United States Patent [19]
`van Phuoc et al.
`
`[54]
`
`[75]
`
`[73]
`
`[21]
`[22]
`
`[62]
`[5 l]
`[52]
`[5 3]
`
`[5 6]
`
`BATTERY PACK HAVING A PROCESSOR
`CONTROLLED BATTERY OPERATING
`SYSTEM
`
`Inventors: Duong van Phuoc. Eching; Rudi
`Wieczorek. Munich; Elmar Zeising.
`Haindl?ng. all of Germany; Louis W.
`Hruska. Northboro. Mass.; Alwyn H.
`Taylor. Wellesley Hills. Mass; Daniel
`D. Friel. Woburn. Mass; Matthew P.
`Hull. Jamestown. Rl
`
`Assignee: Duracell, Inc.. Needham. Mass.
`
`Appl. No.:
`473,340
`Jun. 7, 1995
`
`Filed:
`
`Related US. Application Data
`
`Division of Ser. No. 336,945, Nov. 10, 1994.
`
`Int. Cl.6 ............................ .. H01M 10/44; H02] 7/00
`US. Cl. ............................ .. 320/30; 320/48
`Field of Search ...................... .. 320/5, 19. 20.
`320/22. 30. 35. 48, 324/426; 361/96. 106;
`364/483. 350. 550
`
`References Cited
`
`U.S. PATENT DOCUlVIENI'S
`
`3,971,980
`4,238,839
`4,289,836
`4,377,787
`4,390,841
`4,583,034
`4,595,880
`4,677,363
`4,709,202
`4,716,354
`4,724,528
`4,725,784
`4,737,702
`4,743,831
`4,803,416
`4,885,523
`4,947,123
`
`7/1976
`12/1980
`9/1981
`3/1983
`6/1983
`4/1986
`6/1986
`6/1987
`11/1987
`12/1987
`2/1988
`2/1988
`4/1988
`5/1988
`2/1989
`12/1989
`8/1990
`
`Jungfer et a1. .
`Redfern et al. ......................... .. 365/96
`
`Lemelson .
`Kikuoka et a1. .
`Martin et a1. .
`
`Mam'n .
`
`Patil .
`
`Kopmann .
`Koenck et al. ......................... .. 320/43
`
`Hacker .
`
`Eaton .
`Peled et a1. .
`
`Koenck .
`
`Young .
`Abiven et a1. .......................... .. 320/44
`
`Koenck .
`
`Minezawa .
`
`US005652502A
`Patent Number:
`Date of Patent:
`
`[11]
`
`[45]
`
`5,652,502
`Jul. 29, 1997
`
`4,949,046
`
`8/1990 Seyfang .
`
`(List continued on next page.)
`
`OTHER PUBLICATIONS
`Markus Bullinger. “Quick Cahrging with Intelligence-An
`IC Controls NiCad and NiMH Battery Chargers.” Elec
`tron/‘k, 42. No. 6. Mar. 23. 1993. pp. 74-77.
`Patrick Guelle. “Integrated Circuits for Rapid Chargers”.
`Electronique Radio Plans, Feb. 1993. N0. 543. pp. 57-64.
`Jacques Robert. et al.. “A 16-bit Low-Voltage CMOS A/D
`Converter.” IEEE Journal of Solid State Circuits, vol.
`SC-22. No. 2. Apr. 1987, pp. 157-159.
`
`Primary Examiner—-Peter S. Wong
`Assistant Examiner-——Gregory J. Toatley. Jr.
`Attorney, Agent, or Firm-Scully. Scott. Murphy & Presser
`
`[57]
`
`ABSTRACT
`
`A smart battery device which provides electrical power and
`which reports prede?ned battery parameters to an external
`device having a power management system, includes: at
`least one rechargeable cell connected to a pair of terminals
`to provide electrical power to an external device during a
`discharge mode and to receive electrical power during a
`charge mode, as provided or determined by the remote
`device; a data bus for reporting prede?ned battery identi?
`cation and charge parameters to the external device; analog
`devices for generating analog signals representative of bat
`tery voltage and current at said terminals. and an analog
`signal representative of battery temperature at said cell; a
`hybrid integrated circuit (IC) having a microprocessor for
`receiving the analog signals and converting them to digital
`signals representative of battery voltage. current and
`temperature. and calculating actual charge parameters over
`time from the digital signals. the calculations including one
`calculation according to the following algorithm;
`
`wherein EC is a function of battery current and temperature;
`and I: is a function of battery temperature and CAPFC.
`Superimposed on this equation is reset logic. that self
`corrects the value of CAPFC with a capacity calculation at
`each full charge (EOC) and each end of full discharge.
`
`32 Claims, 31 Drawing Sheets
`
`/.
