JP5233050B2 - Battery charger for industrial vehicles - Google Patents

Description

  The present invention relates to a battery charging device for an industrial vehicle that charges a battery by controlling a current supplied to the battery from an external power source.

  A battery is mounted on an industrial vehicle such as a forklift. In particular, in a battery-type forklift that drives a traveling and working machine using a battery as a main drive source, a vehicle manager is required to regularly carry out full charge in order to prevent a reduction in battery life because the power load on the battery is large. As well as the operator.

  A battery mounted on a battery-type forklift is charged by being supplied with electric power from an external power source, for example, an external AC power outlet. A battery-type forklift is equipped with a controller with a charging function for charging a battery by controlling a current supplied to the battery from an external power source.

  Further, a charging operation panel is provided in the cab. The charging operation panel is provided with a normal charging button for instructing normal charging, a quick charging button for instructing quick charging, and a quick auxiliary charging button for instructing quick auxiliary charging. A stop button is provided for stopping the charging operation after the start of charging.

  Normal charging is charging that completes a full charge in about 8 hours. Rapid charging is charging that is completed in about 5 hours until full charging. Rapid supplementary charging is charging in which charging up to about 80% of the rated capacity is completed with a timer of about 1 hour regardless of the amount of discharge. A quick supplementary charge does not become a full charge.

  Here, in this specification, full charge means charging until reaching a charge amount of a specified value (110 to 120%) of 100% or more with respect to the discharge amount. Further, the full charge amount refers to the charge amount up to full charge. The amount of charge is represented by the product of the current supplied to the battery during the charging operation and the time required for charging.

  The state of charge that does not reach full charge is referred to as incomplete charge.

  When the normal charge button, the quick charge button, and the quick supplement charge button are pressed, the controller with a charge function performs normal charge, quick charge, and quick supplement charge, respectively. When the stop button is pressed, the charging operation is stopped regardless of whether normal charging, rapid charging, or rapid supplementary charging is in progress. The quick charging is performed when the time required for normal charging cannot be secured and full charging is desired to be performed in a shorter time than normal charging. Rapid supplementary charging is performed mainly when charging is performed in a limited short time such as between operating hours (additional charging).

  The following Patent Documents 1 and 2 describe a configuration example of a battery charging device that is a device mounted on a forklift and charges a battery by controlling a current supplied to the battery from an external power source.

JP 2008-303019 A JP 2008-303058 A

  Lead batteries mounted on battery-powered forklifts cause sulfation (fixation of lead sulfate) if they are used in an incompletely charged state, that is, not fully charged. When sulfation occurs, the deterioration of the battery is accelerated and the life of the battery is shortened.

  Most of the causes of battery life reduction are lack of battery management. Here, the management of the battery means that the battery is quickly charged when discharged, the charging is performed until full charge, the overdischarge is not performed, and the like.

  However, “Be sure to charge fully once a day” (however, charge every 2 to 3 days when daily operation time is short to prevent overcharging) Will not be charged until fully charged, which will adversely affect battery performance and life, even if it is stated in the instruction manual or if these items are obliged to the operator or administrator at the work place, The fact is that they are not fully enforced.

  In addition, combined with improved performance of battery-powered forklifts and battery performance, battery-powered forklifts do not reach an excessively discharged state even if work is performed repeatedly and frequently using rapid supplementary charging. Can now be operated. For this reason, the actual situation is that the opportunity to use the battery in an incompletely charged state is increasing.

  From the above situation, sulfation is promoted, and the possibility that the battery deteriorates early is increasing.

  The present invention has been made in view of such circumstances, and an object of the present invention is to prevent early deterioration of a battery due to the occurrence of sulfation.

The first invention is
A battery charged by an external power source;
Full charge instruction means for instructing full charge of the battery;
A full charge control means for controlling the current supplied from the external power source to the battery and performing a charge operation until the full charge amount is reached when full charge instruction is instructed by the full charge instruction means;
Counting means for counting the number of times the charging operation has stopped before the battery reaches the full charge amount;
When the number of times counted by the counting means reaches a specified number, and the full charge instruction means instructs the full charge of the battery, the current supplied from the external power source to the battery is controlled to further increase the full charge amount. The battery charging device for an industrial vehicle is provided with refresh charge control means for performing a charging operation until reaching a refresh charge amount to which a predetermined charge amount is added.

