battery pack from a power source that delivers a higher voltage than the battery, itself.
- any of the hardware assembUes shown in various figures herein will correctly identify a powered device's voltage, when used with software 101 and 800 in Figs. 1 and 1 A. Furthermore, that same software and hardware can verify that an adapter is the correct one for that powered device. 5
- a connector 132 operates by isolating the cells within a battery pack 134.
- FIG. 6A and 6D 10 view of male connector is shown in Figs. 6A and 6D.
- battery cells 182 are electro-mechanically separated from battery housing's exposed contacts 174 and 175 at power interface 194.
- the internal wiring of battery pack 134 has been reconfigured to include a connector interface comprised of contacts 176, 178, and 180.
- conductive lead 188 from ceU(s) 182 only connects to exposed contact 174.
- Positive lead 188 has been rewired with a "T"-
- connection 190 creating new conductor 188 which terminates in spring contact 180.
- Software 101 and 800 in Figs. 1 and 1 A operates according to the various positions of connector 132 in Figs. 6-6C.
- Fig. 6A By referencing Fig. 6A to establish the conductive and insulator of male plug 132, the first position of inserted male plug 132 into the mating contacts 176, 178, and 180 within battery pack 134 is indicated in Fig. 6B.
- the conductive path created by the insertion of male plug 30 132 flows from battery cell(s) 182 along the first conductor 184, to spring contact 176, where the electrical signal is transferred to male plug 132's conductor 202 (as shown in Fig. 6A) then on to an external power source.
- a second electrical path is along conductor 188, then continuing along conductor 18 where the electrical signal is transferred to male plug 132's conductor 206 (see Fig. 6A), then on to an external power source.
- the direction of electrical flow along the paths described above is from the battery cell(s) 182 to the external power source.
- This allows software 101 and 800 (Figs. 1 and 1 A) in the external power source (or a separate device) to acquire power-related information, such as a voltage of battery ceU(s) 182.
- Software 101 and 800 use both a Vmin voltage (under load), and a Vmax (no load).
- a suitable resistive load is applied in the external power supply to allow a Vmin voltage reading. If current readings are required, this resistive load is also used.
- resistive elements 108 and 108 A in Figs. 2 and 2 A and the related text in the Description for further information on the resistive load and related wiring.
- Fig. 13A uses resistive elements 517 and 521, as discussed in the section "Vmin").
- Software 100 and 800 (Figs. 1 and 1 A respectively) use the acquired information on voltage (and current if indicated) to configure an external power supply - for example, the representational power supply 122 in block diagram Fig. 2.
- the software processes are defined in "Software to Configure Battery and Power Delivery Hardware.”
- connector 132 must be repositioned. A user is instructed to remove connector 132 from battery pack 134, and to axially rotate it. This rotation switches the position of conductor 202 and insulator 208 (see Fig. 6A), so the conductor and insulator are now the obverse of their original positions.
- Fig. 6C shows male connector 132 in a second position.
- Power signal from a power source flows along conductor 202 (Fig. 6A) in male connector 132.
- Conductor 202 in connector 132 (Fig. 6C) is now electrically in contact with spring contact 178, so that power from the external power source 122 now continues along powerline 186 to contact 175 on battery pack enclosure's connector 194.
- a power signal from the power source in Fig. 6C flows along conductor 206 in male connector 132 (Fig. 6 A) which is now electrically in contact with spring contact 180, so that power from the external power source can now flow along powerline 188 A to interconnected powerline 192, then to contact 174 on battery pack enclosure's connector 194.
- battery pack connector 194 is mated to connector 196 of "system” (i.e., powered device 136)
- a power signal from the power source flows into powered device 136.
- the two branches of this Y-connector - one of which leads to battery cell(s) 182, and the other branch to powered device 136 - are selectable by positioning the conductive side 202 of a male connector 132 to be electrically attached to one branch or the other.
- Figs. 9A- 9C show either disrupted positive or ground lines.
- Each battery pack is addressed on a case-by- case basis in deterrmning which powerline to wire to spring contact cUps.
- Software 101 and 800 (Figs. 1 and IA) include reverse polarity detection and correction. Since the first position of a male connector 132 causes power to flow from a battery 182, the determination of polarity is obvious to anyone skilled in the art.
- One of the safety functions male connector 132 in Figs. 6-6E achieves is preventing battery charging. By electro-mechanically isolating the cells within a battery pack, battery charging is efficiently prevented. It may seem that the same function could be achieved with a totaUy non- conductive male connector 132 inserted into a battery pack circuit such as that shown in Figs. 6- 6C. With such a fully-insulated connector inserted, power could be delivered to the primary power port of a powered device, yet the battery pack would not charge. While this fuUy-insulated male connector approach would certainly electro-mechanically prevent battery ceUs from charging, the power signal at the primary power port of a powered device can stiU turn on the powered device's internal charger, and potentially damage circuits.
- a number of powered devices especially laptop computers, have a battery pack that is wired in series with the primary system circuits.
- the battery pack must not only be present, but operational (often a reference-voltage circuit is employed) for the powered device to function.
- powered devices are sometimes designed to execute a data handshake with a battery pack during system boot/initialization. If no battery acknowledgment occurs on the battery-system data bus, a host system may not operate. When powered from an external waU adapter, for example, some laptop computers w ⁇ l not operate because the system cannot locate a battery device.
- a laptop's battery is not only a secondary power source when no external power is available, but the battery serves an important Uninterruptable Power Supply (UPS) function. Should external power be lost (e.g., the external AC/DC adapter is inadvertently unplugged from the wall), data could be lost. Therefore, it is essential that the battery always be installed and available to act as a UPS.
- UPS Uninterruptable Power Supply
- Fig. 6E depicts a connector assembly and related wiring 212E, which is another modaUty of such a connector assembly depicted in Figs. 6, 6 6B, and 6C.
- the addition of a diode 185 in the circuit between opposing spring-loaded contact beams 176 and 178 allows a power signal from battery cell(s) 182 to flow along conductor 184, through diode 185 to conductor 186.
- the power signal now available on conductor 186 is accessible at contact 175, making power available from battery 182 to a powered device's system 136.
- diode 185 provides an alternative path for power.
- diode 185 provides an effective Uninterruptable Power Supply (UPS) function, even though connector 132 is still inserted in battery housing 134. This function also apphes should connector 132 be partially disconnected during power-delivery operations ⁇ if male connector 132 were fully withdrawn from mating female connector assembly 179, spring-loaded conductive beams 176 and 178 would close to provide an electrical path between battery 182 and powered
- UPS Uninterruptable Power Supply
- Diode 185 in Fig. 6E also provides a path for a battery 182's power signal at spring-contact 178.
- the male connector 132 is required to operate in a two-position mode.
- Fig. 6B depicts a Position #1 of a male connector
- diode 185 does not allow a power signal to flow from conductor 186 into battery cell(s) 182.
- male connector 132 as inserted in Fig. 6E, can acquire battery cell voltage at conductive beam 178, since the conductive element 202 of male connector 132 is now in contact with conductive beam contact 178, instead of conductive beam contact 176 (see Fig. 6C for male connector 132's Position #2).
- a power signal from battery cell(s) 182 flows along conductor 184, then through diode 185, to conductor 186, where the power signal is available at conductive beam contact 178.
- diode 185 eliminates of the need to insert a male connector 132 in a Position #1. Instead, a single insertion into what was previously male connector 132's Position #2 is now all that is required.
- FIG. 6C shows the Position #2 power- delivery orientation of male connector 132).
- battery ceU(s) 182 can deliver a power signal to conductor 186 through diode 185, and an external power source is also simultaneously applying a power signal to conductor 186 through conductive beam 178, a state of contention appears to exist.
- the external power source's related software software 101 in Fig. 1, or software 800 in Fig. 1 A
- the voltage depression created by diode 185 works in favor of aUowing an external power source's Vout to be the dominant voltage on conductor 186.
- a "bleed resistor" 185 A is available that shunts across diode 185.
- This resistor is not essential to the operation of the invention. It allows a non-depressed voltage value to be available to an external power source. Without such a bleed resistor, software 101 (Fig. 1), or 800 (Fig. 1 A) in an external power source would compensate for the depressed voltage value caused by a diode 185 in the line. Such a resistor arrangement should be approached with caution, since it does create a potential bypass path around diode 185.
- Those skilled in the art will be able to properly implement such a resistor in the circuits shown, but the implementation of a diode 185 without an resistor 185 A is certainly appropriate in most circumstances.
- Diode 185 in Fig. 6E becomes electrically transparent to the battery circuit in battery pack 134, once male connector 132 is removed (see Fig. 6).
- a battery power signal flows through conductive beams 176 and 178, essentiaUy bypassing the strapped diode 185 (diode 185 will only be fully bypassed if there is a proper implementation of a bleed resistor 185 A, so that the power signal does not flow through resistive element 185 A).
- a diode 185 is not limited to that shown in Fig. 6E.
- An alternative location is shown in the detail of a male connector 132A in Fig 6F-1, which differs from the male connector 132 shown in Fig. 6E.
- Male 132A has conductive elements 202 and 202A above and below a central conductor 206, each separated from the other conductors by thin insulators 204 and 204A.
- Conductive element 202 does not pass through connector backshell 210, but instead terminates inside backshell 210.
- Diode 185B is strapped across conductive elements 202 and 202 so that the direction of power signal flow is from upper conductor 202, downward to conductive element 202A.
- conductive beam 176 is electrically active to male connector element 202
- opposing female conductive beam 178 is electrically attached to male connector element 202 A.
- the battery power signal can flow from ceU(s) 182 along conductor 184, to conductive beam 176, where it transfers to male connector element 202, then travels through diode 185B, and along conductive element 202A out to an external power source. This provides the voltage acquisition modes called out in software 101 (Fig. 1) and 800 (Fig, 1 A).
- the Vout voltage from an external power source must be of a higher voltage than that available through diode 185B, to aUow the power signal to be the dominant voltage on the shared conductors.
- the software flowcharts in Figs. 1 and 1 A can be modified by those skilled in the art to conform to the addition of a diode 185 in Fig. 6E (or in Fig. 6F-1). Elimination of the software steps which are used to verify a removal and reinsertion of a male connector 132 are REM'ed out. These are steps 716-758 in Fig. 1, and steps 920-938, and 991-971 in Fig. 1 A. Also, as previously noted, accommodation is made for the depressed voltage values acquired through diode 185.
- a power FET can be used in place of diode 185 in Fig. 6E, providing that there is an MCU (or equivalent controller) available in battery pack 134. Such an MCU 102D is indicated in Fig. 13 residing in battery pack 508B. The power FET would be switched in and out of the circuit, as controUed by the MCU. Those skilled in the art will be able to integrate a controUable FET switch into a battery circuit, using the information provided here regarding the placement and operation of a diode 185.
- FIGs. 9A-D Smart Battery Circuits Smart battery packs are addressed in Figs. 9A-D.
- Four possible wiring diagrams show power conductors configured analogous to Fig. 6-6C. Two major variants are shown as Fig. 9 A and Fig. 9C. These differ in where one of the power conductors ((+) or (-)) is rerouted.. either ahead or behind smart circuit 366. If the smart circuit design requires one of the output powerlines 368 or 5 376 to be electrically attached to smart circuit 366, then the wiring configurations in Figs. 9A or B is appropriate. In these two models, which only differ from each other in their polarity, disrupted powerline 388 is upstream of smart circuit 366. Essentially, external power supply 398 replaces battery cells 384. The downstream smart circuit 366 does not know that power is not coming from ceUs 384, so the entire system, including the corresponding "smart" circuitry in the associated 0 powered device, operates normaUy.
- Critical data values from smart circuit 366 in Figs. 9A and 9B are not disabled.
- the battery ceUs 384 now replaced in the power circuit by power supply 398, deliver adequate voltage in excess of the host system's Vmin requirement.
- Software 101 and 800 in Figs. 1 and 1 A respectively, always 5 round to the next highest voltage after performing its various calculations, so that a generous input voltage is detected on line 388 in Figs. 9A and B.
- Voltage drop toward Vmin is usually a prime indicator for a charge.
- the battery is the system master, and initiates the charging process.
- Fig. 9C and D represent alternative modalities to the wiring schema in Figs. 9A and 9B.
- Powerline 376 is disrupted downstream of smart circuit 366. This takes smart circuit 366 out of the host system's data loop. In certain implementations, this is desirable, especially for those smart circuits which rely on cell capacity (instead of voltage) to determine when charging is necessary. In most battery packs, the choice of which of the four modahties indicated that works best is somewhat 5 inconsequential, as it relates to battery charging. There is no external AC/DC power at a host device's primary power port. Since the wall adapter is not connected, there is no power available to the battery charging circuit in the host device!
- Figs. 6-6D, and 8 are not the only method of isolating a battery (s) 182 from a powered device 136.
- Figs. 10, 11 show externally attached interfaces that provide a suitable way to power a host device through a battery compartment, while maintaining analog (power) and digital (data where applicable) connectivity to a battery pack (see PCT Patent Application No. PCT/US98/ 12807, and U.S. Patent Application No. 10/105,489).
- the battery pack is a "smart" design, it will likely be necessary to include the smart circuitry in such an empty plastic housing, so that the powered device can communicate with its battery.
- the cost of this "empty" battery enclosure and its expensive smart battery circuitry make it a poor substitute for a fully operational battery pack.
- the addition of battery cells to such a construct would not add significantly to the already high price of such a semi-empty enclosure.
- such modified battery enclosures have no practicality in environments where battery charging is desirable. Transporting such empty battery packs is also an inconvenience, since even empty battery housings can be quite bulky. For example, a Digital FfiNote Ultra 2000 laptop's battery pack measures 3/4 x 2 1/4 x 11.”
- Male connector 132 in Fig. 6A is expressed as a flat-bladed assembly 132, comprised of two insulator layers 204 and 208, and two conductive layers 202 and 206. These layers are interleaved so that the outer layer on one side of the "blade" is an insulator 208, while the outer layer on the opposite face is a conductor 202. As configured in Figs. 6-6D, conductor 202 always is negative (-), while conductor 206 is always positive (+).
- the polarity of conductors 202 and 206 is not limited to a negative (-) line being broken by the insertion of a blade assembly 132 into a mating female assembly in battery pack 134 in Figs. 6-6C.
- a positive (+) conductor can be interrupted instead, to ensure that the cells within a battery pack are removed from an active circuit, as illustrated in Fig. 9D. So too, in some implementations, it could be necessary to disrupt only one data line (should there be data and power lines available), to achieve the effect of disabling the battery pack. As previously noted under “Safely Disabling the Battery,” certain powered devices may require a data link between a battery pack and the host system to be preserved in order for the device to operate.
- disrupting the positive (+) power conductor can still provide data communications, if the negative (-) power line is used in conjunction with one or more of the data lines.
- preserving a powered device's functionaUty include disrupting only a data line (for example, the "C" (Clock) line), so that the data communications can still occur, but without sufficient capabilities to let the battery pack charge or perform other undesirable functions.
- Software 101 and 800 can be used without the full A/D functions defined in Figs. 1 and 1 A respectively.
- battery pack "design" voltage, and actual voltage are readily available from a “smart" battery's internal data registers.
- an alternative modality is to acquire digital data.
- the A/D functions would still be necessary, in such examples, for sensing other power functions, such as the output voltage of a power supply 122 in Fig. 2.
- the hardware required to acquire digital data can include a different "key" connector interface 132 between a battery pack 134 and a module 100.
- Fig. 8 illustrates a multi-contact male connector that is capable of being both power and data enabled.
- battery cell(s) 182 in Fig. 6B deliver a positive (+) power signal along power lead 188 to T- intersection 190, than along lead 188 A to spring contact 180. There, the positive (+) power signal is transferred to male connector 132's conductor 206 (see Fig. 6 A), then out to a power lead 114 or 116 in cable 115 (Figs. 2 and 2A). 5
- Battery cell(s) 182 in Fig. 6B deliver a negative (-) power signal along power lead 184 to spring contact 176. There, the negative (-) power signal is transferred to male connector 132's conductor 202 (see Fig. 6A), then out to powerline 114 or 116 (Fig. 2 and 2A).