`
`130
`
`In
`
`an
`
`AID
`
`23
`
`9
`
`’ an 01 as
`
`1
`
`mam
`ready Iraq
`-l
`
`.1 . i. 23
`Standby
`
`Apple Inc., et al.
`Exhibit 1028
`Apple Inc., et al. v. Global Touch Solutions, Inc.
`IPR2015-01175
`
`Exhibit 1028, Page 001
`
`

`
`5,652,502
`Page 2
`
`US. PATENT DOCUMENTS
`4961043 10/1990 Koenck
`4,965,733 10/1990 Bauer et a1. .......................... .. 364/483
`5,027,294
`6/1991 Fakruddin 6141..
`5,043,651
`8/1991 Tamura.
`5,047,961
`9/1991 Simnsen_
`5,130,659 7/1992 Sloan.
`5,196,779 3/1993 Alexandres et a1 7
`5,200,639 4/1993 111mm 61 a1,
`5,216,371
`6/1993 Nagai.
`
`5,254,928 10/1993 Young 6131..
`5’278’487
`1/1994 Koenck‘
`5284719 2/1994 Mud“. m1"
`5,287,286 2/1994 Nmmmya
`5,315,228
`5/1994 HESS et a1. .
`5,321,627
`6/1994 Reher.
`5325041 6/1994 Bn'ggs
`5,341,084
`8/1994 Gotoh et a]. ............................ .. 320/44
`5,349,535
`9/1994 Gupta ......... ..
`. 364/483
`5,455,499 10/1995 Uskali et
`........................... .. 320/43
`
`Exhibit 1028, Page 002
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 1 of 31
`
`5,652,502
`
`Eszm
`
`>m.nE.<m
`
`_.O_u_
`
`Exhibit 1028, Page 003
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 2 of 31
`
`5,652,502
`
`._._am
`
`55
`
`Nam:
`
`83
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`
`Exhibit 1028, Page 004
`
`
`
`
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 3 of 31
`
`5,652,502
`
`.__________
`
`mm.0.n_
`
`
` mm.9,%3..__LL_mm”mm”rCI.IIII.;_uIIInIn
`mm{L»\t3mm8>
`20¢E0505EmILom_ICbI.I5.9EnaEoomV ExmmwE
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`mmW_fiomsa_mm
`
`Exhibit 1028, Page 005
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 4 of 31
`
`5,652,502
`
`Woke up
`
`/
`
`2|
`N
`
`Bus
`request
`B it
`25
`Yr
`r r ~00
`initialization
`Handle request
`\
`|
`
`t30
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`'Disobie bus
`requests
`Enable A/D
`
`'
`
`Standby ~23
`
`Obtain row I,
`U,und T values
`i4!
`1'
`\__36' Am
`meusufemem
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`=
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`
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`x1022“
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`mode
`
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`Set getvniues
`:0
`
`Disable A/D
`converters
`
`FIG. 3
`
`$48
`i f
`Set
`getvolues=t
`‘49
`' /
`
`Start A_/D
`conversion
`
`v f '5‘
`Capacity
`calculation
`
`{152
`Alarm
`controt
`['54
`Charger
`controt
`[I56
`LED display
`
`‘58W
`Enable bus
`requests
`(23
`Standby
`
`Exhibit 1028, Page 006
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 5 0f 31
`
`5,652,502
`
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`or
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`
`Exhibit 1028, Page 007
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 6 0f 31
`
`5,652,502
`
`m .91
`
`w :5 x 2.
`
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`
`Exhibit 1028, Page 008
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 7 of 31
`
`5,652,502
`
`o»Summum1:2:
`
`A223
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`
`Exhibit 1028, Page 009
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 8 of 31
`
`5,652,502
`
`
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`Exhibit 1028, Page 010
`
`
`
`
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 9 0f 31
`
`5,652,502
`
`Exhibit 1028, Page 011
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 10 0f 31
`
`5,652,502
`
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`
`Exhibit 1028, Page 012
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 11 0f 31
`
`5,652,502
`
`FIG. IO
`
`85
`
`W90
`I
`H,_
`.
`_____L__
`T
`low if v00 2v
`
`f Circuit
`II‘ To
`It
`
`Oscillator
`
`85
`\
`POR high If v00 2v
`
`V79
`
`65
`VBUF (
`
`_
`l
`RAM
`T C4
`=330nF v58
`I
`I
`
`VDD
`Power $1
`PR4
`I
`
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`l3
`
`Exhibit 1028, Page 013
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 12 of 31
`
`5,652,502
`
`I1 2
`
`from F'ig 13A
`Convert raw AID
`205
`k current and
`voltage values to
`actual "I" and "U"
`
`200
`
`Enter sleep
`
`213
`HP turns off
`A/D converter /
`
`$
`uP turns off 455
`KHZ
`oscillator
`
`216
`—-/
`
`217
`‘l
`Enable wake-up
`comparator J
`circuit
`r
`218
`.