The second invention is
A battery charged by an external power source;
Full charge instruction means for instructing full charge of the battery;
A full charge control means for controlling the current supplied from the external power source to the battery and performing a charge operation until the full charge amount is reached when full charge instruction is instructed by the full charge instruction means;
Auxiliary charging instruction means for instructing auxiliary charging of the battery;
When the auxiliary charging instruction means instructs the auxiliary charging of the battery, the auxiliary charging control means that controls the current supplied to the battery from the external power source and performs the charging operation until reaching the auxiliary charging amount less than the full charging amount;
Counting means for counting the number of times the charging operation has stopped before the battery reaches the full charge amount;
When the number of times counted by the counting means reaches a specified number, when the full charge instructing means instructs the battery to be fully charged or the auxiliary charging instructing means instructs the battery to be charged, the external power supply A battery charger for an industrial vehicle provided with refresh charge control means for controlling the current supplied to the battery from the above to a refresh charge amount obtained by adding a predetermined charge amount to the full charge amount. Features.

The third invention is the first invention or the second invention,
Charging operation stop instruction means for instructing stop of the charging operation is provided,
The counting means counts the number of charging operation stops including the number of times the charging operation has been stopped in accordance with an instruction from the charging operation stop instructing means.

4th invention is 1st invention or 2nd invention,
When the charging operation is performed until the battery reaches the full charge amount or when the battery is charged until the refresh charge amount is reached, the number of counts by the counting means is cleared to zero.

The fifth invention is the first invention or the second invention,
Battery temperature detecting means for detecting the temperature of the battery;
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and interrupts after a predetermined time. The charging operation is resumed or the charging operation before switching is resumed.

A sixth invention is the first invention or the second invention,
Battery temperature detecting means for detecting the temperature of the battery;
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and the battery temperature is normal. When the temperature drops to the temperature, the interrupted charging operation is restarted or the charging operation before switching is restarted.

The seventh invention
A battery charged by an external power source;
Refresh charging instruction means for instructing refresh charging of the battery;
When refresh charging of the battery is instructed by the refresh charging instructing means, the refresh charging is performed so that the current supplied from the external power source to the battery is controlled to reach the refresh charging amount obtained by adding a predetermined charging amount to the full charging amount. Control means;
Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and interrupts after a predetermined time. The battery charging device for an industrial vehicle is characterized in that the charging operation is restarted or the charging operation before switching is restarted.

The eighth invention
A battery charged by an external power source;
Refresh charging instruction means for instructing refresh charging of the battery;
When refresh charging of the battery is instructed by the refresh charging instructing means, the refresh charging is performed so that the current supplied from the external power source to the battery is controlled to reach the refresh charging amount obtained by adding a predetermined charging amount to the full charging amount. Control means;
Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and the battery temperature is normal. The battery charging device for an industrial vehicle is characterized by restarting the interrupted charging operation or restarting the charging operation before switching when the voltage drops to the point of time.

Full charge and refresh charge can be described with reference to FIG.

  FIG. 1 shows an example of a charging operation when the horizontal axis is time (h), the left vertical axis is charging current (A), and the right vertical axis is battery voltage (V). The charging current is indicated by a solid line, and the battery voltage is indicated by a broken line.

  For example, a lead storage battery configured by connecting 6 cells with a nominal voltage of 2V in series is initially charged to a predetermined voltage V1 (for example, 14.4V) at a relatively high charging current value, and the current value is adjusted as necessary. Recharge to a predetermined voltage V1 after decreasing. The region in which charging is performed up to the predetermined voltage V1 so far is a region with relatively good charging efficiency. While this charge and discharge are repeated, it is an “insufficient charge region” in which a total charge electricity amount corresponding to the total discharge electricity amount cannot be supplied. Further, when charging is performed exceeding a predetermined voltage V1, a shortage, that is, an amount of electricity corresponding to the difference between the total amount of discharged electricity and the amount of charged electricity (110 to 120% of the amount of discharge) is supplied It becomes “full charge”. Furthermore, “refresh charging” is completed by further charging after the full charge amount.