- assembly 212A (Fig. 6B) and 212B (Fig. 6C) assumes a reasonably quick removal of male connector 132 from battery pack 134. There is a transient moment when spring contacts 176 and 178 are reclosing to each other. Laptops typically have capacitor circuits which provide a few milliseconds of hold-up time. This is usually to accommodate minor irregularities in the electrical interface between the battery housing 134's contacts 174 and 175 and the mating 5 contacts 190 and 200 in the powered device 136. Spring clips are often used as contacts 198 and 200, so minor intermittent electrical contact is expected, as the battery pack can shift as a laptop is being carried, or moved around on a desk, while operational.
- the end of the "blade” is tapered to a thin edge. Being 0 conductive, the shape of this tip allows a virtually continuous power flow at spring clips 176 and 178 in Fig. 6 as the connector blade tip 548 in Fig. 6D is being inserted or withdrawn. Should there be a need to keep power flowing more reUably between spring contacts 176 and 178 in Fig. 6, blade tip 548 in Fig. 6D (and any equivalents) can be gold plated, as well as contacts 176 and 178.
- the geometry of the curved portion of the "throat" between spring cUps 176 and 178 can be contoured to allow the mating surfaces of clips 176 and 178 to make reUable contact with each other before the electro-mechanical contact with a blade tip 548 in Fig. 6D is disconnected. This may be nit-picking, especially since it is not anticipated that there will be situations in which powered device 136 in Fig. 6 is still turned on when "key" connector 132 is voluntarily withdrawn. In unanticipated events like a user tripping on a cord and disconnecting it, the contacts 176 and 178 are electrically closed in a matter of a few microseconds, typicaUy.
- Fig. 8 illustrates a multi-contact male connector 290 that is capable of conducting both digital and analog data (see U.S. Patent Application No. 09/378/781, and International Patent Application No. PCT/US99/19181).
- Fig. 8 represents a different modality of a male connector 132 in Figs. 6-6D.
- the eight conductive contacts 306, 308, 310, 312, 320, 324, 326 and 328 can be assigned analog and/or digital lines.
- contact 320 is an analog (-) power contact
- contact 324 is assigned to the ("T") Temperature digital data Une.
- Contact 326 is ("D") data
- 328 is ("C") clock as representing the traditional five-conductor wiring schema of a smart battery (reference Fig. 9A-C and elsewhere).
- male connector 290 's point 316 can be rendered conductive, to accommodate a fifth (+) Une to yield full smart data and power connectivity between an external power source, a battery and a powered device. If the goal is to disable battery charging, typically only one conductor of the five need be disrupted (that particular power or data line can vary from battery to battery, based on a manufacturer's implementation of smart battery communication).
- contacts 306, 308, 310 and 312 are non-functional. They need not be present at all in most configurations. They are shown here because some battery or host system implementations can require them to be jumpered, have a resistive load or, in instances where a device in the system needs an identifier to operate, provide access to a readable chip (not shown).
- a readable chip not shown.
- Castleman's U.S. Patent # 5,570,002 requires a Dallas Semiconductor chip to be read. This chip identifies the output voltage of an external power source.
- This smart chip has some 32 data registers, one of which is the battery manufacturer's design voltage.
- contacts 320 (-) and 326 (D) will deliver the battery's design voltage from the battery pack's smart circuit, without the need for Castleman's proprietary and dedicated chip embedded in a cord or connector. It should also be noted that, while Castleman suggests that power-related information can be elsewhere in the host system (such as in ROM and RAM), the SMBus Smart Battery specifications specifically preclude access to smart battery data at the software level, as well as to any existing analog or digital ports on a host device.
- Male connector 290 in Fig. 8 is designed to rotate like a key inside a mating female connector (not shown), instead of being removed, rotated and reinserted, as does removable connector 540 in Fig. 6D.
- the eight contacts 306, 308, 310, 312, 320, 324, 326, and 328 are offset and staggered along the length of insulated shaft 322. By off-setting the contacts, there can be as many as 16 mating contacts in a battery pack, so that a plurality of data paths can be created as male connector 290 is rotated between two positions. The 16 contacts would result from a two-position rotation, whereby aU 8 contacts are active in each of those two positions.
- Fig. 8 shows five wires 292, 294, 296, 298, and 299 attached to connector 290.
- powerlines 292 attached to contact pad 320
- 299 attached to conductive tip 316
- Connector tip 316 is utilized in this non-Umiting example as making electrically conductive to the (+) contact in the battery pack. If there is a shared ground, only one contact (here 316) need be electricaUy active.
- wires 294, 296, and 298 are data lines, and are typically not essential to the operation of software 101 and 800 in Figs. 1 and 1 A respectively.
- a mux or n-signal switch (not shown) can be incorporated in shaft 322 or connector handle assembly 300/302 of connector 290. Such a switch allows a less-cumbersome 3 -wire cord that has all of the data functions of a five-conductor cord when using a Dallas 1-Wire approach.
- the implementation described here of acquiring a power device's power values at the time of use is not used by Castleman.
- Castleman deals with the voltages that power a host device at its primary power port, and not with the different voltage values used to power that same host device through its battery port.
- Data is stored on the DaUas DS2437 (or equivalent) chip in its 40 bytes of EEPROM memory.
- This memory as designed by Dallas Semiconductor, can survive even short circuits, so its use in a line-switching circuit is beneficial.
- a microcontroller such as the DaUas Semiconductor DS87C530, or the Mitsubishi M37515 (or equivalents) can be used to create a simplex switch, via a multiplexer, that allows two lines to be shared for bi-directional data. There would be no frame ground present.
- Such muxed lines on a serial port require software protocol controls for send/receive collision avoidance.
- RS485 transceiver chips to estabUsh CMOS signals on one side (receive out, driver in) and a send/receive pin.
- the output is a 5-volt differential as simplex.
- a "slave" processor (as circuitry in male connector 290) is in "Usten” mode, until another processor ("master” in an external power supply) sends a command to acquire and send data.
- Software aUows for some period of latency while the slave acquires data, such as actual voltage. Once the data is sent, the slave goes back to a listen mode.
- One line works in both directions, as a shared data line.
- RS485 chips from National Semiconductor (Santa Clara, CA) are available that share common differential Unes and have common CMOS Unes with transmit and receive signals.
- two general-purpose I/O port pins are used, one of which is the Tx/Rx pin.
- Software writes a 0 to put the line in a transmit mode, then changes the pin back to a listen mode.
- the communications protocol can be loaded to the 16 Kb of EPROM on the Dallas Semiconductor DS87C530, for example.
- Power on the two-conductors is +5 VDC, which can be generated by a regulated battery voltage 5 in the circuit. This is preferable to using the variable output voltage of an external power supply. Power supply should be shut down when the system is in a communications mode, to free the two power conductors for data. However a power supply can deliver +5 VDC to its microcontroller, but not apply such a voltage directly on the power/data conductors directly. Those skilled in the art can execute such two-wired communications schema as defined above.
- Fig. 7 shows a simplified power interface 250 with a battery bay 280.
- a thin flexible insulator 262 uses conductive traces 264, 266, 268, and 272 to interact with a rechargeable-battery-powered device 284.
- Two conductors 264 and 266, are separated by insulator layer 262.
- Conductive traces 264, 266, 268, and 272 are separated by insulator layer 262.
- flex assembly 250 When inserted between contacts 274 and 276 of battery cells 288 in Fig. 7, and electrical contacts 20 276A and 278 in battery cavity 280, flex assembly 250 creates two discrete circuits.
- One circuit is to the batteries comprised of traces 264 and 272, while the opposing contacts 266 and 268 electricaUy create a circuit to host device 284, so that traces 266 and 268 create a circuit that effectively bypasses cells 288.
- This aUows external power sources, such as a power supply and/or battery charger, to operate either simultaneously or independently, to power a powered device 25 284, and to charge a battery, both functions being performed on the discrete electrical paths created by a flex-connector 250.
- a flex-connector 250 in Fig. 7 has four discrete wires 252, 254, 256, 258.
- the flex-connector assembly in Fig. 7 has only power conductors. Switching power conductors in order to minimize cable size could require a substantial circuit of power FETS.
- assembly 250 is designed to be compatible with software 101 and 800 in Figs. 1 and 1 A, continuous power along any conductor pair is not required so the use of switching FETS is acceptable. With a four-conductor cable as shown in Fig.
- battery 288 can be 5 hardwired for continuous monitoring.
- Software 101 and 800 (Figs. 1 and 1 A respectively) can be modified to aUow for four-conductor use, and references to insertion/retraction (or, in the alternative, rotation) of a male connector in the software Specification would not be required. Either the use of power switches, or simply relying on the continuous monitoring available from a four-conductor system, will work with the flowchart of software 101 and 800. 10
- Assembly 250 in Fig. 7 has the advantage of being left permanently, or semi-permanently in place.
- a simple 4-pin connector can be fitted to the flex assembly 250 where wires 252, 254, 256 and 258 interface.
- This connector is designed to accommodate the previously-mentioned switching circuit.
- an attenuator n-signal switch such as those available from Maxim Integrated Products (Sunnyvale, CA) can be used. It can be wired so that voltages
- An external power source (such as hardware assembly 100 in Fig. 2, or power box 400 in Fig. 25 13 A) can read the actual voltage (both load and no-load) of battery cell(s) 182. This information is acquired through the various pins of an A D converter 102B (see Fig. 2 A), and either stored in memory 102 or immediately used to compute a valid voltage value to which a configurable power supply 122's output can be set.
- Power Delivery Connector 132 in Figs. 6-6C is first addressed in software 101 and 800 (Figs. 1 and 1 A) as being disconnected.
- Software 101 knows each position of connector 132 as it is repositioned through the various machine states in the software flowchart. The most important connector state is when a male connector is disconnected from its associated battery pack 134. The disconnected state indicates to software 101 (and 800) that a process is expected to start, or has just been completed.
- the state of male connector 132 provides a confirmation that the software logic-flow and state changes have been observed by the user.
- a male connector 540 and its associated power cord, as an assembly, has a known resistive value. That value is fixed at the time of manufacture; pre-calibrated to be all of the same matched impedance.
- a connector cover 530 in Fig. 6D, or equivalent, can be employed. Cover 530 has embedded resistor 534 (or some other resistively-stable component) that expresses a repeated and readily-identified Ohm value. When cover 530 is in place, software 101 (Fig. 1) acknowledges the identification of resistive element 534 as a "pre-operational" state, i.e., a user is present and has attached connector 540 to its power cord.
- ARINC Specification 628, Part 2 was not approved as of the time of this writing.
- the hardware device states can apply to the operation of a power cord on an embedded retractor reel. In that mode, either the motion of the cable extension incorporates a sensor that "awakens" power module 100 (Fig. 2), or MCU 102 (Fig. 2 A) samples powerline impedance as an indicator of impending passenger activity.
- Power supply 122 in Fig. 2 turns on periodically at a low output voltage, e.g., 3 VDC or less, to perform Une load impedance readings. If the load value at A/D I/O port 110 (Fig. 2A) is the same as a stored value that equates (in look-up table 990 in Fig. 20) to a blank cable (no removable connector such as 540 in Fig. 6D present), then power supply 122 shuts down until the next polling test. If connector 540 is removable, instead of permanently affixed to the end of a power cable, as shown in Fig. 6D, then sensing the presence of removable connector 540 is an important indicator of a state change that will result in further software and hardware activity.
- a low output voltage e.g. 3 VDC or less
- connector 540 in Fig. 6D is sensed by an MCU 102 (Fig. 2), either with or without its connector cover 530, hardware assembly 100 in Fig. 2 goes to a full ON state.
- Software 101 or 800 puts MCU 102 into an accelerated powerhne sampling process. That process is to detect the removal of cover 530, in anticipation of the insertion of connector 540 into a battery pack (see Figs. 6-6C).
- a resistive element 534 (or equivalent) is embedded in the connector's shell 544. That resistive element 534 is strapped across electrically conductive connector elements 546 and 548 but is located within connector shell 544.
- resistive element 534 in cover 530 has conductive pads 532 and 536. When cover 530 is in place, pads 532 and 536 make electrical contact with conductive surfaces 548 and 546 respectively on connector 540.
- cover 530 in Fig. 6D (with an internal resistive element 534, or an equivalent) is a beneficial aid to the operation of power system 100 in Fig. 2.
- Nesco Battery Company manufactures a "Smart Cord” which uses a variety of resistors in its powerline connector to identify or distinguish the output voltage of a "Smart Adapter.”
- the Nesco patent uses the resistive load to decrease a power supply's output voltage.
- the resistor element is used as a resistor, and not as an identifier.
- the resistor element used by Nesco is a passive electrical element, for purposes of its load changing (voltage reduction) ability.
- the Nesco patent does not allow for removal of the resistive element, while connector cover 530 is removable, thus taking the resistive element out of the active circuit.
- the software herein interacts with a multiplicity of hardware devices, defined above as "Hardware to Configure Battery and Power Delivery Software,” to configure a power supply output, and/or, in certain modalities, to detect and respond to battery-related activities, such as battery charging.
- Software 101 and software 800 have significant commonalities. Voltage and current sensing processes are common to both, as well as power supply output-voltage determination. While not limiting, software 101 is usually specific to an embedded hardware platform, while software 800 usually runs on an in-line, corded power conversion adapter. One non-Umiting assumed modaUty is that an in-line, corded adapter (running software 800) is attached to an upstream embedded power supply assembly (running software 101). Software 101 is also an abbreviated version of software 800 in certain areas, primarily in not showing every one of a number of nearly-identical powerline-load monitoring sequences.
- Software flowchart 101 in Fig. 1 operates with a plurality of hardware devices, non-limiting examples of which are described in the "Hardware" section.
- the general software principles of operation are shown diagrammatically in Fig. 12. Three overall types of software operations are performed: data acquisition 330, processing 332, and command/control 334.
- Data acquisition 330 operations include identifying the position of a connector such as 132 in Figs. 6-6C.
- a connector such as 132 in Figs. 6-6C.
- FIG. 17 There are three possible connector positions 340, as identified in chart 1001 (Fig. 17).
- Fig. 6 shows connector 132 removed (not connected).
- Fig. 6B depicts connector 132 inserted to create an electrical path that includes only battery 182 (i.e., Position #1 in Fig. 17).
- Fig. 6C shows connector 132 inserted to create an electrical path bypassing battery 182, and only including power lines to system 136 (Position #2 in Fig. 17).
- Later discussion deals with software 101's ability to correctly identify each of these three connector positions.
- Data acquisition operation 330 in Fig. 12 includes the acquisition of electrical (power, or data) values 342. Only two modes exist. The acquisition of battery voltage 354, or the verification of power supply Vout 356. These are detailed later.
- Processing operation 332 in Fig. 12 includes, but is not Umited to, performing various calculations 338, and/or storing various acquired values 328.
- Command and control operations 334 (Fig. 12) of software 101 in Fig. 1 require only one command operation - to configure the appropriate Vout 344 of a power supply.
- the screen display 346 capability of software 101 is optional, but should be considered in implementation because it assists a user in properly using connector 132 in Figs. 6-6C.
- Confirm a power output signal from a power source can compare a manufacturers' output voltage of a battery to the output voltage of a controUable/configurable power supply, to verify that both are either matched, or within predefined nominal parameters.
- look-up tables are created from a database of prior operations that become part of a decision-making process in software 101. The look-up tables, once created from an experiential database, contributing further levels of power output signal verification.
- Control hardware including but not limited to sequencing switches, controlling I/O ports, data lines, power-signal lines, and configuring a power supply's output.
- Functions of software 101 in Fig. 1 are not limited to those described above, but the above non- Umiting examples iUustrate software processes which add operational value to a pluraUty of hardware devices.
- Fig. 14 is an example of an instruction sheet or label that prompts a user to move sequentially through the required steps with connector 132 in Figs. 6, 6B and 6C.
- An optional step is shown in the first instruction in Fig. 14: "Close cap on 'key' connector.”
- Cap 530 is shown in Fig. 6D, and it need not be used to achieve the functionality of software 101.
- An explanation of the use of optional cap 534 is discussed in the hardware section.
- Connector 132 can also be detachable from its power cord, so part of the first instruction in Fig. 14 would prompt a user to attach connector 132 to its cord.
- User instructions are only suggested here, and there are a number of ways such instructions - if necessary at all - can be conveyed to a user.