`uP sets itself
`for sleep \J
`
`215
`Convert raw ND
`temperature value /
`to actual t and
`scale T value
`i
`Check for over
`temperature
`condition
`
`222
`/
`
`224
`I
`f l
`Per orm d T d t
`_
`calculatlon to \J
`determlne d t
`t
`226
`Perform internal
`temperature check M
`l
`Perform dp/dt
`calculation to
`determine (1 p
`
`227
`r...)
`
`Wakeup J
`comparator
`(‘MW-“wigs”
`Slgna s
`221
`f
`Turn on up AID, /
`oscillator and
`ASIC circuits
`
`go to step 100
`Fig. 3
`
`I
`
`& Set E00 ?ag
`_ Set terminate
`discharge alarm
`‘
`
`264
`S
`82225931222
`discharge alarm
`-Cap reset disabled
`
`go to step 165
`Fig. 1 3A
`
`Exhibit 1028, Page 014
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 13 0f 31
`
`5,652,502
`
`Fl a. BA
`
`l5|
`From Fig.3 /
`P f;
`er orm
`‘UT
`calculation
`l
`Update average “A65
`current I Avg
`
`N200
`
`Clear self- NW2
`discharge flag
`
`I75
`5
`
`—State=Ci_3
`~Set selfdischarge
`flag
`‘
`
`impunity
`increasing
`I80
`Y ,/
`Set state
`as CI
`
`4
`
`I82
`I
`Set state
`as CD
`
`I84
`N
`
`To step l92
`Figl3B
`
`Capacity
`reset flag enabl -
`
`To step I92,Fig.l3B
`
`—Set remaining capacity
`as function of WT
`residual capacity value
`-Reset error re ister
`—Disable capaci y reset
`L———-————-———>To step l92,Fig.|3B
`
`Exhibit 1028, Page 015
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 14 0f 31
`
`5,652,502
`
`from step 190 w from step 189
`Determine if state
`change occurred
`
`.1
`
`Check self - discharge
`300
`k-~
`timer
`i
`
`Get self - discharge
`rate as a function of
`S00 and T from look - \J
`up table
`
`305
`
`Capacity
`decreasing .7
`
`315
`
`/
`
`calculate decrease in
`capacity since last
`state change
`320
`&
`(
`increment charge to
`self ~ discharge for
`error calculation
`
`325
`
`l
`
`Increment capacity
`integral by self ~
`discharge rate
`
`400
`
`/
`
`l‘—"_ _ _ _ _ __
`
`Perform current
`integration
`
`198
`
`Capacity
`increasing ?
`
`500
`\__. Perform end
`conditions C l
`L
`
`600
`
`Perform and
`conditions C D
`l
`l_> go to step 152 FIG 3
`
`Exhibit 1028, Page 016
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 15 of 31
`
`5,652,502
`
`400
`/
`f 4l2
`Clamp State of
`Charge = o
`
`Y
`
`4l0
`L Calculate
`stateof charge
`relative to_
`full capacity
`
`4l5
`‘
`\-\ Calculate
`0 rate
`
`4i8
`
`Capacity
`decreasing
`?
`
`- K422
`Integrate charge
`for current
`discharge cycle
`
`45!
`(
`i
`Get residual capacity
`as a function of C
`rate and T from LUT
`
`Self discharge
`lag not set
`
`42° 7
`Get charge
`efficiency factor
`as a function of
`state of charge,
`C rate and T
`from LUT
`
`435
`
`/
`Calculate charge
`to increment the
`integration
`
`High discharge
`rate and E00
`flag set '?
`
`Disable resets
`(reset flag= li
`
`440 7
`
`Calculate charg
`to increment the
`inte ration L _l
`'t
`445k 1. integrate charge for
`error calculation
`2. Calculate error
`3.lntegrate charge for
`capacity calc.
`
`FlG.l3C
`
`End integration
`
`Exhibit 1028, Page 017
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 16 of 31
`
`5,652,502
`
`From step 50l
`
`F I G. l 4 A
`500
`/
`
`State of
`charge) 20% of full
`chage value .
`
`Clear full dlschar ed
`smtus ?gq
`9
`
`5l0
`
`Dt/dl
`trigger enable
`condition met and
`dT) threshold
`limil
`
`go to step
`540,
`Fig.l4A
`
`from
`
`step 555
`520
`(J
`Q
`Set capacity = full
`capacity
`Set error registers
`to zero
`
`Clear error overflow
`flag
`
`53o
`
`Charger
`still on?