Here, “the number of times that the charging operation has stopped before the battery reaches the full charge amount” counted by the counting means is the number of times the charging operation has been stopped by pressing the stop button during charging. The number of times the protective circuit etc. was activated due to an abnormality (battery temperature abnormality, battery overcurrent, etc.), the charging operation stopped, the number of times the charging operation stopped due to an external factor such as a power failure, the number of auxiliary charging ( This is a concept including all the stop counts such as charging operation completed without reaching full charge).

  According to the first to sixth inventions, the following effects can be obtained.

a) Even if the battery is used in an incompletely charged state that does not reach full charge, if the number of times that the charging operation has stopped without reaching full charge reaches the specified number of times, a predetermined charge is added to the full charge amount. Since charging is performed up to the refresh charge amount with the amount added, early deterioration of the battery due to the occurrence of sulfation can be prevented, and a reduction in battery life can be suppressed.

b) If the number of counts reaches the specified number of times, the battery is automatically (forcedly) charged until the refresh charge amount is reached, so the battery management is not sufficiently performed. Also, the occurrence of sulfation can be suppressed.

  However, since refresh charging is performed by adding a predetermined charge amount to the full charge amount, electrolysis of water in the battery electrolyte is promoted, and the battery temperature (electrolyte temperature) increases. It becomes easy. For this reason, there is a concern that the battery temperature rises to an abnormal temperature and the battery is damaged. Therefore, it is necessary to prevent the battery from rising to an abnormal temperature. In view of such circumstances, the fifth and sixth inventions have been made. According to the fifth and sixth inventions, the following effects can be further obtained.

c) When the temperature of the battery reaches a warning temperature (a temperature that does not reach the abnormal temperature) during refresh charging, the charging operation is interrupted or switched to a charging operation in which the supply current to the battery is limited, Since the battery temperature is lowered and then the suspended charging operation is resumed or the charging operation before switching is resumed, the battery can be prevented from reaching an abnormal temperature. Further, since refresh charging is resumed from the middle of the charging operation without being reset to the initial state, refresh charging can be continued until the charging operation is completed.

Refresh charging may be performed automatically under certain conditions (when the number of counts reaches a specified value) as described above, and is manually selected by providing an instruction means such as a manual button. It may be performed automatically.

According to the seventh and eighth inventions, the effect of c) described above can be obtained when refresh charging is performed according to an instruction from the instruction means.

FIG. 1 is a diagram used for explaining full charge and refresh charge. FIG. 2 is a side view of a battery-type forklift as an example of an industrial vehicle. FIG. 3 is a block diagram showing the configuration of the embodiment. FIG. 4 is a diagram illustrating an appearance of the charging operation panel. FIG. 5 is a diagram illustrating a current change pattern of normal charging. FIG. 6 is a diagram illustrating a current change pattern of rapid charging. FIG. 7 is a diagram illustrating a current change pattern of rapid supplementary charging. FIG. 8 is a diagram illustrating a current change pattern of refresh charging when the normal charging button is pressed. FIG. 9 is a diagram illustrating a current change pattern of the refresh charge when the quick charge button or the quick supplement charge button is pressed. FIG. 10 is a flowchart illustrating a procedure of processing performed by the controller with a charging function. FIGS. 11A and 11B are diagrams for explaining the current change patterns when the charging operation is interrupted / resumed (solid line) and when the charging operation proceeds normally without being interrupted / resumed (broken line). It is. FIGS. 12A and 12B are diagrams for explaining the current change patterns when the charging operation is interrupted / resumed (solid line) and when the charging operation proceeds normally without being interrupted / resumed (broken line). It is.

  Hereinafter, an embodiment of a battery charging device for an industrial vehicle according to the present invention will be described with reference to the drawings.

  FIG. 2 shows a side view of a battery-type forklift as an example of an industrial vehicle.

In the battery-type forklift 1, the driving wheel 2 is rotationally driven by a traveling electric motor (not shown), and the working machine 3 is operated by a working machine electric motor (not shown).

Below the driver's seat 4 of the battery-type forklift 1, a battery 10 and a controller 20 with a charging function are provided.

A charging operation panel 40 is provided at a location in front of the driver's seat 4 and visually recognized by the driver, for example, the front console 5.

The battery-type forklift 1 is driven by a traveling electric motor and a working machine electric motor using a battery 10 as a main driving source. Therefore, since the power load applied to the battery 10 is large, the battery 10 having a capacity suitable for the power load for traveling and work is mounted.