- Software 101 in Fig. 1 defines a process achieved by a sequence of steps or machine states, each of which, in and of itself, or in a multiplicity of non-limiting combinations with other discrete steps, adequately perform a desired function. Particular steps required are primarily determined by the function to be performed, as well as available hardware and the hardware assembly's capabiUties and configuration. To perform a function, software 101 must execute at least one step defined in flowchart 101 in Fig. 1.
- Machine states or steps are structured to operate in different sequences. Also, not aU of the steps or machine states need be operational for a specific hardware device or assembly of devices.
- Code for software and sequence(s) can reside on storage media in a powered device, while other core elements can reside on a chip in an external power supply (or even its associated battery), as non- Umiting examples.
- Such division or duplication of software code can, for example, be required because one device of at least the two required to achieve software functionality, can act as a master, while another device in the assembly can require equivalent software to function properly as a slave. It is not essential that there be more than one hardware device in which software code is resident.
- Software 101 in Fig. 1 is not limited to configuring the power requirements for hardware devices that have pre-stored information, or even by a device's ability to store information. Nor is software 101 limited in any way to delivering power to hardware devices which are comprised of memory, computer chips or DSPs, pre-determined resistor values, cords with pre-configured components (resistive or otherwise), or data storage. In actuality, software 101 is capable of power configuration and delivery functions with such diverse battery-powered devices as an ordinary flashlight, or a laptop computer.
- software 101 can reside in a configurable power supply embedded behind the dashboard of an automobile, with an available electrical outlet comprised of at least two power contacts (e.g., a cigarette lighter outlet).
- a controUable power supply can be configured, by the use of software 101, to automaticaUy power a 24-volt lantern, then a 9-volt portable radio, as well as a 5.5-volt ceUular phone.
- Each of these devices can be connected to this "universal" power port without any intermediate power-conversion adapters.
- software 101 provides functionality to an automotive distress situation, where a pluraUty of diverse input- voltage devices are required to operate properly without intermediate power conversion adapters.
- Minimal Software States Software 101 in Fig. 1 need only perform minimal processes to achieve the automotive functions as exemplified above.
- the hardware configuration in Fig. 7 represents a non-limiting example of a simple battery-powered device 284, like a flashlight, TV remote control, or portable radio.
- Software 101 to deliver a compatible power signal from an embedded power supply behind a car's dashboard, need only read battery 288 's voltage, and configure an external power supply (not shown, but the equivalent of a power box 400 in Fig. 13 A) to match that voltage.
- the battery's voltage would be 2.50 VDC.
- Software 101 configures the voltage output of a controllable power supply to 2.60 VDC.
- Software 101 if necessary, confirms and continuously monitors an external power supply's output voltage, but such confirmation is not essential to the proper functioning of device 284.
- Vmax 658 is the no-load voltage of a battery
- Vmin 680 is the under-load voltage of a battery.
- Software 101 can be programmed to look at either or both Vmax or Vmin values, but it must acquire at least one. The selection of Vmax or Vmin is typically not essential.
- a powered device with a battery source is designed to accept a Vmax voltage, since all batteries have an initial "pulse" voltage which can be a substantially higher voltage spike than a continuous Vmax. Therefore, matching Vmax is typically acceptable, if only one voltage parameter is to be acquired.
- Vmin the under-load voltage value of a battery
- the significance of Vmin is that it may, under certain conditions, also be a viable voltage parameter for an external power supply to match or to use as a basis of a calculation.
- the conditions which determine the vaUdity of Vmin are:
- the type of device being powered For example, complex powered devices such as laptop computers have a pre-determined shut-down or "not-to-exceed" minimum battery output voltage. This shut-down voltage is pre-set by the manufacturer of the powered device to prevent total discharge of a battery. In such complex devices as a laptop computer, the user usually receives audible and visual prompts that the remaining capacity of its battery source is approaching a critical state. While a "fuel gauge” which reads and monitors battery capacity can be used to trigger such alerts, a voltage parameter is often used to trigger alerts, as well as an eventual shutdown. The voltage parameter for powered device's pre-determined shut-down is always set enough above the battery ceU's minimal safe discharge voltage so that cell reversal does not occur.
- a flashUght In simple powered devices, such as a flashUght, there may be no pre-determined minimum battery voltage values.
- a flashUght because of cost considerations, is typically designed so that the consumer is responsible for keeping the battery charged. The only indicator that the battery is at Vmin may be that the light bulb no longer glows. 3). Battery care and charge/discharge life expectancy are determinants of a vaUd Vmin. Batteries self-discharge over time. If a battery has not been charge in 30 days, it's under-load output voltage could have gone below its powered device's minimum voltage shut-down value, especially is the battery capacity was nearly depleted when stored. Should the time between recharges become 5 excessive, the battery may be approaching (or have exceeded) its non-recoverable voltage value.
- Cell chemistry determines the non-recoverable voltage of a battery.
- Fig. 15 is a look-up table of common cell chemistries showing recognized manufacturer's design cell voltage, and a not-to- exceed minimum cell voltage. Below the minimum cell voltages indicated, damage to the cell can 10 occur, primarily from cell polarity reversal. Once cells are reversed in polarity, it is usually impossible to recover the battery, even with charging.
- Memory is a charge/discharge characteristic of some cell chemistries. Primarily Ni-Cad (and some NiMH) ceUs can exhibit an induced voltage threshold below which the cell will no longer 15 discharge. Repeated operations of a powered device which don't fuUy discharge ceUs usuaUy causes memory.
- the impact of memory on software 101 in Fig. 1 is not significant, because a memory-induced Vmin value wiU always be above the cell-chemistry-determined manufacturers' design voltage, as indicated in item #4 above.
- CeU "recovery” is a characteristic of many battery chemistries which causes a drained battery to have transient recovery of voltage after a period of rest. This is often observed when a flashlight that would not operate is turned on hours later, and the bulb burns for a brief moment. This characteristic of battery cells is a positive characteristic that makes it possible to acquire a valid Vmax from a battery that is, for all intents and purposes, fully discharged. That's why software
- a battery tester/reconditioner can be included in an assembly 100 in Fig. 2. This is indicated in situations where a large number of mixed-type powered devices are attaching to a hardware assembly 100 (Fig. 2). As a non-limiting example, on a commercial aircraft, passengers may be connecting everything from cellular phones, laptops, rechargeable electric shavers, etc., to an embedded power assembly 100. Should battery charging be one of the functions prescribed for software 101 in Fig. 1 and related hardware, a battery tester and reconditioner screens many of the issues relating to Vmin and Vmax.
- Such testers/reconditioners as manufactured by Cadex Electronics (Burnaby, BC, Canada), enhance software 101 by evaluating battery aging, cell chemistry, and even voltage parameters.
- software 101 operates in a data acquisition mode and captures battery values and functional parameters. Much of this data can be acquired as pre-processed digital or analog values, so that software 101 operates to evaluate known data values, and configures appropriate hardware. While not shown, such a software program that operates with a battery tester/conditioner can be written by those skilled in the art, based on information herein.
- Software 101 acquires voltage and current readings and correlates them to user actions. Actions such as connecting a power cord to a male connector, and detecting the position of a male connector 132 in Fig. 6-6C are determined by states which software 101 defines in terms of voltage, or line current.
- Software 101 operates with only two basic acquisition modes, reading voltage and sensing current.
- reading voltage is used to acquire power-signal values of a battery, as previously discussed.
- Detecting voltage is also used to determine states of a male connector 132 in Figs. 6-6C. If voltage flow is detected along power lines 115 in Fig. 2, the power can only be from battery 134, or from external power supply 122.
- software 101 commands the operations of power supply 122, and voltage detected on power lines 115 when power supply 122 is shut down must come from battery 134. Since connector 132 in Figs. 6-6C (and elsewhere) can only be in the Position #1 shown in Fig. 6B, software 101 identifies the position of connector 132 as being in the position shown in Fig. 6B by sensing battery voltage.
- Connector 132's Position #2 from Fig. 17, shown in Fig. 6C is only subtly different from connector 132's "Not Connected" position shown in Fig. 6. Both positions have connector 132 in a non-voltage-carrying modality, so detecting voltage with software 101 is not appropriate. Sensing current as a software acquisition value resolves the issue. Connector 132 in a "Not Connected" position shown in Fig. 6 is only different from that same connector 132 as shown inserted in Fig. 6C (Position #2).
- an electrical load is available that is not present when connector 132 is in the "Not Connected" position shown in Fig. 6.
- This load is created by the internal circuitry of a powered device's 136 system wiring.
- Such circuitry would include loads imposed by capacitors commonly used to allow a small hold-up time related to contacts at system-to-battery connector 1 6.
- Also present can be circuits which include battery selectors, various power switches, voltage regulators, an internal charger etc. Any or all of these can be present, which provides sufficiently identifiable resistive load to differentiate a current reading from one taken on a no-load powerline (See discussion and Chart of Fig.
- Table 1001 in Fig. 17 is a description of connector positions, with corresponding software sensing functions.
- Software 101 in Fig. 1 monitors load on powerlines 115 in Fig. 2.
- Conductors 114 and 116, along with unattached connector 132 constitute a very rr ⁇ nimal resistance, which software 101 logs as the "Not Connected" device state of Fig. 17.
- Fig. 6D illustrates a removable connector cover 530, which has an embedded resistive element 534. Resistive element 534 has a known resistive value, which software 101 uses as a current-sensing load comparator.
- Connector 540 in Fig. 6D can also have a first (or even a second) resistive element, so that software 101 can sense that a connector 540 (or equivalent) is attached to a power cord (assuming that connector 540 is made removable, a feature which is not necessary for the proper operation of software 101).
- Supplemental resistive elements can consist of part of the internal wiring of a battery housing, as shown in Fig. 6C.
- Fig. 6E shows a diode that wiU indicate some load. This will assist software 101 in situations when there is no available resistive load from a powered device's internal system circuitry. It can also be practical to build a resistive element into the circuitry in a battery pack as positive indication that connector 132 is in the position shown in Fig. 6C.
- Resistive element 199 in Fig. 6C is optional. If used, it has a resistive value distinctively different from resistive element 534 in Fig. 6D. This allows software 101 to identify each of connector 132's two positions in Fig. 6 and 6C as uniquely different and readily distinguishable.
- a resistive element 199 does cause a load to battery 182, so the use of such a resistive element must be viewed in Ught of faster battery drain.
- One of the system states identified in look-up table 990 is LL 4 , a battery pack that is removed from its associated powered device.
- the known value of resistive element 199 in Fig. 6C is a valid indicator of this state.
- Power supply 122 in Fig. 2 is turned on and configured by software 101, to output a low voltage, e.g., 3 VDC. At this low voltage resistive loads can be sensed on power lines 115.
- step 233 is a powerline voltage check. If there is voltage detected on the powerlines, connector 132 is in its Position #1 (Fig. 6B). Since software 229 has shut down its associated power supply in previous step 231, the only source of power in the circuit can be the battery pack. Therefore connector 132 is in its first position in the battery pack where it is electricaUy active with battery ceU(s) 182. If connector 132 were in the battery pack, but in its Position #2, no battery voltage would be detected on the powerlines in software step 233.
- a second powerline voltage check is performed in step 237.
- the state of connector 132 is unknown, because there is no battery voltage detected on the powerlines.
- Step 243 confirms that the voltage detected on the powerUnes is from the power supply.
- step 245. By consulting a look-up table such as in Fig. 20, the powerUne load value acquired in step 245 is determined to match the load expected when connector 132 is inserted into a battery pack in its Position #2 (see Identifier states LL 4 and LL 5 in Fig. 20). Thus, step 247 confirms that connector 132 is in its Position #2. Since this is the correct position for delivering power to the battery's associated powered device, step 249 applies the correct output voltage at the powerlines. Note that all error states, indicated by what are FALSE answers to any query statement, loop back to a power supply shutdown in step 231.
- Software 101 in Fig. 1 monitors user actions in operating connector 132 in Figs. 6-6C. While software 101 can identify each of the three required connector positions ("Not Connected" as Fig. 6); inserted to create a circuit with battery ceUs (Position #1 as Fig. 6B); and inserted to create a circuit to a powered device (Position #2 as Fig. 6C), the software must wait for each of the two 10 last actions to be performed before continuing. This creates a timing issue. A user may, for unknown reasons, take an indeterminate amount of time to move connector 132 from Position #1 to its next position as Position #2.
- a user's actions are detectable by software 101 when inserting and removing connector 132, as 15 represented by "Not Connected” in Fig. 6, and Position #1 in Fig. 6B.
- Software 101 sees a voltage from battery 182 upon the insertion of connector 132, as represented as Position #1 in Fig. 6B.
- Software 101 can also, by applying a low voltage to powerlines 115 (Fig. 2), monitor current load to verify that connector 132 is removed as "Not Connected” in Fig. 6.
- a user could, while connector 132 is delivering the low voltage required to sample current, reinsert connector 20 132 in the same configuration as shown in Fig. 6B instead of going to Position #2 in Fig. 6C.
- a diode in the positive (+) output line of a power supply (such as the representational schematic in Fig. 4) wiU eliminate this.
- the voltage sense Une at header Jl, pin 20 in Fig. 4 should be tied to the 25 positive power output line so as not to be impacted by the diode. Those skilled in the art will understand how to properly implement such a protective diode.
- a diode that will protect power supply 122 in Fig. 4 also aUows software 101 to turn on power supply 122 to a low voltage (e.g., 1.5-3.0 VDC), in anticipation of the insertion of 30 connector 132 in its correct Position #2 configuration, as shown in Fig. 6C.
- software 101 While waiting for connector 132 to be reinserted software 101 continuously switches from voltage sampling to current sampling.
- This switching assumes three dedicated A/D circuits, with a circuit 110 in Fig. 2 A which samples powerline voltage, while two dedicated current-sensing circuits 106 and 112 monitor current by means of a resistive element 108 and 108 A. Each resistive element has a different resistive value, with one being approximately 50% of the anticipated maximum load of a powered device.
- Fig. 5A shows a circuit for applying a load at an A/D port, which is compatible with the circuit of a typical MCU in Fig. 5.
- Software 101 in Fig. 1 can be configured to operate in a number of data acquisition modes. Of these, the most popular is probably a "point count" based schema, instead of an actual-acquired value model. The use of point-counts and Boolean variables is well understood by those skilled in the art, so specifics of such software processes is not detailed here.
- Point-count based software algorithms and logic statements are preferred in the implementation of software 101. Acquisition of voltage and current should be addressed as relative values, not absolutes. Battery discharge states are relative, so that Vmax and Vmin can differ for the same battery when sampled at different times. Ranges of battery voltage values are more important than absolute values. Software 101 reUes on the spread between a Vmax and Vmin to achieve a proper output voltage from a power supply. In one modality of software 101, acquired battery voltage values are arranged, from lowest to highest (see steps 913-915 in Fig. 1), to determine whether the original Vmax and Vmin are potential errors.
- Granularity of the A D Point-count software schemas are dependent on the bits available from an A/D converter.
- An 8-bit converter will offer only a 190-250 maximum point count across the range of values being acquired and compared.
- a 10-bit or 12-bit A/D converter will allow significantly enhanced point- count scales.
- Software 101 in Fig. 1 works reasonably well with 8-bit A/D converters, but a 10-bit A/D, available from MCU's Uke the Mitsubishi M37515 in Figs. 3 A and B, considerably enhances the reliabiUty and accuracy of software 101.
- the granularity available from the A/D hardware should be considered, as 10-12 bit A/Ds will enhance the points available.
- the accuracy of the final power supply Vout value calculated by software 101 in Fig. 1 is only as vakd as a configurable power supply's ability to deUver precise voltages.
- the representative configurable power supply 122 in Fig. 4 provides a resistor ladder 160 which is only capable of voltage adjustments in .375 VDC increments. This restriction is accounted for by always "rounding up" software 101's final voltage value to the next higher avaUable voltage from a configurable power supply 122.
- a power supply that offers more granular voltages can be built, so that software 101 can be more accurate, if the appUcation requires.
- Power supply 122 in Fig. 4 has a minor anomaly in its SHUT DOWN mode.
- the LT1339 requires a minor modification to its shut down circuit.
- Power supply 122 in Fig. 4 should also have a small load (100 ⁇ ) strapped across the output Unes, since the power supply works best when under a minor load.