`
`532
`
`t
`t
`$238 5 ep
`Fig ‘4B
`
`Accumulate
`overcharge in
`overcharge
`register
`
`Remalning
`capacltyz
`full capacity
`
`go to step
`575
`
`535
`\
`get
`overcharging
`alarm
`
`1
`
`G0 to slep 575
`
`Exhibit 1028, Page 018
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 17 0f 31
`
`5,652,502
`
`FIG.I4B
`
`From step 5l2
`
`L
`
`Learn
`number of cells
`
`700
`
`570
`
`LSet EOC flog
`2.8et cepecity= 95%
`full cup.
`3.Cleor error registers
`4.Clec|r error overflow
`?ag
`5. Set fully charged
`status flog
`
`G010 step 575
`
`Exhibit 1028, Page 019
`
`

`
`US. Patent
`
`Jul. 29, 1997
`
`Sheet 18 0f 31
`
`5,652,502
`
`From step 510
`
`FIG.|4C
`
`Char e
`current clue
`and d\/ trigger
`reached
`
`charge) I50% and
`C/S (Crate( 6/50
`
`Y
`
`730
`
`Learn
`number of cells
`525i )
`Set EOC ?ag
`
`From
`step
`535
`
`From
`step
`514
`
`From
`step
`570
`
`55f
`
`Set futly
`charged status
`?ag
`
`‘
`
`i
`
`I
`
`575A Set terminate
`charge alarm
`
`Go to step 520
`
`End
`
`Exhibit 1028, Page 020
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 19 of 31
`
`5,652,502
`
`705
`
`F|G.l4D
`
`Col ibrated
`?
`
`/700
`
`
`
`
`
`Voltage >25
`
`
`
`
`
`
`Set number
`Set number
`Set number
`of cells = 4
`of ce||s= 9
`of ce||s= 6
`
`
`
`
`
`
`Set EOD
`Cutoff voltage
`=number of
`cells (l.02V)
`
`
`
`Exhibit 1028, Page 021
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 20 of 31
`
`5,652,502
`
`625
`Tt°
`
`5 °p
`640
`
`Cycle Count
`flag clear and
`capaclty< I5’/o
`
`
`nomo.cup
`
`
`
`
`I. Increment number
`of cycles
`2.Cycle count flag
`
`set
`
`
`1
`
`From step 60!
`605
`
`Voltage
`)EDV voltags
`lus hysteresis
`
`/
`
`N
`
`
`
`6l3
`
`Clear charging
`alarms
`
`615
`Capacfl
`
`( calcula ed
`error
`?
`
`
`
`Set fully
`dlschar ad
`status
`ag
`
`
`
`6l8
`
`6l9
`
`
`
` SOC
`
`( hysteresis
`value (SOC
`
`620
`39%’
`
`
`
`Clear fully
`charged status
`flog
`
`
`
`Exhibit 1028, Page 022
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 21 of 31
`
`5,652,502
`
`From step 625
`
`FlG.l5B
`
`
`
`
`EOD fla
`set AN
`
`
`resets enabled
`(flaq=O)
`
`
` EOD flag
`
`
`645
`
`set AND
`
`error value (8 %
`of full cap.
`
` Reset full capacity
`
`lcalcwate present
`capacity value 2
`last ful|+capacity
`
`residual capacity
`2. Clear EOC flog
`
`
`
`
`
`
`EDV
`Current-‘=0
`OR
`C-rate (EDVC-rate
`AND CAP. Reset
`nabled
`
`
`
`
`660
`
`
`
`Set EOD current=
`
`
`Set C-rate;
`
`delayed capacity
`
`reeet= present
`
`residual capacity
`Set delay capacity
`
`flags after EOD
`
`Exhibit 1028, Page 023
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 22 of 31
`
`5,652,502
`
`
`
`Decode command
`code
`count. = Z
`
`750
`
`F|G.l6
`
`
`
`Timeout
`or error
`
`763
`
`Set Unknown
`error
`
`
`
`Se’:
`Unsupported
`Command bit
`
`
`
`
`
`Requires
`Ca|cu'|?atlon
`
` Acc es:
`domed
`
`758 b
`
`
`
`
`
`
`
`Terminate
`Perform
`erminqte.
`ironsmiseion
`Write— Block
`transmission
`
`
`
`
`
`
`End handle request
`
`Exhibit 1028, Page 024
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 23 of 31
`
`5,652,502
`
`
`
`ERROR or
`TIMEOUT
`
`
` [Adr] =12c-DATA
`
`
`
`decrement count
`Adr= Adr + I
`
`788
`
`787
`
`
`
`
`
`
`
`Set BAD SIZE
`
`Set
`unknown error
`
`ermmqte _
`transmission
`
`
`
`89N
`
`790
`
`
`
`End write block
`
`
`
`Exhibit 1028, Page 025
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 24 of 31
`
`5,652,502
`
`802
`
`FlG.!8
`
`800
`
`/
`
`
`
` Dotob ta
`entere
`on
`I 2C bus
`
`
`
`Ackbit
`received
`
`
` I2c doto= [Adr]
`
`increment [Adr]
`
`
`decrement count
`
`
`
`8I8
`
`Set Iostbyta
`flog
`
`82
`
`Stop bit
`.