FIG. 3 is a block diagram showing configurations of the battery 10, the controller 20 with a charging function, the battery voltmeter 31, the battery ammeter 32, and the battery temperature sensor 33.

The battery 10 is, for example, a lead battery having a configuration in which eight 1-module 10b connected in series is connected in parallel with a 12V lead-acid battery 10a configured by connecting six cells having a nominal voltage of 2V in series as one unit. It is. If the rated capacity of one module 10b is 60Ah, for example, it has a capacity of 48V-480Ah.

In the battery voltmeter 31, the battery voltage V at the positive terminal 11 of the battery 10 is detected and input to the controller 20 with a charging function. In the battery ammeter 32, the charging current I supplied to the plus terminal 11 of the battery 10 is detected and input to the controller 20 with a charging function. The battery temperature sensor 33 detects the temperature Tm of the battery 10, that is, the electrolyte temperature of the battery 10, and inputs the detected temperature to the controller 20 with a charging function. For example, the surface temperature of the casing of the battery 10 can be detected to estimate the internal electrolyte temperature.

The battery 10 is charged with power supplied from an external power source, for example, an outlet 99a of an external AC power source 99.

The controller with charging function 20 controls the current supplied from the external AC power source 99 to the battery 10 to charge the battery 10.

At the time of charging, the plug 98a of the charging cable 98 is inserted into the outlet 99a, and the AC power source 99 is electrically connected to the controller 20 with a charging function via the charging cable 98. The controller 20 with a charging function includes a power supply unit 21 that converts alternating current power into direct current power and further steps down to a direct current voltage for charging to supply a current for charging.

In addition to the power supply unit 21, the controller with charging function 20 includes normal charging control means 22, rapid charging control means 23, rapid supplementary charging control means 24, refresh charging control means 25, and counting means 26.

The charging instruction is performed by operating a button on the charging operation panel 40.

FIG. 4 shows the appearance of the charging operation panel 40.

The charging operation panel 40 is provided with a normal charging button 41 for instructing normal charging, a quick charging button 42 for instructing quick charging, and a quick auxiliary charging button 43 for instructing quick auxiliary charging. A stop button 44 for instructing to stop the charging operation after the start of charging is provided. The normal charge button 41, the quick charge button 42, and the quick supplement charge button 43 are respectively provided with a normal charge lamp 41a, a quick charge lamp 42a, and a quick supplement charge lamp 43a.

Normal charging is charging that completes a full charge in about 8 hours. Rapid charging is charging that can be completed in about 5 hours until full charging. Rapid supplementary charging is charging in which charging up to about 80% of the rated capacity is completed with a timer of about 1 hour regardless of the amount of discharge. A quick supplementary charge does not become a full charge. The quick charging is performed when the time required for normal charging cannot be secured and full charging is desired to be performed in a shorter time than normal charging. Rapid supplementary charging is performed mainly when charging is performed in a limited short time such as between operating hours (additional charging).

The refresh charge is a charge that is automatically performed when the normal charge button 41, the quick charge button 42, and the quick supplement charge button 43 are pressed and the number of counts by the counting means 26 reaches a specified number. . Refresh charging is charging performed up to a refresh charge amount obtained by adding a predetermined charge amount to a full charge amount. When the normal charging button 41 is pressed, charging is performed in a time obtained by adding a predetermined time tr to the time required for normal charging. When the quick charge button 42 and the quick supplement charge button 43 are pressed, charging is performed in a time obtained by adding a predetermined time tr to the time required for the quick charge.

When the normal charging button 41, the quick charging button 42, and the quick auxiliary charging button 43 are pressed, the controller 20 with a charging function performs normal charging, quick charging, and quick auxiliary charging, respectively. When the stop button 44 is pressed, the charging operation is stopped regardless of normal charging, rapid charging, rapid supplementary charging, or refresh charging. The controller with charging function 20 performs refresh charging when the normal charging button 41, the quick charging button 42, and the quick auxiliary charging button 43 are pressed and the number of counts by the counting means 26 reaches a specified number. Do.