- Look-up Tables can be used to assist in verifying software 101 's calculation results.
- Another look-up table can be created to provide a voltage template which indicates typical battery voltage and current parameters for specific classes of powered devices.
- a look-up table that delineates the power signal parameters of ceUular phones, and differentiates them from parameters for laptop computers, can prove helpful. This could be beneficial, in an example of an airline that may aUow the owners of laptop computers to use the aircraft's power-delivery system at each seat, but prohibit power use for cellular phone operations.
- a simple look-up table can be created that templates the two types of devices, as defined by each one's unique power parameters (Vmax, Vmin, and current-load). Should a passenger connect a ceUular phone to the power system, software 101, by referencing such a look-up table, would not activate its associated power supply. "Power Signatures"
- Look-up tables can contain templated information that link voltage and load, as a function of time and "events.” Such a look-up table provides a "power signature" template for a defined and documented class of powered devices.
- a non-limiting example of a "power signature” can be a voltage and current profile of laptop computers.
- This power-signature table plots anticipated load values as a template. Such a template resembles Fig. 19, where the BIOS POST of a generic laptop tracks changes in load over time (as the basis of identifying a laptop as distinct from other powered devices that can attach to an embedded power system).
- BIOS POST The boot sequence of a laptop computer is unique to that type of powered device. Because the BIOS boot sequence has been historically a regimented process, the BIOS POST lends itself to a template.
- a BIOS POST template (Fig. 19) can serve as an effective means of distinguishing a laptop connected to a power assembly 100 like that in Fig. 2.
- Software 100 written to capture real-time power-load data can access a "power signature" template in a look-up table, and match a sequence of changes in current (load) to a generic (or specific) power signature template.
- BIOS POST Basic-sample-rate capture-scope
- BIOS and CMOS initialize each of these hardware sub-systems every time a laptop boots. Note: Many of the traditional hardware BIOS functions have moved to the operating system, but the net effect when monitoring load will still resemble the boot sequence depicted in Fig. 19. Detailed descriptions of various implementations of the BIOS POST are avaUable from The BIOS Companion, by Phil Croucher. Electrocution, P.O. Box 52083, Winnipeg, MB, Canada R2M 5P9.
- Fig. 19 is a graphical representation of a hypothetical BIOS POST. Each spike in electrical current, logged over time, represents an event within the BIOS POST sequence. Note that the events are not Unked specificaUy to an actual sub-system operation. Which device turned on and off is irrelevant. The fact that a defined sequence of on/off events (in a context of other measurable power events) can be identified, leads to a reliable power signature template. As technology changes occur in such powered devices as laptop computers, the representative generic template Fig. 19 represents will change. The important issue is that aU laptops wUl change accordingly, so the purpose of a table such as that shown in Fig. 19 wiU still be served - to differentiate a certain class of powered devices, (e.g., laptop computers) from other classes of electronic goods (e.g., ceUular phones).
- a high-bit-rate A/D converter wUl yield more granular power-signature templates.
- Databases Database creation can be part of the processes of software 101 in Fig. 1.
- Flowchart 101 indicates a number of instances where acquired or calculated values are stored (e.g., step 624). Some of the stored values are transient (e.g., step 658), and only relevant to software processes specific to a particular powered device and its battery pack. Other stored values have long-term (or historical) relevance.
- software 101 can be configured to permanently log the final Vout value in step 795. This is relevant, should a user allege that hardware assembly 100 in Fig. 2 (and its related software) delivered an incorrect voltage to the user's powered device, which consequently caused damage.
- Software 101 can be modified to run sub-routines which log user information, such as number of users who have accessed the software, number of users who did not complete the sequence of required connector 132 attachments (see Figs. 6-6C), the number of errors generated, the number of Vmin (or Vmax) readings that fell outside existing look-up tables, etc.
- Data which has value to owners of software 101 (and its related hardware) can include the parameters expressed in the "Power Monitor" screen display in Fig. 18.
- Displayed information includes a power supply's Vout (556), a match of a known battery pack manufacturer's design voltage (562), position of connector 132 (560), LED warning lights or active indicators (568), whether a powered device's battery is being charged (564), power consumption expressed as Amps (558), and other data relating to the activities at a particular power outlet.
- the "Power Monitor” GUI displays relevant data to either owners/providers of hardware/software for power delivery. Such an owner/provider may be, for example, and airUne which offers power at each passenger seat. Logging such information from "Power Monitor” software can prove beneficial in analyzing the amount of fuel burned to deliver electrical power to passengers. Detection of battery charging is also relevant, when an airline elects not to allow battery charging on its flights. Power Monitor then becomes a "policing" agent which can, in software 101, be configured to automaticaUy shut down its power supply if battery charging is detected. The proper use of connector 132 disables battery charging when connector 132 is in the position shown in Fig. 6C, so knowing that connector 132 is being used properly can be vital information that gets logged in a database.
- Software flowchart 101 in Fig. 1 offers a sophisticated method of not only calculating a vaUd Vout value for a configurable power supply, but of recognizing various positions of a connector, and determining the manufacturer's design voltage of a battery pack, among other functions. In many appUcations, software 101 can be reduced to a very simple, yet effective algorithm that delivers a useable Vout value.
- Figs. 13 (and 13 A schematically) show a manually-selectable power converter.
- Connector 508 in Fig. 13 A is representative of a type illustrated in Figs. 6-6C, 6D, and 8.
- the three-step algorithm above operates with a control of a switch 526.
- LED 402 is software controlled so that it illuminates only when calculated Vout in step 3 above is matched at the manual voltage
- selector voltage tick marks e.g. 16 volts is the calculated Vout, but selector dial 337 offers only 15 or 17 volts
- a basic voltage-comparator can also be used in assembly 20 400.
- FIG. 1 Software flowchart 101 in Fig. 1 operates with embedded power-delivery hardware.
- Fig. 2 Ulustrates a representational diagram of an embedded controUable-output-voltage power supply 122 and related hardware that is enabled by software 101, as a means of determining Vout of a powered device 136.
- Power module 100 executes software 101 using an interface provided by a connector 132 (see Figs. 6-6E, and Fig. 8) attached to a powered device 136's battery pack 134.
- a user manipulates connector 132 so that software 101 (and MCU 102) can acquire voltage values from a battery 134.
- Software 101 then uses those voltage values, in conjunction with lookup tables (see Figs. 15, 17 and 20), to configure a power supply 122.
- Software 101 is also capable of monitoring all user activities by using various data-acquisition processes. A full discussion of related hardware appears in the "Hardware" section.
- FIG. 1 The foUowing description of software 101 (Fig. 1) details step-by-step processes. These should be read in conjunction with the information presented in companion-section "Software For In-Line, Corded Power-Delivery Hardware.”
- the flowchart for in-line hardware power devices appears in Fig. 1 A as software 800. That section discusses general operational concepts, specifics of connectors and related hardware. Note that In-Line hardware does differ from embedded power- delivery hardware. As a non-limiting example, a corded power-conversion module can use a manuaUy-configurable voltage selector, while its embedded counterpart would not have any manual controls. Therefore, differences between embedded and in-line power hardware should be taken into account when reading these companion software descriptions. Neither software 101, nor software 800, is limited to use only with the hardware devices referenced herein. In many appUcations, software 101 and 800 are totally interchangeable.
- Software flowchart 101 in Fig. 1 is a slightly abbreviated version of flowchart 800 in Fig. 1 A. Repetitive sequences in software 800 often are minimized in software flowchart 101, for example. Such sequences are fully described in software flowchart 800. Flowchart 101 and 800 are meant to be examined together.
- FIG. 2 One set of connector 103's pins (Fig. 2) provides a discrete short-to-ground used only by an inline power adapter. A second set of pins at connector 103 is reserved for an adapter-less power- cord 115. Software flowchart 101 describes this second sequence, with two-conductor cord 115 connecting power supply 122 (in power module 100) to battery 134 (and its associated powered device 136).
- Embedded power hardware for software 101 is typicaUy connected to a powered device 136 via a simple two-conductor power cord 115.
- a previously referenced example of an embedded hardware appUcation is to embed a power module 100 behind the dashboard of a car, so that it can deliver power through the cigarette-Ughter outlet (element 103 in Fig. 2).
- the configurable power supply 122 can change its Vout to match the Vin of a powered device 136.
- This abUity for a module 100 to auto- configure its power output eliminates the need to use the in-line DC/DC converter typically associated with powering a device 136 from a car's cigarette-Ughter power port.
- the hardware of the invention is also available as an external, in-line DC/DC (or AC/DC) converter adapter, as in Figs. 10, 11, and 13.
- This type of hardware operates with software 800 (Fig. 1 A), which principally differentiates itself from software 101 (Fig. 1) by its ability to operate with a variety of input power sources.
- Another differentiator is that the external power-conversion adapters aUow for both a user-adjustable, or an auto-configuring, output voltage.
- power module 100 is compatible with a variety of external power-conversion adapters (Figs. 10, 11, 13, and diagrammatically depicted in Fig. 13 A).
- Assembly 400 A typifies an interchangeable alternative to the simple two-conductor cord 115 (and associated connector 132). A user can select either of these two means of deUvering power from a module 100 to a powered device 136.
- Power module 100, and power-conversion adapter 400 A are compatible, and operate together to optimize the final output power to a powered device 136 (See discussion of power box 400 in Fig. 13 A).
- Connector 103 in Fig. 2 is a nine-conductor (two power, and seven data lines) interface.
- This style of connector is identified as an "ARINC 628" style connector available from Hypertronics (Hudson, MA). It uses two discrete non-power pins to create a short-to-ground when the two mating elements of the connector are attached. This is a commonly used method of determining when a connection is made, and is readily known to those skiUed in the art.
- Software flowchart 101, in step 602 identifies the short-to-ground, indicating a cord-only connection.
- step 604 executes, since the FALSE report indicates that an external power conversion adapter 400A (Fig. 2) is connected to power module 100. This FALSE value results in a 5 VDC output from power supply 122. This 5- volt power signal provides power to an attached in-Une power adapter.
- the description of software flowchart 800 (Fig. 1 A) addresses how an in-line power adapter utilizes this 5-volt power delivery from embedded power module 100.
- One of the basic bmlding blocks of software 101 in Fig. 1 is a simple powerUne voltage acquisition, foUowed by sampling load on the powerhnes. This two-sequence process is so central to the operation of software 101 that it is highlighted in box 606.
- Step 608 samples powerhnes 114 and 116 in Fig. 2 identified in software as port #1 (there are multiple A/D ports at MCU 102 in Fig. 2A).
- One hardware state is whether a connector 132 (see Fig. 6B) is inserted in its Position #1. If connector 132 is inserted as shown in Fig. 6B (but not 6C), battery 182 wUl deliver power along powerlines 114 and 116.
- Software 101 uses this voltage indicator at A/D port 110 (Fig. 2 A) to verify the position of a connector 132, as weU as to acquire battery-voltage information necessary to configure power supply 122's output voltage.
- step 612 executes a GOTO command which puts software 101 at step 648 — connector 132 is in the configuration shown in Fig. 6B. This event could happen because a user attached connector 132 to battery pack 134 before attaching power cord 115's connector 103 to embedded power module 100 (Fig. 2).
- step 610 of software 101 If the statement in step 610 of software 101 is FALSE, i.e., there is no voltage detected on powerlines 115 in Fig. 2, then software 101 configures power supply 122 to a low output voltage, here 3 VDC. This low voltage is applied to power cord 115, in preparation for acquiring a current sample (load activity). Load parameters are detailed in the "Identifiers" column of look-up table
- step 620 a quick line- voltage check is performed to make sure that power supply 122 (Fig. 2) is properly configured.
- This power supply output-voltage sequence (steps 614-620) is performed only once, prior to the first time that a powerhne load sampling is done. If the answer to query 620 is
- step 618 executes a full shut down (618) of power supply 122 in Fig. 2. FaUure of power supply 122 to properly execute a voltage command is considered a critical error.
- software 101 makes a call to MCU 102 (Fig. 2) to sample line load at A/D I/O port #3 (Unes 106 in Fig. 2A). This port is configured to read electrical current directly using a resistive element 108.
- the acquired load value is stored in memory (step 624) as an Ohm- value labeled as "LL*", then this value is compared in a look-up table (steps 626 and 628). Look-up Table 990 (Fig.
- Step 20 serves as the Ust of valid comparators to which is compared the resistive-load value acquired in steps 622-626.
- the results of the look-up table comparison is presented in step 630.
- LL 3 defines an Ohm-value that equates to a power cord 115 and connector 132 in a final configuration that is ready to be attached to a battery pack.
- the resistive Ohm values in look-up table 990 can be converted to actual current values @ 3 VDC.
- Look-up table 990 (Fig. 20) is expressed as resistive values, in Ohms. This is because Ohm values are more suitable to the hardware descriptions in look-up table 990. Since the Une voltage is known for most of these expressions, these Ohm values can be converted to miUiamps or other suitable electrical current expressions to minimize computational activity during line-load samplings. As powerline voltage can vary after step 760, where power supply 122 (Fig. 2) is turned on, all values expressed as direct current readings should be recalculated, and look-up table 990 updated accordingly.
- step 634 initiates a user prompt that is intended to promote compUance with the expected hardware state.
- the expected hardware state here is that power cord 115, and connector 132 are attached. If connector 132 features a protective cap 530 (Fig. 6D), it is supposed to be removed. Note that the error-loop goes back to step 608, where a line-voltage check is again performed. No low-voltage power is ever appUed to powerlines 115 (see step 614), without a check to see if the powerlines are available, or if there is already a voltage present from a battery pack 134.
- the hardware is in a state of having a power cord 115 and a connector 132 already properly inserted in a battery 134.
- the final step in sequence 606 of software 101 (Fig. 1) is to reconfigure the output of controllable power supply 122 (Fig. 2) to 0 VDC, i.e., shut down. This frees the powerlines for further line-voltage sampUngs.
- software 101 uses hardware that functions as the equivalent of a multi-meter to discern what is happening in its environment. By reading voltage and current, software 101 is able to respond to events in a meaningful way. Monitoring hardware by reading line voltage and current (Une load)enables software 101 to prompt a user to configure various hardware elements in a specific sequence. By performing these functions in software, the need for a user to know anything about the power requirements of a host device is eliminated.
- Software flowchart 101 in Fig. 1 only shows a single execution of each process sequence, such as one voltage and load sampling in box 606.
- software 101 is constantly looping through repetitive voltage and current samplings. No functions, such as turning on power supply 122 (Fig. 2), are executed without first checking Une voltage and current to make sure that aU hardware elements are properly configured. More importantly, since a user is involved in all processes, software 101 repeats voltage and load samplings to make sure that a user hasn't performed some action while repositioning a connector 132 that creates an error state. Therefore software 101 performs continuous samplings to assure that aU machine states are as they should be. Data acquisition sampling rates, while not specified here, should be timed based on the critical nature of a user's actions at any given stage in software 101 's progression.
- MCU 102 in Fig. 2 is configured to be able to acquire both positive and negative voltage values. This is likely not necessary, since aU elements of the power system, including the power cord, and aU connectors are manufactured to be mating components. However, MCU 102 does have the abiUty, if necessary, to reverse the polarity of the powerhnes.
- a power switch 112A in module 100 is needed to perform polarity reversal.
- Software 800 (Fig. 1 A) does not detail polarity reversing, but, this function is also included in the in-line adapter version, and can easily be integrated into software 101 by one skilled in the art.
- A/D I/O Port #4 which is polled in step 670.
- This port includes a large resistive load such as a power resistor.
- the resistive value of this load is substantial enough to simulate an operational level of a powered device 136 (Fig. 2).
- the Ohm-value of this load is roughly computed by referencing the "Load Current” expressions in Fig. 15. As can be seen, this supplemental load is based on the charge rate "C" of each type of battery ceU chemistry.
- AU computations and calculations of voltages performed in software steps 678-714 can be executed at any time prior to software step 760 which is the software step that performs a first Vout command to power supply 122. As with many of the software sequences, this sub-routine does not have to be executed in the exact order of state changes listed in software flowchart 101 in Fig. 1 (or in software 800 in Fig. 1 A).
- Fig. 6E shows a modified female connector in a battery pack 134.