`recneved
`9
`
`
`
` End Read Block
`
`
`Set unknown
`error and
`terminate transmit
`
`Exhibit 1028, Page 026
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 25 of 31
`
`5,652,502
`
`I52
`
`
` / FlG.l9A
` ltf-Itf_err
`
`90:
`
`N
`
`
`
`AL- Rem_CAP
`>
`
`906
`
`Set
`
`REM_CAP_.ALARM
`
`Clear
`REM_CAP.. ALARM
`
`
`Culculuter C _ Rate
`
`
`based on avg .
`current
`Obtain residual
`capacity (C_rute)
`
`
`
`
`908
`
`
`
`
`9|O
`
`AL..R§M.TlME
`
`Cdlculate time==
`Average Time To
`Empty
`
`
`
`Time
`<
`
`
`
`AL..REM-TlME
`
`92|
`
`G010 FIG. 19B
`
`
`
`Set
`
`Clear
`
`REM..TlME_.ALARM
`
`REM.TIME .. ALARM
`
`Exhibit 1028, Page 027
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 26 of 31
`
`5,652,502
`
`925
`
`From FIG.
`
`|9A
`
`FiG.i9B
`
`
`
`926
`
`
`
`Clear
`
`alarming flag
`
`
`
`
`
`Alarming
`flag
`cleared
`
`Decrement alarm
`
`broadcast timer
`
`
`
`
`
` - Set alarming flag
`-Set alarm broadcast
`timer to zero
`
`—Alarm sent to host
`fla set
`
`
`
`
`
`Alarm broadcast
`time =9’
`
`935
`
`7
`
`
`
`
` Siadr:= Host
`Comcodei=Battery
`
`Data Adr2=
`AL_STATUS-L
`
`945
`
`Send
`
`message
`
`947
`
`
`
`
`to rf‘J§{"?|qg
`-Reset broadcast
`
`clea red
`timer=N-ALARM
` -Toggle alarm to
`?
`host
`
`
`
`
`
`Siadr I=Charqer
`
`
`
`Send
`alarwito
`
`End alarm
`control
`
`charger
`
`?
`
`
`Exhibit 1028, Page 028
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 27 of 31
`
`5,652,502
`
`F|(3.2O
`
`
`
` 850 F4
`
`
`
`Battery
`in s yste m
`’?
`
`
`
`
`
`C1ear_
`CapacIty_mode
`bit and charger.
`mode big
`
`chargermode bits
`
`
`
`
`
`
`
`
`
`
`
`Set constant
`current
`
`charge variable
`
`374
`
`End
`charger control
`
`harger- mode
`bit cleared
`
`
`
`'?
`
`Y es:
`
`Decrernenfi message
`hmer
`
`Message
`timer timed
`out
`
`
`
`?
`
`
`
`
`
` Charging
`
`current= Q
`
`-Reset message
`_
`timer
`-Calculate chargmg
`current
`
`Exhibit 1028, Page 029
`
`
`
`
`Just
`
`inserted
`
`
`
`
`
`SlAdr == CHARGER
`Comcode ==CHAR_CURR
`7
`Data Adr == Charghg -
`
`current- L
`
`
`- Message time =1
`
`- offline = G
`
`- Clear Cap-mode and
`
`868
`
`
`
`870
`
`872
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 28 of 31
`
`5,652,502
`
`F|G.2|A
`
`945
`/
`
`To FIG. 22B
`
`
`
`Set slave
`
`address
`
`Set battery as
`master
`
`.
`Clear terminate
`transmission
`
`953
`
`954
`
`
`
`D
`
`1°.°
`
`receaved
`
`955
`N
`
`958
`
`?
`
`Y
`
`957
`
`Transmit
`battery address
`
`(Command Code)
`
`E.:':,
`
`"
`
`?
`
`
`Time out
`?
`
`
`Error
`Of
`
`To FIG. 228
`
`Exhibit 1028, Page 030
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 29 of 31
`
`5,652,502
`
`FromFIG. ZIA
`
`Frort;1!;G.2lA
` 950
`
`Dam
`
`
`
`received
`
`
`'?
`
` 965
` [Sf
` Transmit
`
`b y te of data
`received
`
`
`Data
`
`
`968
`
`Transmit 2 "d
`byte of data
`
`Em"
`
`
`
`. or
`time out
`
`
`
`969
`
`Date
`
`
`
`received
`
`?