When the normal charging button 41 of the charging operation panel 40 is pushed, the normal charging control means 22 is instructed to perform normal charging. In response to the instruction, the normal charging control means 22 adds power from the power supply unit 21 to the plus of the battery 10. The current supplied to the terminal 11 is controlled, and the charging operation is performed until the full charge amount is reached. This normal charging control is performed in a normal charge current change pattern by feeding back the detected battery voltage V, the detected charging current I, and the detected temperature Tm of the battery 10. FIG. 5 illustrates a current change pattern 51 for normal charging.

FIG. 5 shows an example of charging operation during normal charging when the horizontal axis is time (h), the left vertical axis is charging current (A), and the right vertical axis is battery voltage (V) as in FIG. Indicates. The charging current I is indicated by a solid line, and the battery voltage V is indicated by a broken line. FIG. 5 shows the battery voltage V converted to a 12 V lead storage battery 10 a which is one unit of the battery 10. In FIG. 5, V1 indicates the switching voltage V1 (V1 = 14.4 + 0.03 (25−Tm)). In the first-stage step 51a in the normal charge current change pattern 51, a constant current is supplied to the battery 10 until the switching voltage V1 is reached. The last step 51e in the normal charge current change pattern 51 is a region where charging is performed until the full charge amount is exceeded by exceeding the switching voltage V1, and a constant current is supplied to the battery 10 by operating a timer for a set time te. Supply. The timer set time te is given based on the time t1 required for the first step 51a and the temperature Tm of the battery 10 at the end of the first step 51a. For example, data of the timer setting time te corresponding to the time t1 required for the first step 51a and the temperature Tm of the battery 10 at the end of the first step 51a is provided in the data table format, and the timer setting time te from the data table is provided. Is read out.

During the normal charging operation, the normal charging lamp 41a of the charging operation panel 40 is lit.

When the quick charge button 42 of the charging operation panel 40 is pushed, the quick charge control means 23 is instructed to perform quick charge, and in response to the instruction, the quick charge control means 23 sends the battery 10 plus from the power supply unit 21. The current supplied to the terminal 11 is controlled, and the charging operation is performed until the full charge amount is reached. This quick charge control is performed by feeding back the detected battery voltage V, the detected charge current I, and the detected temperature Tm of the battery 10 with a rapid charge current change pattern. FIG. 6 illustrates a current change pattern 52 for quick charging.

FIG. 6 is a diagram similar to FIG. 5 and shows an example of a charging operation during rapid charging. Compared to the normal charge current change pattern 51, the quick charge current change pattern 52 is provided with one step having a higher constant current value as the first step 52a. This shortens the time until full charge. In the last step 52e of the current change pattern 52 of the quick charge, a constant current is supplied to the battery 10 for the timer set time te as in the normal charge.

During the quick charging operation, the quick charge lamp 42a of the charging operation panel 40 is turned on.

When the quick auxiliary charge button 43 of the charging operation panel 40 is pushed, the quick auxiliary charge control means 24 is instructed to perform quick auxiliary charge. In response to the instruction, the quick auxiliary charge control means 24 is supplied from the power supply unit 21. The current supplied to the positive terminal 11 of the battery 10 is controlled, and the charging operation is performed until the auxiliary charge amount is smaller than the full charge amount. “Supplementary charge less than full charge” means, for example, a charge amount up to about 80% of the rated capacity regardless of the discharge amount. The control of the rapid supplementary charging is performed by feeding back the detected battery voltage V, the detected charging current I, and the detected temperature Tm of the battery 10 with the current change pattern of the rapid supplementary charging. FIG. 7 illustrates a current change pattern 53 of the rapid auxiliary charging.

FIG. 7 is a diagram similar to FIG. 5 and FIG. 6 and shows an example of the charging operation at the time of rapid supplementary charging. In the rapid supplementary charging, a high constant current similar to that in the first stage 52a of the rapid charging is supplied to the battery 10 in the step 53a for a certain time (for example, 1 hour). However, if the switching voltage V1 is reached within a predetermined time depending on the remaining amount of the battery 10 at the start of charging, the second and subsequent steps 53b (. ).

During the charging operation of the rapid auxiliary charging, the rapid auxiliary charging lamp 43a of the charging operation panel 40 is turned on.

If the stop button 44 of the charging operation panel 40 is pushed during the normal charging operation, the normal charging control means 22 is instructed to stop the charging operation, and the normal charging control means 22 The charging operation by the pattern 51 is stopped. After the charging operation is stopped, even if the normal charging button 41 is pushed again, the normal charging current change pattern 51 is started from the beginning.