- a diode 185 is introduced into the wiring circuit in battery pack 134. This diode wUl depress any acquired voltage values.
- Software 101 in Fig. 1 (and 800 in Fig. 1 A) should be recaUbrated to reflect the voltage loss (approx. 0.3-volts for a typical diode).
- the diode only impacts voltage values acquired from battery ceU(s) 182.
- Output voltages from power supply 122 (Fig. 2) are not impacted by diode 185, because the electrical signal to a powered device does not flow through diode 185.
- Software 101 (Fig. 1) and 800 (Fig. IA) are modified shghtly when diode 185 is involved in battery voltage acquisition. Software already distinguishes two voltage acquisition modes. After a voltage-configuration command is sent to a controllable power supply 122 (Fig. 2), software 101 verifies power supply 122's output by sampling line voltage (see steps 614-620 in Fig. 1, for example). Since power supply Vout readings are not effected by diode 185 in Fig. 6E, software 101 (and 800) these voltage acquisitions as non-compensated values. The differentiator software 101 uses is whether power supply 122 is in an ON or OFF state. Therefore, any voltage values that are acquired whtte power supply 122 is in an OFF state must be voltages coming from battery 134. Thus, any voltage value acquired during an OFF state of power supply 122 are mathematically voltage compensated.
- the voltage configuration commands sent to a configurable power supply such as 122 in Fig. 2 (or 5 122A in Fig. 13 A) must output a value higher than the Vmin (under-load) voltage value acquired from battery ceU(s) 182. If the power supply voltage is lower than the sustainable voltage of battery 182, battery 182 wiU dominate the powerlines and be delivering power to a powered device 136 (in Fig. 6E).
- the final monitoring loop for line voltage (and current) performed by software 101 (repetitive steps 788-798) allows the software to readjust and optimize a power 0 supply's Vout (step 797).
- Look-up table 799 in Fig. 15 Usts battery cell-voltage ranges for commonly-used rechargeable 5 battery chemistries. An observation of the voltage values indicates that a number of ceU-pack configurations "look" like others.
- the voltage range of an 8-cell Ni-Cad or NiMH pack fall within the same voltage range as an 8-cell Li-Ion (Coke) pack, for example.
- software 101 (Fig. 1) and software 800 (Fig. 1 A) are not looking at mean or average 0 voltage values ⁇ software 101 reads voltages that are identifying ceU-voltage extremes.
- An 8-ceU Li-Ion (Coke) pack can generate voltage readings as high as 16.80 VDC, while a simUar ceU construct for Ni-Cad or NiMH wUl only yield a maximum no-load voltage of 10.560 VDC.
- the maximum ceU design voltages shown do not necessarily reflect the actual no-load output voltage a particular cell type is capable of producing.
- An NiMH ceU, for example, wUl read approximately 1.46-volts when freshly charged.
- the 1.320-volt value shown in Fig. 15 is the mathematical E°cell value. This lower voltage is used in the look-up table as a safety measure. Its use avoids excessively high Vout voltage values being delivered to a powered device.
- AU of the voltage values in look-up table 799 are industry-recognized ceU design parameters.
- battery pack state of charge/discharge wiU shift the voltage readings.
- Condition of the ceUs also plays a major role in depressing both Vmin and Vmax.
- the test load can be 750-900 ma, which is fairly substantial.
- CeUs that are deeply discharged, or suffering from abuse or mistreatment, can be expected to drop precipitously in voltage when placed under load.
- voltage and ceU capacity are interrelated. Voltage drops as a function of ceU capacity. Compromised cell capacity will quickly show up as a depressed under-load voltage (Vmin).
- Vmax is a no-load test.
- the most valid Vmax test will be one that introduces the least amount of load to the battery pack. Therefore, some attention should be paid to line-load look-up table 990 in Fig. 20.
- the lower the total resistive value of LL 3 the more effective wiU be Vmax tests.
- Figs. 9A-C show various ways to wire a smart circuit. In Ught of decreasing overall resistance when reading Vmax, the optimum scenario is to wire the cells so that the load of the smart circuit is eliminated.
- Transient ceU "recovery” is a characteristic common to all battery chemistries. CeUs that have had time to recover from a load event will temporarily regain increased no-load voltage characteristics. Thus, when Vmax is acquired, for some smaU amount of time (determined by how long it has been since the battery pack was used), the no-load voltage will read higher than the sustainable cell voltage. That is one reason why a Vmax value is acquired first, before the Vmin (load) acquisition (see steps 660 and 676 in software flowchart 101 in Fig. 1). This "recovery" characteristic of rechargeable cells is beneficial to capturing a set of cell voltages that yield a significant spread of values between Vmax and Vmin.
- Look-up table 799 in Fig. 15 expresses ceU ideals, and is therefore, only a reasonable 5 approximation of reality. But look-up table 799 is helpful to interpret software 101 (and 800) Vref* and Vref 2 values (see steps 662 and 682 in software flowchart 101).
- look-up table 799 (Fig. 15) is iUustrated using the table below for a battery pack voltage test that yields a Vmax of 14.00- volts, and a Vmin of 10 12.00-volts.
- the following possible voltage matches are avaUable:
- Vmin 12- volt, and Vmax 14.00- volt parameters each fits at least one of all of the 15 above voltage ranges. However, only the four battery packs shown in bold fit both acquired voltage parameters. Since the Li-Ion Coke and Polymer 4-cell packs and 8-cell packs only differ in the capacity of each pack (see footnote 15), these can be considered the same. Therefore, only one vaUd voltage-range match of a battery cell's chemistry is achieved by implementing software 101's Vref 4 and Vref 2 calculations. The 12-cell Ni-Cad and NiMH packs are included because the 20 minimum cell voltage of these packs can be as low as 12.00-volts.
- Vref* 10.00 volts
- Vmin 12.00 volts
- Vref 2 16.80 volts Cell Impedance
- battery cell impedance can be a valid indicator of ceU type.
- AU ceUs increase impedance as a function of discharge.
- decreases in voltage are related to changes in battery discharge levels.
- do impedance changes reflect battery discharge states. These changes in voltage and impedance aren't very pronounced in Ni-Cad and NiMH cell chemistries, but Li-Ion cells do show clearly defined impedance changes that track with decreases in voltage.
- Impedance checks can be integrated into software 101 or 800, if further granularity in identifying a battery pack's discharge state is required.
- Step 716 Software 101 (Fig. 1) then moves to a new machine state in step 716, with a user prompt to remove a connector 132 already in Position #1 (Figs. 6B and 17) from its battery pack 134 (Fig. 2).
- Steps 718-720 verify that line voltage has dropped to 0 VDC, indicating that connector 132 has been removed from battery pack 134. Further validation of the presence or absence of connector 132 is achieved in steps 722-736, which is the previously-described line-load test.
- step 736 software 101 anticipates that the cord/connector combination has reported back an Ohm value that matches LL 3 in look-up table 990 (Fig. 20), i.e., male connector 132 is removed from its associated battery pack 134.
- step 736 If the response to the query in step 736 is FALSE, software 101 loops back to step 716, first generating a user prompt 734 to remind user to remove connector 132. These prompts are not always available, in which case software 101 continuously loops through the voltage and Une load sampling steps 716-736, until the answer to the test in step 736 became TRUE (YES).
- the results of a look-up table matching in step 730 can be any one of the pre-defined "Identifiers" in table 990 (Fig. 20).
- the Ohm-value match value can be reported as an actual value LL 2 , instead of NOT A MATCH to LL 3 .
- software 101 can execute an appropriate user prompt 734 that matches the LL 2 hardware configuration detected. By returning the appropriate value (e.g., LL°, LL 1 , LL 2 , etc.) the user prompt can be 5 better suited to the machine state at that time.
- Look-up table 990' s value LL 2 indicates, for example, that a power cord 115, and connector 132 are attached (see Fig. 2), but that resistor-equipped connector cap 540 in Fig. 6D is in place. A user prompt would indicate a need to remove connector cap 540. Obviously, connector 132 is
- step 15 the appropriate sequence (steps 823-835) to issue a user prompt associated with a reported value of LL 2 (user prompt 834).
- Software 101 can be similarly configured.
- Steps 738-758 indicate a new machine state, with connector 132 to be reinserted in battery pack 20 134 with its green side (Position #2 in Fig. 17) upward (Fig. 2).
- Fig. 6C shows connector 132 in Position #2.
- a powerline voltage check 740-742 is performed prior to a line load sampling 744-754.
- step 742 the response to step 742 's question "Vin Detected?" can differ in the anticipated 25 TRUE/FALSE response at any voltage check in the flowchart.
- the TRUE answer is NO
- the FALSE (error response) is YES in step 742 (and also, for example, to the same question in step 720).
- Software 101 does not want to see a line voltage in this software sequence.
- voltage verification steps 644 and 674 for example, the TRUE response is YES, and the FALSE response is NO. Steps 644 and 674 expect a line voltage to be present.
- Power Delivery Sequence Software 101 (Fig. 1), in steps 760-798, addresses the final configuration of power supply 122's output voltage (see Fig. 2), and power delivery to a powered device 136.
- Step 714 has already defined the most probable (and safest) output voltage for a power supply 122 (Fig. 2).
- a second possible output voltage "Vavr” (Average Voltage) is also available from step 712.
- Software 800 detaUs additional steps taken to determine a "Vbst,” (Best Voltage).
- Power supply 122 is turned on in software step 762.
- the system state, at this juncture, is that powered device 136 has not yet been turned ON.
- Software 101 executes an output-voltage confirmation in steps 764-768.
- MCU 102's A/D I/O port #1 (110 in Fig. 2A) is polled to acquire Une voltage. If the commanded Vout value in step 760 matches the acquired line voltage in step 764, a TRUE value (YES) is reported in step 768. If the two voltage values do not match, an error loop 770 occurs, and software 101 tries to reconfigure power supply 132. If this loop faUs after three attempts, a critical error occurs and power supply 132 is totally shut down.
- Step 772 acquires a powerline load value LL H .
- This line load needs to be converted to a value that reflects the new Vout from steps 760-768. This is a calculated value, using previously stored line- load value LL G from step 148, multiplied by the value of Vout (from step 760). The result becomes new voltage-adjusted value LL H in step 776.
- the new load value is stored in memory as LL 6 , and is made avaUable in look-up table 990 (Fig. 20). A verification is made on the load calculation in step 778, to confirm that acquired load value LL 6 is the same as calculated value LL H
- Steps 780-785 is a sequence of powerline voltage acquisitions. This sequence differs from previous line-voltage acquisition activities. This set of two voltage values is specific to determining possible changes in output voltage commands to power supply 122.
- Step 780 acquires a no-load voltage (Vnol), which is stored in memory (step 781). Then, a load at A/D I/O port #4 (106 in Fig. 2A) is introduced into the circuit, in step 782.
- the resistive load available at A/D port #4 is substantial, being within a range of 750-900 ma.
- a second voltage is acquired as Vlod, but this value is voltage under load (783).
- the additional 750-900 ma drain on the powerlines roughly simulates the operational power requirements of a powered device 136 (Fig.
- step 785 The two stored voltage values Vnol (a no-load voltage stored in step 781), and Vlod (an underload voltage stored in step 784) are compared in step 785. If the two voltage values are within a tolerance of 5% to each other, no output voltage adjustments are made to power supply 122. However, if there is more than a 5% deviation between the load (Vlod) and no-load (Vnol) voltages, a voltage adjustment is commanded in step 786. This helps to avoid voltage sags that could occur when the powered device turns on. Software 101 uses this basic approach to assure that a power supply 122's (Fig. 2) output voltage does not drop below the Vout value of Vmin when the load of the powered device is induced in the system (i.e., when the powered device is turned on).
- Step 787 prompts a user to turn on powered device 136 (Fig. 2).
- Software 101 samples powerline load (step 788) to determine whether this user action has happened.
- the load value will likely be expressed as any increase in current above previously defined load value LL 6 from step 776 (and available in look-up table 990 (Fig. 20).
- This new line load value LL 1 has stored in step 789 as LL 7 , and is compared to LL 6 in step 790.
- a powered device 136 in Fig. 2 is a laptop computer
- a BIOS POST sequence will occur within a window of the first 5-30 seconds after a user turns on device 136 (the time at which the BIOS POST occurs can vary from laptop to laptop).
- Fig. 19 illustrates a BIOS POST event. Hardware devices within a powered device are turned ON and OFF during this activity, so it would be appropriate to sample line load during this 8 seconds of intense activity. The large spikes in current draw are easily detectable as confirmation that the powered device is activated.
- a template of a BIOS POST in Fig. 19 can be implemented in software 101, which is used to identify the type of powered device being powered. Other powered devices, for example a CD-ROM audio player, would not exhibit the characteristic boot sequence of a laptop computer. This device-class identification process is not critical to the operation of software 101, or any related hardware.
- Steps 791-796 are a repeat of steps 780-786, as previously discussed. Again, this is a voltage- stabiUty check used specifically to assure that the output voltage of power supply 122 (Fig. 2) does not sag in the actual under-load conditions being created by the powered device 134.
- the final sequence 798 in software 101 is a continuous monitoring of powerUne voltage.
- Software 101 is looking for a power disconnect, which would occur when a user removes connector 132 from battery pack 134 (Fig. 2). If a zero-voltage value is detected, software 101 immediately commands MCU 102 to shut down power supply 122. This is to ensure that a connector 132 is not powered whUe its electrical contacts are exposed to a user.
- Software 101 also monitors powerline load during its monitoring sequences 798, sampling current readings and comparing them to Ohm values expressed in look-up table 990 (Fig. 20). Any regression to resistive value LL 6 indicates that a powered device has been turned OFF, but that a connector 132 is still attached to a battery pack 134. Recognizing this OFF state can be useful for power conservation — as power supply 122 (Fig. 2) can be put into a standby or sleep mode. If power supply 122 is put into such a wait mode, software 101 retains its last Vout value, should a user turn the powered device back ON. However, if a powered device is turned OFF, and connector 132 is removed from battery pack 134, power supply 122 is shut down. If a user reconnects the same powered device, software 101 executes again, in its entirety.
- Figure 1 A illustrates software 800 that operates primarily with external power conversion adapter hardware, a non-limiting example of which is device 335 in Fig. 13 (and shown diagrammatically as 400 in Fig. 13 A), or equivalent external power adapters.
- the hardware is comprised of manually-selectable output-voltage indicator 337, configurable DC/DC (or AC/DC) power supply 122A, blink/solid LED indicator 402, powerline switch 526, and a source of logic, controller and data acquisition, such as microcontroller (MCU) 102 A.
- MCU microcontroller
- a user manipulates voltage selector 504 in selectable indicator 337 (Figs. 13 and 13 A).
- MCU 102 A acquires at least one voltage from a battery 508B of an associated powered device 508C that is attached at output connector 508. The attachment is via a connector 132 5 (reference Figs. 6-6D), and a power cord 508A.
- At least one acquired, or processor calculated, voltage value is stored in MCU 102A's memory 518A as a value which, when matched at selector indicator 337, serves as a confirmation that a user has properly configured voltage selector 504.
- MCU 10 102A locks out voltage selector 337 from any further inputs, and also iUuminates LED 402 to confirm to a user that power adapter 400 is properly configured.
- LED 402 can iUuminate in a non-Umiting number of ways, such as blinking, solid ON/OFF, or by changing color.
- the rate of blink will be used herein as a non-limiting example of how LED 402 15 operates.
- Rate of bhnk slows as voltage selector 504 moves away from the target voltage to be matched and, conversely, LED bUnk rate accelerates as voltage selector 504 is rotated toward the desired voltage. When an acceptable voltage match is achieved, LED 402 stays solid ON in this example.
- MCU 102 A configures power converter 122A to output the desired voltage.
- the MCU verifies, at conductors 527 and 529, that the output voltage is correct, then MCU 102 A closes powerline switch 526, aUowing power to flow to powered device 508C.
- Power converter 122 A can also be an AC-input/DC-output power converter (or even a DC-to-AC inverter).
- Those skiUed in the art can make changes to software 800 (Fig. 1 A) to provide compatibUity and operability with AC power.
- Some features of power box 400 (Fig. 13 A) and software 800 do not operate the same, such as the initial voltage initialization process between a power source and power box 400.