`
`973
`
`Terminc_1te_
`transmission
`
`End send
`message
`
`Exhibit 1028, Page 031
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 30 of 31
`
`5,652,502
`
`FIG. 22A
`
`m_U_‘|m8D.mT...
`
`FIG. 22B
`
`Exhibit 1028, Page 032
`
`
`
`

`
`U.S. Patent
`
`Jul. 29, 1997
`
`Sheet 31 of 31
`
`5,652,502
`
`FIG. 22C
`95% soc
`l"""""""""""'*~.I5'.-.-..
`
`I "“[i'§‘| -:&r.':..
`"3I|T'iI[|_
`I
`1“.
`
`
`
`cm
`
`TEMPERATURE
`
`|.O
`
`I
`. mg
`I $§
`. gt
`.
`ow
`
`,0
`
`
`
`L
`
`L.
`
`Fi
`
`O.|C
`
`RATE OF CHARGE----'*
`
`Exhibit 1028, Page 033
`
`

`
`1
`BATTERY PACK HAVING A PROCESSOR
`CONTROLLED BATTERY OPERATING
`SYSTEM
`
`CROSS~REFERENCE
`
`This application is a divisional of U.S. Ser. No. 08/336.
`945. filed Nov. 10. l994.
`1. Field of the Invention
`
`The present invention relates to generally to the art of
`rechargeable batteries and more specifically to a smart
`battery for use in an intelligent device having power man-
`agement capabilities. The invention is a smart battery appa-
`ratus for controlling the operation of rechargeable Nickel
`Metal Hydride (NiMH) or Nickel Cadmium (NiCad)
`batteries. and the like. to enable the reporting of accurate
`information to the intelligent device for power management
`and charge control specific to the battery’s state of charge
`and chemistry.
`2. Description of the Prior Art
`The advent of intelligent portable electronic devices such
`as notebook computers. video cameras. and cellular phones
`has enabled the development of smart rechargeable batteries
`that can communicate with the intelligent device to provide
`accurate information on the battery’ s present state of charge.
`and how best to recharge the battery to maintain maximum
`battery life. thus enabling the highest number of charge-
`discharge cycles. A user of such intelligent portable devices
`utilizing such smart batteries will not only know how much
`charge is left in the battery. but battery run time at various
`rates of power consumption. This enables the user to select
`a mode of operation that will enable maximum service life
`on the remaining state of charge and. how long the device
`will continue to operate.
`Prior art rechargeable battery units have been provided
`with means for generating some desired information to their
`users. including for instance. a charge monitor and fuel
`gauge such as that disclosed in U.S. Pat. No. 5.315.228
`which discloses a method for calculating state of charge and
`reporting run time to empty to the host computer system.
`However. there is a need for a rechargeable power unit
`that will accurately maintain its own state of charge infor-
`mation even when nominally fully discharged such that a
`user will have instantaneous access thereof. Moreover. there
`is also a need for an intelligent rechargeable battery that can
`provide the user with an accurate prediction of its remaining
`operating time at various levels of power consumption. The
`user of such an intelligent device. such as a portable
`computer. can thus elect to power down a hard disk drive to
`extend the operation of the portable computer for a longer
`period of time than would have been possible at the higher
`rate of power consumption.
`SUM.MARY OF THE INVENTION
`
`Accordingly. it is an object of the present invention to
`provide a smart battery device for use with a rechargeable
`battery to be installed in a host computer that will optimize
`the performance of the rechargeable battery throughout its
`life cycle.
`It is another object of the instant invention to provide a
`smart battery device that includes a microprocessor for
`controlling a rechargeable battery that performs battery
`capacity calculations for communication to a host computer
`device or a smart battery charge device.
`It is still another object of the instant invention to provide
`a smart battery device that includes a microprocessor for
`
`10
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`65
`
`5,652,502
`
`2
`
`controlling a rechargeable battery and that provides intelli-
`gence in the form of present state of charge and battery
`charge parameters to a host device for communication to a
`smart charger.
`It is yet still a further object of the instant invention to
`provide a smart battery device that includes a microproces-
`sor for controlling a rechargeable battery that monitors
`battery operating parameters such as voltage. current. and
`temperature to thereby enable either a rapid charging rate or
`an optimal charging rate from any charged state.
`Still yet another object of the instant invention is to
`provide a smart battery device that includes a microproces-
`sor for controlling a rechargeable battery that calculates
`predictive data such as the battery’s remaining life at the
`current rate of drain and at alternate rates of drain.
`
`It is still a further object of the instant invention to provide
`a smart battery device that is an application specific inte-
`grated circuit (ASIC) having analog and digital components.