When the stop button 44 of the charging operation panel 40 is pushed during the quick charging operation, the quick charge control means 23 is instructed to stop the charging operation, and the quick charge control means 23 The charging operation by the pattern 52 is stopped. After the charging operation is stopped, even if the quick charge button 42 is pressed again, the quick charge current change pattern 52 is started from the beginning.

When the stop button 44 of the charging operation panel 40 is pushed during the quick auxiliary charging operation, the quick auxiliary charging control means 24 is instructed to stop the charging operation, and the quick auxiliary charging control means 24 The charging operation by the charging current change pattern 53 is stopped. Note that after the charging operation is stopped, even if the quick auxiliary charging button 43 is pressed again, the rapid auxiliary charging current change pattern 53 is started from the beginning.

When the stop button 44 of the charging operation panel 40 is pushed during the refresh charging operation, the refresh charge control means 25 is instructed to stop the charge operation, and the refresh charge control means 25 performs the refresh charge later described. The charging operation by the current change patterns 54 and 55 is stopped. After the charging operation is stopped, the refresh charging current change patterns 54 and 55 are started from the beginning even if the normal charging button 41, the quick charging button 42, and the quick auxiliary charging button 43 are pushed again. become.

The counting means 26 counts the number of times that the charging operation has stopped before the battery 10 reaches the full charge amount.

The counting means 26 counts the number of times that the charging operation has been stopped, including the number of times that the charging operation has been stopped, in response to a stop instruction by the stop button 44.

The “number of times that the charging operation has stopped before the battery 10 reaches the full charge amount” counted by the counting means 26 includes all of the following number of stops.

a) The number of times the charging operation is stopped by pressing the stop button 44 during normal charging, quick charging, quick supplementary charging, or refresh charging. When the stop button 44 is pressed during refresh charging, the number of counts is equal to or greater than the specified number, but a +1 count value is further added.

b) The number of times that the charging operation is stopped due to the activation of the protection circuit or the like due to an abnormality during the charging operation, for example, an abnormality in the temperature Tm of the battery 10 or an overcurrent to the battery.

c) Number of times the charging operation is stopped due to an external factor such as a power failure.

d) Number of times of quick supplementary charging (the charging operation ends without reaching full charge).

When the number of times counted by the counting means 26 reaches a specified number, and the normal charging button 41 of the charging operation panel 40 is pushed, the refresh charging control means 25 is instructed to perform refresh charging. Accordingly, the refresh charge control means 25 controls the current supplied from the power supply unit 21 to the positive terminal 11 of the battery 10 and performs the charging operation until the refresh charge amount is obtained by adding a predetermined charge amount to the full charge amount. To do. This refresh charge control is performed by feeding back the detected battery voltage V, the detected charge current I, and the detected temperature Tm of the battery 10 to the current change pattern 51 of the normal charge for the extension time tr. The refresh charging current change pattern 54 is added with the current step 54r. FIG. 8 illustrates a current change pattern 54 of refresh charging when the normal charging button 41 is pressed.

As shown in FIG. 8, the refresh charge current change pattern 54 is obtained by adding a charge addition time step 54 r corresponding to the extension time tr to the last step 51 e of the normal charge current change pattern 51. In the additional charge time step 54r, the constant current is supplied to the battery 10 by operating the timer for the set time tr. This timer set time tr is given based on the time t1 required for the first step 51a and the average temperature Tma of the battery 10 that has been used without being fully charged. The “average temperature Tma of the battery 10 in a state in which the battery 10 is continuously used without being fully charged” is detected by, for example, detecting the temperature Tm of the battery 10 when the counting is performed by the counting means 26 and averaging the detected temperatures. can get.

The timer set time tr is determined in consideration of prevention of unnecessary overcharge, progress of sulfation due to operating temperature, and battery charging efficiency.

The progress of sulfation (immobilization of lead sulfate (chemical reaction)) differs depending on the operating temperature, and therefore the amount of charge required for eliminating the sulfation varies depending on the operating temperature. The use temperature is obtained from “the average temperature Tma of the battery 10 in a state where the battery 10 is continuously used without being fully charged”.