- Hardware Variants Manual voltage selector 337 is not essential to the operation of configurable power adapter 335 in Fig. 13 (digramatically device 400 in Fig. 13A).
- MCU 102A is capable of automatically configuring power converter 122 A without any user intervention. This would be a preferred mode for deUvering a matched voltage to a powered device.
- An alternative modaUty uses a simple voltage comparator circuit to match a voltage input from a battery source 508B (Fig. 13 A) to an output voltage of a power converter 122 A.
- the battery voltage value in the comparison is Vmax (no-load voltage).
- Vout The actual output of a power converter 122 A (Vout) would be depressed by 10% of Vmax or, a more simple approach , would be expressed as:
- Vmax - 1 volt Vout
- An LED 402 is used to indicate a successful voltage match.
- a gated FET serves as a switch 526 to create an electrical path between power converted 122 A and battery 508B, and the FET also switches the LED circuit ON.
- Fig. 11 shows a variant, with an intermediate power conversion box 357 that is inserted in-line between a manually configurable power adapter 335 A and a host device 349 's battery pack 355.
- This configuration of power-conversion box 357 is comprised of an MCU 102B, an LED 338, and a powerUne switch 562B (reference Fig. 13 A for equivalents).
- Power conversion box 357 having acquired at least one voltage from battery 355, then samples the output voltage of power adapter 335 A whUe a user rotates selector 337A. Once the output voltage from power adapter 335 A matches the desired voltage, the MCU in box 357 illuminates its LED as described above.
- PowerUne switch 526B is held closed by MCU 102B as long as the output voltage from power adapter 335A matches the defined voltage. Should a user rotate selector 337A to a position that is not a match, even whUe power adapter 335 A is in operation, software 800 commands MCU 102B to open powerline switch 526B, which discontinues power to powered device 349.
- FIG. 10 is essentially the same as Fig. 11, except that power conversion box 357 in Fig. 11 has been integrated in battery housing 347 in Fig. 10.
- Battery housing 347 can be an empty plastic sheU, or have some (or all) of its battery cells removed. Because migration of MCU 102C, power switch 526C, and optional LED 338C to battery 347' s enclosure creates a dedicated device specific to a mating powered device 349. In the early 2,000s, automotive accessory voltage could change to 42 VDC. Whatever voltage is currently in use is considered relevant here. WhUe restrictive in being dedicated to a particular powered device 349, such a battery housing assembly 347 eliminates the external power conversion box 357 shown in Fig. 11.
- Fig. 10 shows a laptop computer 349, with a dedicated battery pack 347 which contains an MCU 102C that is pre-programmed with the input voltage required to properly power laptop 349.
- the pre-programmed voltage information can be expressed as digital data, made avaUable to an external power adapter 335 by means of powerline modulation.
- a modulator/demodulator 339 in battery 347, and its corresponding MD/DM 339A in power adapter 335 provide a simple, yet effective means of communicating data between the two devices. Given that Fig.
- UPS Uninterruptable Power Supply
- a power switch 526C, a diode 185, or a power FET (or equivalents) is used to switch from external power to battery power (see Fig. 6E, and related text section "Diode UPS").
- Input power to power conversion box 400 in Fig. 13 A can be either a fixed input voltage, or is a power source that can have a configurable output voltage, equivalent to that described in Figs. 2 through 5 A. If the input voltage to power box 400 is coming from a fixed voltage source, MCU 102 A in Fig. 13 A is wired with its own voltage regulator, so that MCU 102 A is powered as soon as electrical input is avaUable at Unes 505 and 507.
- a controllable power source 100 has been pre-configured with resistive values that are specific to a power box 400 (as detailed in the foUowing "Software Operation” section. In sensing these resistive loads, and finding them to match expected pre-determined values, a controllable input power source 100 deUvers voltages expected by power box 400 at the appropriate time.
- a +5 VDC power signal is first deUvered to power box 400, which powers its MCU 102 A only.
- LED 402 changes its state (e.g., turns ON). This indicates a change in the overall load sensed by controUable input power source 100, which then increases its power to a pre- determined value.
- This pre-determined voltage value may be 12 VDC (for example, if power box 400 is to be used in an automobile), or the output voltage can configure to 15, or 28 VDC (as a non-limiting example of which is a power box 400 manufactured to operate at such voltages because its intended use is on an airplane where such input voltages are common).
- FIG. 13 A An alternative power source is available from which MCU 102 A in power box 400 (Fig. 13 A) can be powered.
- Battery 508B can power MCU 102A when a user attaches connector 132 to couple battery 508B to power box 400.
- the connector in the description of a unique connector 132 in Figs. 6- 6C, the connector must be inserted in the manner shown in Fig. 6B for power to be available.
- Fig. 6E and its associated description in the section "Diode UPS", define a non-limiting means of configuring the circuit within a battery 508B with a diode, so that there is only one position for a connector 132.
- the connector modality in Fig. 6E resolves the issue of a dual-position connector 132, and provides a convenient means of powering MCU 102A.
- Software 800 in Fig. 1 in its first state determines the characteristics of its input power source.
- Software 800 assumes that there is power avaUable as soon as its associated hardware (for example, power box 400 in Fig. 13 A) is connected to a power source. In the modaUty shown here, that power source outputs either 5 VDC (as detected in software voltage- comparator steps 802-803), 15 VDC (in voltage-comparator step 804), or 9-14 VDC (in voltage- comparator step 805).
- a 5 VDC-detected input voltage is an indication to software 800 that it is connected to specific matching hardware.
- Such hardware as exemphfied in assembly 100 Fig. 2, and its related software 101 in Fig. 1, are configured to perform interactions with hardware equivalent to 400 in Fig. 13A and software 800.
- MCU 102A in Fig. 13 A performs functions, such as turning on LED 402, that alter the overall detectable load of hardware 400.
- Software 101 is configuring its power supply 122 A to output a low voltage (in this non-Umiting example, +5 VDC) from its power supply 122 A.
- Software 101, and related hardware 100 as exemplified in Fig. 2, is monitoring the load at input powerlines 114 and 166 (which are the same as powerlines 505 and 507 in Fig. 13 A).
- LED 402 in Fig. 13 A turns on
- software 101 detects that change in load (the value of which was predetermine at the time of manufacture of power box 400).
- Software 101 then changes its output voltage to 28 VDC.
- Software 800 in Fig. 1 A senses the change in input voltage from +5 VDC to 28 VDC, and switches on DC/DC power converter 122 A in Fig. 13 via control line(s) 510.
- a resistor array 509 is pre-configured to induce three specific pre-determined load values detectable by software 101 at powerlines 114 and 116 (505 and 507).
- upstream hardware 100 in Fig. 2 (or equivalents) with its software 101, needs only to detect three pre-determined resistive load values.
- Load value #1 serves as a device ID, which teUs hardware 100 (and its software 101) that a compatible device 400 is attached.
- This handshake function can also be performed by a simple resistor in connector 103 (Fig. 2) that attaches a power box 400 in Fig. 13 A to a hardware assembly 100 in Fig. 2.
- the pin outs of connector assembly 103 which provides a means of detecting the presence of a power box 400.
- a powerUne load value #2 detectable by software 101 in Fig. 1 is used to notify software 101 of the proper time to reconfigure the power output of its power supply 122 (in Fig. 2).
- the previous voltage of 5 VDC changes to 28 VDC (or any other pre-determined output voltage deemed appropriate).
- a powerUne load value #3, detectable by software 101 in Fig. 1 is used to notify software 101 to shut down its power supply 122.
- This is for critical error states, such as hardware 400 in Fig. 13 A experiencing over-voltage, over-current, excessive thermal activity, or other abnormalities of operation.
- This shut-down capabihty is not defined specifically in software 800 in Fig. 1 but anyone skilled in the art can readUy include such safety checks and error-reporting states.
- software 101 defaults to its standby output voltage of 5 VDC.
- power supply 122 wiU stay in its 5-volt state as long as a connector assembly 103 (Fig. 2) remains attached. If software 101, having reconfigured the output of its power supply 122 in Fig.
- Power source 100 in Fig. 2 and power box 400 in Fig. 13 A can communicate with more sophistication than the basic resistive-load schema defined above. With proper power factor correction (PFC) and powerline filtering, traditional powerUne modulation can be performed over the low-voltage lines. Since such methodologies are well understood and famiUar to anyone who is skUled h the art and who is familiar with X-10-style (X-10 USA Inc., Closter, NJ), or Echelon (Palo Alto, CA) powerline communications, they are not detailed here.
- PFC power factor correction
- powerline filtering traditional powerUne modulation can be performed over the low-voltage lines. Since such methodologies are well understood and famiUar to anyone who is skUled h the art and who is familiar with X-10-style (X-10 USA Inc., Closter, NJ), or Echelon (Palo Alto, CA) powerline communications, they are not detailed here.
- a rudimentary 1 and 0 binary "code” can be constructed. Because the voltage along the powerlines that connect power source 100 in Fig. 2 to power box 400 in Fig. 13 A can include two voltages (5 VDC and 28 VDC, for example), the resistor "code” must have two value sets, one for each voltage. Also, since the output-line load downstream of power converter 122 A in Fig. 13 A can fluctuate considerably while powered device 508C is in operation, adequate power factor correction and line-load filtering between power source 100 and power box 400 is important.
- Vin-detection 803, 804, or 805 differentiates whether software 800 in Fig. 1 A is executing with its hardware 400 (Fig. 13 A), or equivalent, connected to an automotive or commercial aircraft power source.
- Automotive output voltages to devices like those on which software 800 resides can range from 9-16 VDC.
- Commercial aviation voltages are 15 VDC (+/- 1 volt), or 28 VDC. While 15 VDC is within the spectrum of automotive output voltages, rarely do automotive voltages run that high. Typically 13.5 VDC is the upper limit of real-world automotive voltages at the dashboard.
- software 800 can be configured to perform functions unique to its operational environment. As a non-limiting example of which is that aviation functions can preclude charging the battery of a powered device.
- Figs. 6A-E, 7, 8, and 9A-D show methods of disabling battery charging, while still deUvering power to a host device.
- Software 800 relies on detecting a match for input voltage as an initial indicator of its operational environment. If input voltage parameters indicate an 5 aviation voltage (15 VDC. or 28 VDC), software 800 runs subroutines that are specific to unique hardware (connectors referenced Figs. 6A-E, for example) that are only used on commercial aircraft.
- elemental input-voltage-sensing function in software steps 803-805 in Fig. 1 A provide differentiators that define intended operations within specific environments.
- step 807 in software 800 (Fig. 1 A) locks out any inputs from manual voltage selector 337. AU activity of LED 402 is latched up. This is precautionary, only. Because MCU 102, and not the actual rotating of manual voltage selector 337, controls power converter 15 122 any user manipulation of voltage selector dial 504 cannot impact the operation of power converter 122 A.
- Software 800 in Fig. 1 A monitors other user activities, particularly those associated with output connector 508 in Fig. 13 A.
- a user may have to attach a cord 115 and/or a connector (132 in Fig.
- MCU 102 would be powered only after the battery connection was made, so software 800 would be "blind” to previous battery- and connector- related user actions.
- Software 800 can be rewritten to accommodate this.
- the power from a battery 508B can turn on MCU 102 A using inputs 527 and 525.
- MCU 102 A can be
- Software sequence 809-811 is a simple voltage check at A D I/O Port #1. If no voltage is present, the user has not yet reached the stage of attaching power box 400' s output cord 523 and 524 to a battery pack (see battery 355 in Fig. 11, for example).
- Software 800 in Fig. 1 A differentiates from among a series of eight separate and distinct load- related events. These are defined in line-load look-up table 990 in Fig. 20. States for a power cord, connector, and battery connection are defined. This Ust assumes that a power cord and connector are discrete assembhes, and that a user must attach a connector to the cord. Look-up table 990 also assumes that there is a cap on a connector (see item 530 in Fig. 6D). Two states LL 4 and LL 5 differentiate whether a battery pack is removed from, or is installed in, its associated powered device. Not all of these states need be present for software 800 to operate. These powerline load states are separately defined to show where, in the sequence of software processes described in software flowchart 800 (Fig. 1 A), each is monitored.
- Look-up table 990 (Fig. 20) links an Ohm-value to each configuration of connector, cord and battery pack.
- each reference to "Look-up Table of ⁇ Values" (815, 831, 844, etc.) compares an acquired powerline load value to each of the pre-defined resistive values in look-up table 990.
- the captured Ohm-value in software step 816 is .32 Ohms, then only LL 1 is vaUd.
- the null-value LL° is not considered in any of software 800' s comparisons, because it indicates no user activity, and is therefore the absence of any other "LL" value.
- AU pre-defined Ohm values in look-up table 990 are defined in the manufacture of the power cord, connector (and its cover), and battery packs. Allowable manufacturing tolerance is indicated as 5%.
- Load Software 800 in Fig. 1 A is structured so that a voltage check always precedes a load check at the output powerlines, for example output powerlines 523 and 524 in Fig. 13 A .
- a user may have already performed an action that is further along in flowchart 800 than the present step in software 800.
- step 813 indicates a GOTO step 883 "Battery Connected.” If a user connects to battery 508B prior to software step 809, software 800 has a way of checking for such out-of-sequence user activity.
- power converter 122 A in Fig. 13 A must be turned on to do a line load test during power- output functions.
- software steps 812-822 represent a typical hne load test sequence.
- Power converter 122 A is turned on in step 812. If, at that moment, a user is inserting a connector 132 into a battery pack 508C in a manner that wUl aUow battery voltage to flow (see Fig. 6C), there wiU be two contending voltages on powerlines 523 and 524 of power box 400 (Fig. 13 A). If the battery's output voltage is higher than 3 VDC, power wiU flow into power converter 122A's output (this assumes that power switch 526 is closed). If a battery voltage is less than 3 VDC, power from converter 122A wiU flow into battery 508B. This situation can damage either power converter 122 or battery pack 508C.
- Diode protecting power converter 122A's output lines in Fig. 13A is prudent, and has been discussed in the section "Diode UPS" but, incorporating diodes in a battery pack may not be advisable. Diodes in the battery pack can distort the battery values (particularly voltages) being reported by a smart battery circuit.
- Optional powerline switch 526 can be used as a safety valve. This switch is only closed after confirmation that powerlines 523 and 524 are inactive.
- Software 800 handles this issue by always sampling output-line voltage at MCU 102A's input Unes 525 and 527 (as exempUfied in steps 809-811) before initiating a load-sampling sequence.
- step 834 a screen display prompts a user to remove the cap from a male connector (reference Fig. 6D). Note that the error loop then reverts to a line-voltage check first (steps 823-824), before again sampling for a change in load (indicating that the cap 530 has been removed from connector 540 in Fig. 6D). Screen displays are discussed in the section "GUI Considerations.”
- Software 800 in Fig. 1 A performs a series of output-Une voltage and powerline load samplings, starting at step 809 and continuing to step 876.
- various user screen prompts (821, 834, 848, 863 and 876) can be indicated in order to direct a user to properly configure power cord 508 and the correct Position #1 and Position #2 sequencing of connector 132 into battery pack 508B (reference Figs. 6-6C, and Fig. 17).
- Software 800 in Fig. 1 A executes steps 884 - 892 to acquire a battery Vmax (Maximum Voltage) value. This is a no-load voltage reading of the ceUs inside the battery housing. MCU 102's A/D I/O Port #1 (conductors 525 and 527 in Fig. 13 A) acquires this value in step 884.
- Vmax Maximum Voltage
- step 888 the Vmax value is compared to look-up table 799 (Fig. 15).
- Look-up table 799 is comprised of a database of individual cell voltages, with known combinations of cells in battery packs. AU common cell chemistries are charted in look-up table 799.
- Look-up table 799 (Fig. 15) is not critical to the proper operation of software 800. However, there can be battery pack conditions that are at the fringes of "normal" voltages. For example, a battery pack that is at a very low state of charge. A deeply discharged battery pack condition wUl not distort the Vmax (no load) value acquired in software 800' s step 884. This deeply-discharged battery scenario is a good reason to avoid using resistors in output power cords, connectors, etc., since these wUl only apply unnecessary loads when acquiring a Vmax value. If the resistance is substantial, the voltage range between Vmax and Vmin will be unnecessarily depressed.