`Furthermore. another object of the present invention is to
`provide a smart battery device that includes an analog to
`digital (A/D) converter for measuring battery charge param-
`eters such as voltage. current. and temperature.
`Yet still another object of the present invention is to
`provide a smart battery device having an A/D converter with
`a single positive power supply that is capable of bipolar
`operation for converting both positive and negative analog
`signals representing battery charge and discharge currents.
`respectively.
`Another object of the instant invention is to provide a
`smart battery device as above wherein the analog and digital
`components of the ASIC comprise CMOS semiconductor
`technology designed for improved accuracy. and high A/D
`converter resolution with minimal power consumption.
`Still another object of the present invention is to provide
`a smart battery device having a microprocessor that. when
`nominally discharged. will place itself in a sleep mode with
`virtually no power consumption.
`Yet a further object of the present invention is to provide
`a smart battery device that includes a microprocessor with
`RAM memory. and comprises means for retaining RAM
`memory contents when the device is in a sleep mode.
`Yet still a further object of the invention is to provide a
`smart battery device that comprises short circuit protection
`means for preserving RAM memory contents when battery
`is temporarily short circuited.
`Another object of the instant invention is to provide a
`smart battery device that includes a ROM memory that is
`manufactured by a process that facilitates the programming
`of ROM in an upper or respectively later produced layers.
`Yet furthermore. an object of the instant invention is to
`provide a smart battery device that includes a ROM memory
`device whereby the programming of the ROM is effected in
`a metal mask
`
`Furthermore. an object of the instant invention is to
`provide a smart battery device having incorporated therein
`an error treatment algorithm. for taking into account mea-
`surement errors. interpolation from look-up tables. etc..
`wherein the errors are considered to be a function of time.
`It is contemplated that if a total error is larger than a
`predetermined value. certain operating modes are disabled.
`and. in particular. Variables are substituted by default values
`to result in a smaller error. In case of displayed information.
`such as LED battery pack display. the error can be addi-
`tionally taken into account. for e.g.. a quantity of: capacity—
`total error in capacity. may be displayed If an error that is
`
`Exhibit 1028, Page 034
`
`
`

`
`5,652,502
`
`3
`too big is produced. the end criterion for determining end of
`charge condition may be changed. for e.g., using a change in
`battery voltage instead of the error influenced criterion.
`These and other objects of the present invention are
`attained with a smart battery device which provides electri-
`cal power and which reports predefined battery parameters
`to an external device having a power management system.
`wherein the battery includes:
`(a) at least one rechargeable cell connected to a pair of
`terminals to provide electrical power to an external
`device during a discharge mode and to receive electri-
`cal power during a charge mode, as provided or deter-
`mined by said remote device.
`(b) a data bus for reporting predefined battery identifica-
`tion and charge parameters to the external device.
`(c) an analog means for generating analog signals repre-
`sentative of battery voltage and current at said
`terminals. and an analog signal representative of bat-
`tery temperature at said cell.
`(d) a hybrid integrated circuit (IC) having a microproces-
`sor for receiving the analog signals and converting
`them to digital signals representative of battery voltage.
`current and temperature, and calculating actual charge
`parameters over time from said digital signals. said
`calculations including one calculation according to the
`following algorithm:
`
`cAP,.,,=cAP,¢->:1,,A:,rz1,A:s+r.ec1C/Arc
`
`wherein ec is a function of battery CLlIl'Cl1t and temperature;
`and I, is a function of battery temperature and CAP,-C.
`(e) a data memory defined within said hybrid IC for
`storing said predefined battery identification and actual
`charge parameters. even when nominally fully
`discharged. said charge parameters including at least
`full charge capacity and remaining capacity,
`(f) a bus controller defined within said hybrid IC for
`sending battery messages to said remote device over
`said data bus. said messages including said predefined
`battery identification and said actual charge parameters.
`Superimposed on this equation is reset
`logic,
`to be
`explained below. that self corrects the value of CAP,-C with
`a capacity calculation at each end of full charge (EOC) and
`each end of full discharge.
`Further benefits and advantages of the invention will
`become apparent from a consideration of the following
`detailed description given with reference to the accompa-
`nying drawings. which specify and illustrate preferred
`embodiments of the invention.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a diagrammatic block diagram of a smart battery
`device connected to a host computer and battery charging
`device.
`
`FIG. 2(a) is a simplified block diagram of the smart
`battery device and connector. including a pinout diagram of
`an Application Specific Integrated Circuit (hybrid IC) used
`in the present invention.
`FIG. 2(b) illustrates a simplified block diagram of the
`hybrid IC 32 that includes the microcontroller of the smart
`battery device of the instant invention.
`FIG. 3 is a general flow diagram illustrating the primary
`functional features of an algorithm and method for control-
`ling the smart battery device of the instant invention.