The sulfation is more likely to proceed at a higher temperature, but considering the charging efficiency depending on the temperature, it is necessary to lengthen the set time tr as the temperature Tm of the battery 10 decreases. Therefore, the set time tr is set longer as the average temperature Tma of the battery 10 is lower.

For example, data of the timer setting time tr corresponding to the time t1 required for the first step 51a and the battery average temperature Tma is provided in a data table format, and the timer setting time tr is read from the data table.

During the refresh charging operation when the normal charging button 41 is pressed, the normal charging lamp 41a of the charging operation panel 40 blinks. By blinking the normal charging lamp 41a, the operator can be informed that refresh charging is being performed instead of normal charging (lighting).

When the number of times counted by the counting means 26 reaches a specified number, and the quick charge button 42 or the quick supplement charge button 43 of the charging operation panel 40 is pushed, the refresh charge control means 25 is refreshed. In response to the instruction, the refresh charge control means 25 controls the current supplied from the power supply unit 21 to the positive terminal 11 of the battery 10, and refresh charge obtained by adding a predetermined charge amount to the full charge amount. Charging operation up to the amount. The refresh charging control is performed by feeding back the detected battery voltage V, the detected charging current I, and the detected temperature Tm of the battery 10 to the current change pattern 52 of the rapid charging for the extension time tr. The refresh charging current change pattern 55 is added with a current step 55r. FIG. 9 illustrates a current change pattern 55 of the refresh charge when the quick charge button 42 or the quick supplement charge button 43 is pressed.

As shown in FIG. 9, the refresh charge current change pattern 55 is obtained by adding an additional charge time step 55r corresponding to the extended time tr to the last step 52e of the rapid charge current change pattern 52. In the additional charging time step 55r, the constant current is supplied to the battery 10 by operating the timer for the set time tr. As described with reference to FIG. 8, the set time tr is determined in consideration of prevention of unnecessary overcharge, progress of sulfation due to use temperature, and battery charging efficiency.

During the refresh charge operation when the quick charge button 42 or the quick supplement charge button 43 is pressed, the quick charge lamp 42a of the charging operation panel 40 blinks. By flashing the quick charge lamp 42a, it is possible to notify the operator that refresh charging is being performed, not rapid charging (lighting) or rapid supplementary charging (lighting).

When the number of counts by the counting means 26 is less than a specified value, normal charge or quick charge is performed, and the charge operation is completed until full charge, the count value is cleared to zero.

When the number of counts by the counting means 26 is equal to or greater than a specified value, the count value is cleared to zero when the charging operation up to the refresh charge amount is completed. Therefore, if the charging operation is stopped in the middle of reaching the refresh charge amount, the count value is not cleared to zero even if the full charge amount is exceeded.

FIG. 10 is a flowchart showing a processing procedure performed by the controller 20 with a charging function.

When any one of the normal charging button 41, the quick charging button 42, and the quick auxiliary charging button 43 is pressed, the charging process shown in FIG. 10 is started.

First, it is determined whether or not the number of counts by the counting means 26 is a specified value (for example, 12 times) or more (step 101).

When the number of counts by the counting means 26 is less than a prescribed value (for example, 12 times) (determination N in Step 101), it corresponds to each of the pressed normal charge button 41, quick charge button 42, and quick auxiliary charge button 43 buttons. The normal charging charging operation, the quick charging charging operation, and the quick auxiliary charging operation are started, and the corresponding normal charging lamp 41a, quick charging lamp 42a, and quick auxiliary charging lamp 43a are turned on (step 102). .

When the number of counts by the counting means 26 is a specified value (for example, 12 times) or more (determination Y in step 101), refresh charging of the current change pattern 54 corresponding to the pressed normal charging button 41 is started. The corresponding normal charging lamp 41a blinks. In addition, refresh charging of the current change pattern 55 corresponding to the pressed quick charge button 42 or the quick supplement charge button 43 is started, and the corresponding quick charge lamp 42a blinks (step 103).

Next, it is determined whether or not a predetermined time (for example, 3 minutes) has elapsed since any of the normal charge button 41, the quick charge button 42, and the quick supplement charge button 43 is pressed. That is, in order to prevent unnecessary counting by the counting means 26 due to a wrong pressing of the charging buttons 41, 42, 43, etc., the counting up is performed after a predetermined time elapses after the charging buttons 41, 42, 43 are pressed. The permission is allowed (step 104).