- the battery pack wiU Because the battery cells are not under load when the Vmax value is acquired, the battery pack wiU most likely read close to its nominal manufacturer's "design" voltage. All battery chemistries exhibit a transient voltage "recovery" characteristic when at rest. This is often experienced with a flashlight that wiU no longer hght. After the flashUght rests for a period of time, the bulb wUl momentarily respond.
- CeU voltage look-up table 799 (Fig. 15), referenced in software steps 888 and 899, will aid in identifying deeply discharged battery packs.
- the Vmin (under load), and Vmax (no load) values wUl be distorted when compared to the expected voltage readings for a battery pack that has been charged. Note that batteries that are freshly charged wiU swing to the opposite end of the voltage- reading spectrum, with high Vmax (no load) values. In that respect, freshly charged battery packs are considered as "abnormal" as deeply discharged ones, when interpreting look-up table 799.
- Software 800 in Fig. IA acquires a Vmin voltage value in steps 893 - 903.
- a load 517 is introduced in the powerline at MCU 102A's conductors 522 A and 527 as A/D Power Port #4 (Fig. 13A). This load should be of sufficient impedance to depress the battery pack 508B's output voltage. If the battery packs to be addressed by the invention are for laptops, as a non-limiting example, the load should be at least 750 mA (based on a typical laptop drawing 1.2-1.5 Amps from a battery pack). If the load is too small, there may not be enough difference between the Vmax (no load) and Vmin (load) voltage values. High resistive loads also pull down a battery's voltage more quickly.
- Vref 2 A Vmax (no load) voltage value is stored in memory 518A as Vref 2 (step 892), and a Vmin (under load) voltage value is stored as Vref* (step 903).
- Vref* a Vmin (under load) voltage value is stored as Vref* (step 903).
- look-up table 799 Fig. 15
- the two acquired voltage values Vmax and Vmin can determine the optimum output voltage for power converter 122 A in Fig. 13 A.
- Step 907 in software 800 determines an accuracy for values Vref 2 and Vref* with a tolerance of less than 5%, when compared to look-up table 799.
- Vref 2 and Vref* are listed and sorted in ascending order. If aU acquired voltages are from a stable battery pack, i.e., one that isn't freshly charged (or precipitously near total discharge), the sequence of voltages wUl be:
- look-up table 799' s (Fig. 15) values confirmed that there was a correct configuration of cells in a battery pack that, by their design cell voltages, indicated that the actual load and no-load voltages acquired (Vmin and Vmax respectively) are within normal parameters.
- step 915 of software 800 (Fig. IA). If the outcome of step 914's LIST and SORT is a valid voltage progression, from lowest to highest, then MCU 102 A (Fig. 13 A) uses Vmin as a first output voltage at which to configure the Vout of a power converter 122 A.
- Vmin The output voltage of a battery pack, under load, is expressed as Vmin.
- Vmin a battery's Constant Current Voltage (CCV).
- CCV Constant Current Voltage
- the input voltage to a battery's powered device can also be expressed as Vmin, or the minimum operating voltage of the device. Understanding the relationship of a battery's Vmin to its associated powered device's Vmin will shed some light on what relevance software 800' s voltage acquisition has to successfully delivering an optimized voltage to a powered device.
- battery output voltage Vmin wiU be labeled, for purposes of this discussion, "BattVmin,” whUe a powered device's minimum operating voltage wiU be labeled “PDVmin.”
- BattVmin is closely related to PDVmin, because PDVmin determines how deeply a powered device's battery pack wiU be aUowed to discharge (expressed here as a function of voltage, and not a "fuel gauge” reading of battery capacity).
- a powered device's rninimum operating voltage, ideaUy would only be shghtly above its battery pack's lowest possible discharge voltage.
- the lowest possible discharge voltage of a battery is determined by a "point of no return" in vokage, below which the battery wiU face potential internal cell damage.
- a Ni-Cad ceU rated at a manufacturer's design voltage of 1.25 volts, would be damaged if that ceU's voltage dropped below 1.0 volts.
- the risk of permanent cell reversal is significant.
- Cell reversal means that the cell suffers internal damage which renders the ceU incapable of being fully recharged.
- cell voltages would never be aUowed to drop below 1.0 volts.
- the lowest BattVmin would be 10.0 volts.
- the device's minimum operating voltage PDVmin would likely be very close to its battery's BattVmin, e.g., 10.0 volts in this example. In reaUty, the device's lowest operational voltage would probably be below 10.0 volts, to allow for the transient sag in the battery's output voltage that occurs when the device turns on (sudden load). Although device manufacturers are often tempted to run the battery voltage down to absolute niinimums, a reserve of 10% or more is a often aUowed.
- the under-load voltage Vmin acquired in step 896 of software 800 (Fig. 1 A) wiU be above its powered device's pre-set battery shut down voltage of 10.1 volts. Since the powered device's minimum operating voltage (PDVmin) is less than 10.0 volts, any voltage above that might properly operate the device. The conditional "might properly operate the device" is relevant, because any input voltage to the device below the pre-set shut down voltage of 10.1 volts would trigger a shut down! But, for purposes of software 800' s optimizing the input voltage to a powered device, as long as the output voltage of power converter 122 in Fig. 13 A is no less than 10.1 volts, the powered device the converter is powering wiU operate satisfactorily. At these extremes of the voltage spectrum, a powered device may produce "low battery” warnings.
- the optimum voltage delivered to such a powered device in the example should be above 11.00 volts.
- Software 800 operates with a load that is conservative, when acquiring BattVmin (i.e., Vmin). Since the 750-900 mA load appUed when acquiring Vmin is typically only 50-60% of the operational load of the powered device, BattVmin is sUghtly higher that it would be if a fuU 1.5 Amp load were applied (assuming that the battery has already been partiaUy discharged). In Ught of this, the acquired voltage value Vmin should be used only as a first output voltage to a host device. Although not probable, Vmin may not provide sufficient voltage to properly power the powered device. Since Vmin is below Vmax (see step 907), it is certainly a safe first vokage to apply.
- the description and figures related to software 101 (Fig. 1) further discuss output-voltage-compensation strategies.
- Vmax as a valid voltage value on which to base the output of power converter 122 in Fig. 13 A can be used as a safe operational voltage for some battery-powered devices.
- Vmax is a no-load voltage value. As such, it can be substantially higher than the battery's manufactured design voltage. For example, a Ni-Cad battery pack having a design voltage of 12.00 volts can yield a no- load Vmax value of 14.6 volts, especially if the battery has just been charged.
- Most powered devices aUow for a reasonably generous over-voltage, because batteries exhibit a transient "pulse" voltage when first turned on that delivers a substantial upward voltage spike.
- Power converter 122 A in Fig. 13A is designed to not exhibit significant voltage drops under load. Pronounced output voltage drops can create problems when Vmin- or Vref 1 -level voltages are delivered. Under a substantial load, a voltage drop from a calculated Vref* could plummet below PDVmin, causing the powered device to shut down.
- Alternative Optimum- Voltage Calculation Software 800 in Fig. IA provides an alternative method of determining an optimized output voltage for a converter 122A in Fig. 13 A.
- Steps 909 - 912 indicate an output-voltage calculation that is both simple, and reliable.
- Acquired Vmin, from steps 893 - 897, and acquired Vmax, from steps 884 - 885, are added together, and the result is divided by two (step 911).
- the resulting voltage value is stored in memory in step 912 as Vavr (Vokage Average). WhUe this less comphcated process for determimng an output voltage may seem too simplistic, it's accuracy is only tainted by battery packs that are deeply discharged.
- step 911 Deeply discharged batteries exhibit very limited spreads between Vmin and Vmax, and the resulting Vavr voltage can be too low for the powered device to sustain operations, especiaUy if a power converter 122 A exhibits voltage sags under load.
- the calculation method employed in step 911 is very acceptable, and this simple method is also used by software 101 (Fig. 1).
- Battery ceU impedance can be a vaUd indicator of cell type. All cells increase impedance as a function of discharge. As such, decreases in voltage have some relationship with changes in battery discharge levels. So too, do impedance changes reflect battery discharge states. These changes in voltage and impedance aren't very pronounced in Ni-Cad and NiMH cell chemistries, but Li-Ion ceUs do show clearly defined impedance changes that track with decreases in voltage. Impedance checks can be integrated into software 101 or 800 (Figs. 1 and 1 A respectively), if further granularity in identifying a battery pack's discharge state is required.
- Step 942 in software flowchart 800 activates manual voltage selector 337's I/O line 506 in Fig. 13A.
- a user by rotating selector dial 504, can match MCU 102A's "Best" output voltage value (step 946).
- MCU 102 A can compare a user's voltage selection to software 800' s "best" voltage selection, and confirm if they are a match.
- the perspective as to how the computed best voltage value and a user's selected output voltage value interact is left to the discretion of a product designer.
- This model of considering a user-selected voltage as the constant to which a best output voltage is compared appUes to hardware applications like that in Figs. 10 and 11. If a power adapter 335 is of a fixed output voltage, a software-800-enabled module 357 gives a user feedback as to whether the fixed- voltage power adapter 335 is an adequate match to voltage requirements of a powered device 349.
- MCU 102A retrieves from memory stored voltage values in steps 940 and 944. How the "best" 5 voltage is determined is discussed above in “Determining 'Best' Vout Value.” Once the best Vout value is determined, that value is compared to a pre-configured look-up table of possible selector voltage values (step 950).
- This look-up table (not shown) consists of each voltage value on the face of selector 337, with an assigned computer-readable value (binary, hex, "byte-word,” etc.).
- Software 800 converts the "best” Vout value to the same language (binary, hex, byte- word, etc.), 10 then looks for an exact match in this look-up table.
- step 960 looks for a reasonable match, i.e., one that is within +/-5% of the desired value. If this statement fails, a critical error is generated (step 962), which loops software back to steps 885-918 (this loop is not graphically shown in flowchart 800). In looping back to the voltage calculation processes, no new data acquisition is performed. Instead, previously-acquired voltage values are retrieved from memory and recalculated. Steps that involve user activities are
- step 968 labels this voltage value as VLout.
- Voltage target VLout is stored in memory in step 964, for later access. If there was an exact match available as a result of comparator step 954, it is labeled as Vbst in step 958, and stored for future reference (step 956).
- a software sequence can be implemented into software 800 whereby MCU 102A's "best" output voltage value (step 946) overrides any considerations of a user's incorrect manual voltage selections.
- MCU 102A's "best" output voltage value step 946
- step 946 overrides any considerations of a user's incorrect manual voltage selections.
- Previously described selector voltage value look-up table in the "Manually Selecting Output Voltages" section above contains the voltage values displayed on the face of selector 337 (Fig. 13 A) arranged in ascending order.
- the programming code considers the "voltage-to-be-matched" as a target, and each incremental voltage value above or below it is considered x-points away from the target voltage.
- software 800 assists the user by indicating whether the user is turning selector dial 504' s pointer closer-to, or farther-from the target voltage.
- LED 402 features variable-rate blinking.
- software 800 uses point-count values associated with all voltages above and below the target voltage to control the blink rate of LED 402.
- Slower LED blink rates are associated with voltage values farthest from the target voltage. Faster rates occur at numbers nearer to the target voltage value. The fastest LED blink rate occurs at the voltage values directly adjacent (on either side) to the target.
- the LED bhnk rate assists a user's manipulation of selector dial 504 by blinking more slowly as pointer 504 is rotated away from the target voltage. More rapid blinking occurs as selector dial 504 is rotated in a direction toward the target voltage.
- Final visual confirmation of a valid voltage match is a non- blinking, solid ON state of LED 402.
- Step 966 When software 800 in Fig. 1 A is ready to accept a user-selected voltage in step 966, there is either an exact-matching (or almost-exact-matching) voltage value that serves as a target.
- Step 970 indicates that either Vbst (an exact voltage match), or VLout (an almost-exact voltage match) is avaUable as a target. Since the criteria for a vaUd VLout "almost-exact" voltage is that it must be within 5% of an exact match (see step 960), the use of VLout is not necessarily a less-effective target voltage.
- Vbst voltage (exact match) happened to be 16 volts
- a corresponding VLout (almost-exact) vokage target can be as high as 16.9 volts.
- the nearest selector 337 value is 17 volts, so 17 volts would be the vaUd target.
- 15.1 voks would mathematically be as "almost-exact" a vaUd target as 16.9 volts, such spUt-decisions that precisely straddle a Vbst value always defer to the higher voltage value.
- the higher voltage is preferred because a 5% error factor is magnified at the higher voltages.
- a 5% error at 3 volts is only .15 volt, whUe 5% of 24 volts is a fuU 1.2 volts.
- Another way of looking at the 5% error-factor is that it would depress all battery design voltages by a full 5% if the lower voltage value approach was used.
- EssentiaUy a battery pack rated at 15 VDC by the manufacturer would be treated as a derated 14.25 VDC pack, just because of the allowable voltage selector error.
- Software 800 in Fig. 1 A can also employ an alternative Boolean statement to determine the relative blink rate of an LED 402 (Fig. 13 A). Instead of a point count that controls the blink rate of the LED, software steps 970-994 describe an LED blink-rate control that compares two acquired voltages. One of the two acquired voltages will always be closer to the target voltage than the other. Instead of using absolute comparisons of each acquired voltage to the target voltage value as described above, software 800' s Boolean statement determines the relative relationship of the last two previous voltages acquired.
- step 970 if the first acquired voltage from selector 337 (step 970, then stored as a value VS1 in step 974) is 9 volts, and the second acquired vokage from selector 337 (step 976, then stored as VS2 in step 978) is 7.2 voks, a simple mathematical comparison of VS1 to VS2 is performed:
- Vbst actual target voltage
- VS 1 "X"
- the voltage selector is being rotated away from the target voltage. If TRUE is reported, the LED blinks slower than the last reported answer.
- the voltage selector is being rotated toward the target voltage. If FALSE is reported, the LED blinks faster than the last reported answer.
- Vbst actual target voltage
- VS 1 "X"
- Vbst actual target voltage
- the first bUnk rate is "medium-slow," and the next blink rate (the selector arrow is now only one value away from a match) is a "medium” blink rate. If the selector matches the target on the next dial movement, the LED goes to fuU-ON. The user is only concerned with achieving a selector rotation direction that is an improvement, so the relative speed of the LED blink is important.
- Connector Unplugged Software 800 in Fig. 1 A uses a line-voltage test (steps 922-926), foUowed by a Une-load test (steps 928-938), to determine that a connector 132 (Figs. 13A, and 6) has been removed from battery 508C. Once output voltages have been calculated, the user activity of removing a male connector 132 from battery pack 508B (Fig. 13A) is important. In its Position #1, connector 132 creates a circuit that could cause power from a power converter 122 A to flow into the cells in battery 508B. This is not desirable. Software 800 relies on its model of always repeatedly sampling powerline voltage to determine if battery 508B is in the power circuit.
- step 922 and 924 software 800 has successfuUy confirmed that connector 132 has been removed from battery pack 508B. Also, as described in software 101 (Fig. 1), power converter 122A always operates at a minimal output voltage (1.5-3 VDC) through all software sequences before step 983, when a fuU operational voltage is applied to the powerlines.
- the next connector 132 insertion will look like that shown in Fig. 6C (reference Position #2 in Fig. 17).
- Battery 182 has been electro-mechanically bypassed, and the newly created circuit wUl deUver power directly to battery 508B's associated power device 508C. Because power will be flowing from power converter 122A in Fig. 13A connector 132, a reinsertion of connector 132 oriented again as it was previously in Fig. 6B (position #1) wUl cause power to flow into battery cells 182. This is undesirable.
- FIG. 13 shows voltage selector 337 being manipulated with a male connector 404 (connector 404 is best Ulustrated as connector 540 in Fig. 6D). Blade tip 548 in Fig. 6D fits a slotted selector dial 504 in Fig. 13. A user needs a male connector 404 in order to operate voltage selector dial 504. Therefore, software 800 can rely on the fact that, if activity at voltage selector dial 504 is detected (as it would be along conductor 506 in Fig. 13 A), a male connector 404 (Fig. 13) is not connected to a battery pack at that moment.
- a resistor 337B can be integrated into the slot.
- the metal tip 548 of male connector 404 comes into electrical contact with resistor 337B, creating a circuit.