`FIG. 4 illustrates a general schematic diagram of the A/D
`converter 60.
`
`10
`
`20
`
`25
`
`30
`
`35
`
`45
`
`50
`
`55
`
`65
`
`4
`
`FIG. 5(a) illustrates a schematic sketch of dc voltage
`shifting circuit arrangement.
`FIG. 5(b) illustrates a second embodiment of the dc
`voltage shifting circuit arrangement.
`FIG. 6 is a schematic sketch of the circuit arrangement in
`the A/D converter 60.
`
`FIG. 7 is a phase diagram in the operation of the A/D
`converter pursuant to FIG. 6.
`FIG. 8(a) illustrates the timing of the operating cycles
`under normal and sample mode operating conditions.
`FIG. 8(b) illustrates the approximate time durations for
`the various measurements per operating cycle.
`FIG. 9(a) illustrates a schematic sketch of a sample
`transition arrangement for the ROM included in the smart
`battery device; and
`I FIG. 9(b) is a schematic sketch of the transistor arrange-
`ment of a ROM programmed pursuant to the prior art.
`FIG. 10 is a detailed schematic of the power-on reset 85
`and RAM de-latching circuit 85'.
`FIG. 11 illustrates a detailed schematic diagram of the
`comparator wake-up circuit 80.
`FIG. 12 is a flow diagram illustrating the IUT (current.
`voltage. and temperature) calculation program 200.
`FIGS. 13(a) and 13(b) are flow diagrams illustrating the
`sequential processes 151 programmed in the microprocessor
`for calculating the current capacity and the amount of
`battery self discharge for the smart battery of the instant
`invention.
`
`FIG. 13(c) illustrates the integration program 400 for
`calculating the amount of battery charge or discharge flow-
`ing into or out of its terminals.
`FIGS. 14(a) through 14(c) are flow diagrams illustrating
`the sequential processes 500 programmed in the micropro-
`cessor for determining battery charging end conditions when
`the battery is in a capacity increasing state.
`FIG. 14(d) illustrates a flow diagram of the learn number
`of cells program 700.
`FIGS. 15(a) and 15(b) are logic flow diagrams illustrating
`the sequential processes 600 programmed in the micropro-
`cessor for determining battery end conditions when the
`battery is in a capacity decreasing state.
`FIG. 16 illustrates a logic flow diagram of the handle
`request routine that is invoked when there is communication
`between the smart battery and the host computer or battery
`charger.
`FIG. 17 illustrates a detailed logic flow diagram of the
`write block routine for writing data to the smart battery.
`FIG. 18 illustrates a detailed logic flow diagram of the
`read block routine for reading data from the smart battery.
`FIGS. 19(4) and 19(b) illustrates a flow diagram describ-
`ing the logic steps invoked by the smart battery system when
`broadcasting an alarm condition to an external device.
`FIG. 20 illustrates a logic flow diagram describing the
`steps invoked by the smart battery system when broadcast-
`ing a charge condition to a battery charger.
`FIGS. 21(a) and 21(b) illustrates a logic flow diagram
`describing the steps invoked by the smart battery system
`when broadcasting a message.
`FIG. 22(a) is a three-dimensional graphic representation
`of look up tables that depict predicted residual capacity
`values as a function of discharging current and temperature.
`FIG. 22(b) is a three-dimensional graphic representation
`of look up tables that depict the amount of self-discharge
`
`Exhibit 1028, Page 035
`
`
`

`
`5,652,502
`
`5
`current (vertical axis) as a function of relative battery state
`of charge and temperature.
`FIG. 22(c) is a three-dimensional graphic representation
`of charge efiiciency look-up tables showing charge efii-
`ciency factors as a function of relative state of charge.
`charging current. and temperature.
`FIGS. 23(a) and 23(b) illustrates two voltage versus time
`graphs. a and b. comparing calculated battery capacity
`characteristics at various discharging current rates for a six
`(6) cell battery pack.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`The smart battery device of the present invention is
`intended for use with an intelligent host device such as a
`portable computer. portable video camera or cellular tele-
`phone having a system management bus and a smart charger.
`or an intelligent host device having a system power manager
`that can receive and send data over a system management
`bus.
`
`Arepresentative example of such a system is illustrated in
`FIG. 1. wherein the smart battery 10 is connected to a power
`plane 12 to supply and receive electrical energy over the
`power plane. and a system management bus 14. which is a
`bi-directional modified I2C data bus (communication
`interface) that communicates with a host device 16 which
`may be a portable computer. The host device 16 may be
`powered by the smart battery 10, or by the system power
`supply 18 and a conventional AC source 20. A system power
`supply or power management system also communicates
`with a smart charger 22 which may be