- Software 800 detects the actual presence of the male connector's blade in the dial slot, via a line between resistor 337B and MCU 102A's A/D converter. This would require an entry in look-up table 990 (Fig. 20) expressed as LL 8 .
- This Identifier would express an Ohm-value that equates to the cumulative load of a power cord, connector 404, and the newly added resistor 337B.
- This approach is simUar to the use of a resistor-equipped cover cap 530 for connector 540 in Fig. 6D, which is referenced as if it were here in its entirety.
- Newly-created resistor value LL 8 should not be the same Ohm value as that used in cap 540, to avoid confusing LL 8 with LL 2 .
- This methodology is only vaUd if connector 540 cannot be removed from its cord.
- the section "Connector Unplugged" above defines a method of tracking a male connector 404 (Fig. 13), once it is removed from a battery pack (see software 800's steps 920-938 in Fig. 1 A). However, there is still a period of time during which a user is expected to reinsert male connector 404 into a battery pack. Male connector 404 must be inserted in its Position #2 (reference Fig. 6C), and not in its previous Position #1 (see Fig. 6B). If a user reinserts connector 404 in Position #1, an application of power from power converter 122 in Fig. 13A onto powerhnes 523 and 524 wUl find the battery voltage also present on that line. Such contention on the powerline is to be avoided, since it can compromise either battery ceUs 182 (Fig. 6B), or power converter 122 A.
- Software 800 is Umited to detecting line voltages, since sampUng Une load requires outputting a low-voltage power signal from power converter 122 onto powerlines 523 and 524 (Fig. 13 A). SampUng line voltage only wUl not yield sufficient data at MCU 102 A to aUow software 800 to differentiate between a removed male connector 132, and a male connector 132 that is properly inserted in its Position #2 (see Fig. 6C). If the battery voltage is higher than this low-voltage power signal, the dominant battery voltage wiU flow into the active power converter 122.
- Female connector and wiring in assembly 212 A (Fig. 6E) can be protected with diode 185 on spring-loaded connectors 176 and 178.
- a user who has invested the effort to construct a connector and cord combination removed a connector cap (Fig. 6D), inserted that connector in its Position #1 (reference Fig. 6B), then removed the connector and used it to adjust manual voltage selector 504 (Fig. 13), exhibits behavior that has a high probability of continuing the process by completing the remaining last action inserting the connector into the battery pack. Common sense suggests that, since a user is performing these actions in order to use a powered device, that the sequence of actions wUl be completed.
- a male connector 132 can only be in three states: 1). Male connector 132 is not attached to anything (Fig. 6), or 2). Male connector 132 is attached to a battery pack in incorrect Position #1 (Fig. 10 6B), or
- Male connector 132 is attached to a battery pack in correct Position #3 (Fig. 6C).
- the continuous line voltage samplings (steps 20 987-985) performed by software 800 immediately detects the voltage from a battery.
- the window of time in which a user error inserting a male connector incorrectly can happen only in the milhseconds it takes to loop back to a repeat of a line voltage sampUng sequence 987-985.
- any real-world concern about delivering power to an incorrectly inserted male connector is statistically insignificant. If there is a concern, adequate hardware modifications 25 within a battery pack, as described above, can be made to totally eUminate any possible ambiguous situations.
- MCU 102 A (Fig. 13 A), is capable of determining an optimized output voltage for power 30 converter 122 A user activity at selector dial 504 is not essential to the operation of software 800 and its related hardware. Therefore, a lack of response from a user in software steps 942 - 998 should not prevent software 800 (Fig. 1 A) and its hardware from executing the remaining sequences required to deliver output power. A reasonable amount of time should be aUocated during which software 800 wUl expect user voltage-selector 504 activity. Since MCU 102A does provide a clock generator (152 in Fig. 3 A), a timing function can be used to establish a window of anticipated selector dial 504 activity. This function is not detailed in software flowchart 800, but one skUled in the art can implement this additional timing sequence.
- Software 800 does have certain indicators that point toward a user having omitted the voltage selector sequence 942-998.
- the primary indicator is the location and position of a male connector 132 in Fig. 13A (reference Figs. 6-6C).
- connector 132 can only be in one of three states: still inserted (see Fig. 6B), removed (see Fig. 6), or reinsterted in its next position (see Fig. 6C).
- the processes of determining these connector states has already been addressed, by sampUng Une voltage and line load (see chart 1001 in Fig. 17, and the related description for software 101).
- the next activity is that of a user rotating voltage selector dial 337 (Fig. 13A), in preparation for reinserting connector 132 into battery 508B.
- a time delay allocated for this anticipated next user activity is important. Assuming that there is no method avaUable for prompting a user to reinsert connector 132 (step 936), software 800 has no choice but to wait.
- the section "Disconnected Selector 'Key'" above addresses various monitoring steps performed by software 800, to determine when connector 132 is removed and reinserted.
- Power box 400 does have one user prompting device.
- LED 402 can be an effective attention-getter. Blinking the LED at different rates (or having it change colors) helps to focus a user on the next required connector action.
- Steps 987 and 985 in software flowchart 800 represent the last voltage check prior to activating power converter 122A (Fig. 13A).
- This Vin sampling loop like all others in software 800, continuously repeats, and is always followed immediately by a line-load test (steps 983-973).
- Vin test 987-985 is looking for a no-line-voltage status, prior to executing Une-load test 983-973. If Vin test 987-985 reports back a state of voltage on the powerlines, male connector 132 has been incorrectly inserted into battery pack 508B (as indicated in Fig. 6B). The resulting error state causes software 800 to loop back to step 989.
- a final load test in steps 983-973 prior to activating power converter 122A is identifying a resistive load value on the powerlines that validates male connector 132's proper insertion into battery pack 508B (reference Fig. 6C).
- the load-value for this state is not fully known. It cannot be, because software 800 and its associated hardware have no determination capabilities of whether it has interacted with this specific powered device 508C. Every powered device wiU exhibit different load values, resulting from the impedance of circuits inside the powered device 508C (downstream of battery pack 508B).
- LL 4 is an Ohm-value expression of the mathematical sum of the three elements: power cord, connector, and battery pack. If internal battery pack wiring circuits in Figs. 9A-9D are manufactured to return a fixed impedance value, then LL 4 in Fig. 20 is predetermined. Since LL 4 has a known resistance (Ohm) value, any load detected in software 800 steps 983-973 that is greater than (>) LL 4 is considered to be the additional load added by a powered device's internal circuitry.
- LL 5 in look-up table 990 is defined as any load that is greater than LL 4 , but only if the resistive value of the battery pack's internal wiring is known.
- Steps 996-997 in software 800 define the resolution of user manipulation of voltage selector dial 337 (Fig. 13A), with step 996 being the command from MCU 102A to turn LED 402 fuU ON (no blink), indicating to the user a successful voltage match.
- Software 800 then shuts down Selector I/O line 506 in step 997. Once selector I O 506 is shut down, no activity at selector 5 dial 504 is acknowledged by MCU 102A, or its associated software 800.
- the safety aspects of this are obvious. This is a useful feature if a power adapter 400 is used on an airplane, or other confined area where power problems can pose serious safety risks.
- selector dial 337 Fig. 13 A
- the 10 "OFF" selector dial position has a separate line 511 to MCU 102 A.
- the OFF selector setting is effectively a user "panic button.”
- a user can totally shut down power box 400 by turning selector pointer 504 to the OFF position.
- the detents on either side of the OFF position are more aggressive than the others on dial 337, so a user must make a concerted effort to put pointer 504 into the OFF position.
- the area of the faceplate at the OFF label is painted red to indicate the 15 special significance of "OFF . "
- power box 400 (Fig. 13 A) and its associated software 800 (Fig. 1 A) are capable of communicating with its input power source (reference module 100 in Fig. 2).
- Software 800 manipulates resistor array 509 in power box 400, adding resistive elements to create a discernible change in the overall load detectable at input powerlines 30 505 and 507 (powerlines 505 and 507 in Fig 13 A are the same as powerlines 114 and 116 in Fig. 2). Such is the case in software step 997.
- LED 402 is Uluminated full ON (step 996).
- a discernible power load is created, by inserting a load from resistor array 509 on powerlines 505 and 507, as a non- limiting example.
- This pre-determined increase in load from resistor array 509 in Fig. 13A is sensed by power module 100 in Fig. 2, which is already delivering a voltage (3-5 VDC, for example) to power box 400 in Fig. 13A.
- This increase in line load indicates to software 101 (Fig. 1) resident on MCU 102 (Fig. 2) that power box 400 has issued a caU for increased power.
- Power module 100 responds by increasing power supply 122's output voltage to a pre-determined value, for example, 28 VDC.
- Software 800 in power adapter 400 samples input line voltage at MCU 102's A/D I/O Port #2 (518), and detects the change in input voltage from a low voltage (3-5 VDC, for example), to the new higher voltage (see software steps 995 and 993). Sufficient input power for DC/DC converter 122A is now available.
- Software 800 in its shutdown mode (not detailed in software flowchart 800 (Fig. 1 A)), loops back to step 807, but not before writing all stored values to non-volatile memory. Such a reset aUows software 101 to recover, and to even go back to the last executed step prior to shutdown, if necessary. As a default, this mode of resuming from the last-executed line of code is not prudent.
- a user may perform some undetected and undesirable activity, such as removing a connector 132 in Fig. 13A and reinserting it in an unwanted position. This could happen, since the extinguished LED could precipitate such user behavior.
- MCU 102A can be kept active by traditional temporary power storage methods. These hold-up methods can include an internal battery, (see also Figs. 6E to 6F-1, and related text in the section "Diode UPS'
- Step 991, and 989 indicate prompts to a user.
- the first prompt is to reattach a male connector 540 (reference Fig. 6D) to its power cord. If the cord and male connector are hardwired, this prompt is not required.
- Step 989 prompts a user to insert a male connector 540 to a battery pack in its Position #2 (see Fig. 6C). If there is no adequate prompting method, such as a display screen, series of LEDs (see Fig. 14), etc., then steps 965 and 967 are not executed.
- LED 402 available on power box 400 can be an effective way of signaling a user to move the process along. This method must be used with caution, so as not to confuse a user who only expects to see LED activity whUe engaged in rotating voltage selector dial 337.
- a multi-color LED can be beneficial here, perhaps with a label suggested by the non-limiting example in Fig. 14.
- A/D I/O lines 525 and 527 can be used to confirm that converter 122A is delivering the correct voltage. However, since MCU's A/D lines 525 and 527 are downstream of power switches 526 and 526 the way to prevent power delivery to a battery circuit 508B is to include a controllable power switch 508G in the battery's circuit. Battery MCU 102D controls power
- switch 508G MCU 102 A in power box 400 communicates a request to open switch 508G by powerUne modulation to battery 508B's MCU 102D (as described in the sections "Data Paths,” and “Other Data Links”).
- Software step 953 compares MCU 102A's commanded voltage to converter 122 A with the actual 20 output of converter 122 A. If there is a mismatch, error 959 is reported, and software 800 loops back to step 969 to configure the converter once more. If both the commanded voltage and the actual output voltage match in step 953, software 800 signals MCU 102A to open switch 526. Power then flows along powerlines 523 and 524 to connector 508, then along power cord 508A into connector 132, then through battery pack 508B's wiring, and finaUy into powered device 25 508C.
- Two line-load checks are performed in software steps 951-933. These two line-load sampUngs constitute a final check that the power circuitry from power box 400 to powered device 508C is still intact.
- Previously-stored line load value LL G (see step 971) is retrieved from memory 518A.
- 30 Look-up table 990' s value LL 5 (Fig. 20) is used as a baseline, since Ohm value LL 5 is a valid load value that tested the entire circuit.
- Software step 951 acquires this line load value.
- step 949 a calculation is made to provide an Ohm value at the new output voltage that is equivalent to the LL 5 Ohm value previously acquired in step 981 at a lower voltage. This value is stored in memory as LL 6 .
- step 957 the newly-acquired Ohm value LL 6 is compared to LL 5 . If the values (with this mathematical 5 adjustment for different vokages) are the same, a user prompt is displayed that the powered device can be turned on (step 929).
- the load at A/D I/O Port #4 should be in the range of 600-900 mA. 750 mA is a reasonable value.
- Step 937 samples line voltage, whUe the additional load in steps 917-913 is still applied. If the output voltage of power converter 122 A drops by 5% or more (step 913), step 911 increases 15 converter 122A's output voltage by 10%.
- This voltage compensation step is not necessary if power converter 122A's design adequately protects against voltage sags. In reahty, power converter 122 A cannot be a perfect power conversion device across its 3-24 volt output range. So, performing a voltage compensation 20 sequence is a reasonable way to enhance a power converter 122A's inherent voltage stabihty limitations.
- Step 909 powerline activities throughout its operational use. Repeated samplings of line load can provide information as to whether a powered device 508C has been turned ON (and later, turned OFF). Steps 927-923 are a repeat of software 800's previous line- load sequence in steps 951-945, except the newly acquired Ohm value LL 1 is compared to the stored LL 6 value. If LL 7 expresses more load than LL 6 , then it is reasonable to assume that the
- LL 7 is stored in memory 518A.
- Software 800 continues to sample line load by repeating steps 927-923. As long as a reported value of an LL 1 that is greater than LL 6 is reported, software 800 assumes that powered device 508C (Fig. 13 A) is stUl turned ON. If an LL 6 value is acquired, it can be safely assumed that powered device 508C has been turned OFF, and that power cord 508 A and connector 132 are stUl attached to battery pack 508B. One cannot compare any acquired LL 7 value to any other. Powered devices exhibit dynamic, not static, loads, so the only vaUd logic statement that can be used is that if an LL 7 is greater than the stable value of LL 6 , the device must be ON.
- Helpful information to avoid excessive voltage compensations 911 in Fig. 1 A can include tracking voltage adjustment trends.
- a consistent pattern of upward adjustments is a reasonable indicator that the baseline voltage stored in step 957 was too low. Determining an increase in baseline voltage is not a simple matter, so it should always be approached cautiously and with a substantial, long-term voltage history to support the decision.
- initial deviations in load which precipitate voltage fluctuations
- BIOS POST activities are usually created by the BIOS POST activities, as powered sub-systems and devices are intentionally turned ON and OFF.
- BIOS diagnostics Hardware devices cycled ON and OFF during the BIOS POST may never be caUed upon during later user operations.
- Line- voltage monitoring steps 921-913 in software 800 are also used to determine a specific user activity, namely, disconnecting power by removing connector 132 from battery pack 508B (Fig. 13A).
- MCU 102A and software 800 immediately issue a shut-down command to power converter 122 A
- Precursors of this disconnect state include changes in line load which are identified with an Ohm value previously identified as LL 6 .
- Ohm value LL 6 corresponds to powered device 508C being turned OFF. If the answer to software test in step 945 is FALSE (NO), software 800 commands power supply 122A in Fig. 13 A to shut down.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Power Sources (AREA)
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IL14407199A IL144071A0 (en) | 1998-12-31 | 1999-12-31 | Systems for configuring and delivering power |
CA002355909A CA2355909A1 (en) | 1998-12-31 | 1999-12-31 | Systems for configuring and delivering power |
EP99967750A EP1147591A1 (en) | 1998-12-31 | 1999-12-31 | Systems for configuring and delivering power |
AU23977/00A AU2397700A (en) | 1998-12-31 | 1999-12-31 | Systems for configuring and delivering power |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11441298P | 1998-12-31 | 1998-12-31 | |
US11439898P | 1998-12-31 | 1998-12-31 | |
US60/114,412 | 1998-12-31 | ||
US60/114,398 | 1998-12-31 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2000039907A1 true WO2000039907A1 (en) | 2000-07-06 |
Family
ID=26812135
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/031195 WO2000039907A1 (en) | 1998-12-31 | 1999-12-31 | Systems for configuring and delivering power |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP1147591A1 (en) |
AU (1) | AU2397700A (en) |
CA (1) | CA2355909A1 (en) |
IL (1) | IL144071A0 (en) |
WO (1) | WO2000039907A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
EP1147591A1 (en) | 2001-10-24 |
CA2355909A1 (en) | 2000-07-06 |
AU2397700A (en) | 2000-07-31 |
IL144071A0 (en) | 2002-04-21 |
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