When a predetermined time (for example, 3 minutes) elapses after any of the normal charging button 41, the quick charging button 42, and the quick auxiliary charging button 43 is pressed (determination Y in step 104), the charging operation with the corresponding current change pattern is performed. continue. When normal charging and quick charging are performed, the set times te of steps 51e and 52e among the current change patterns 51 and 52 are calculated. When refresh charging is performed, the set time te of steps 51e and 52e and the set extension time tr of additional charging steps 54r and 55r of the current change patterns 54 and 55 are calculated (step 105).

Next, it is determined whether or not the charging operation is stopped without being completed. This stop of the charging operation includes pressing of the stop button 44, abnormality of the battery 10, and power failure (step 106).

Next, it is determined whether or not the quick complementary charging operation is completed (the charging operation is stopped before the full charge amount is reached) (step 107).

When the charging operation is stopped (determination Y in step 106), or when the quick auxiliary charging operation is completed (the charging operation is stopped before reaching the full charge amount) (determination Y in step 107), the counting means 26 is incremented by 1 (step 109), and the charging process according to this flowchart is terminated.

If the charging operation is not stopped (determination N in step 106), and the charging operation of the rapid supplementary charging is not completed (the charging operation is stopped before reaching the full charge amount) (determination N in step 107) Next, it is determined whether or not the charging operations of normal charging, quick charging, and refresh charging are completed (step 108).

If the charging operation for normal charging, quick charging, and refresh charging has not been completed (determination N in step 108), the procedure returns to step 105, but the charging operation for normal charging, quick charging, and refresh charging has been completed. If it is determined (determination Y in step 108), it is a case where the full charge has been made up to the full charge amount by the normal charge or the quick charge, or the refresh charge has been made up to the refresh charge amount by the refresh charge. The count value by the counting means 26 is cleared to zero (step 110), and the charging process according to this flowchart is terminated.

As described above, according to this embodiment, even if the battery is continuously used in an incompletely charged state that does not reach full charge, if the number of times that the charging operation has stopped without reaching full charge reaches the specified number. Since charging is performed until reaching the refresh charge amount obtained by adding a predetermined charge amount to the full charge amount, early deterioration of the battery 10 due to the occurrence of sulfation can be prevented, and the life reduction of the battery 10 can be suppressed. it can.

In addition, when the count reaches the specified number, charging is automatically (forced) until the refresh charge amount is reached, so even if the battery management is not sufficiently performed, Occurrence of sulfation can be suppressed.

In the above embodiment, it is assumed that there are normal charging and quick charging as charging modes for charging until full charging, but this is an example, and charging is performed only to normal charging or only to quick charging to full charging. Implementation is also possible.

In addition to the charging mode in which charging is performed until the battery is fully charged, it is assumed that there is a charging mode that does not lead to full charging (rapid supplementary charging), but this is an example, and charging mode that does not lead to full charging Implementation without (rapid supplementary charging) is also possible.

Further, in order to inform the operator that the refresh charging is in progress, the corresponding normal charging lamp 41a and the quick charging lamp 42a are blinked. Any lighting method can be used as long as it can be distinguished from a lighting method during charging, rapid charging, and rapid supplementary charging. In addition, the operator may be informed that refresh charging is being performed. Further, a dedicated refresh charge lamp for informing that “refresh charging is in progress” may be provided on the charging operation panel 40.

It is also possible to warn the operator that the refresh charging is scheduled to be performed automatically before the count by the counting means 26 reaches the specified value (12 times).

For example, a threshold value (for example, 8 to 10 times) for giving a warning to the number of counts by the counting means 26 is provided, and when the count value reaches this threshold value, the corresponding normal charge lamp 41a, quick charge lamp 42a is turned on by a predetermined lighting method to warn that refresh charging is scheduled. Alternatively, a separate independent refresh charging warning lamp is provided to warn that refresh charging is scheduled. As a result, the operator can be guided to full charge by normal charge or quick charge.

Further, it may be displayed on a display tool such as an in-vehicle meter panel, or on a service tool for vehicle maintenance, indicating that refresh charging is being performed or the number of times charging operation has stopped.

5 to 9, the constant current charging method has been described as an example of the charging method of the battery 10, but this is only an example, and any other charging method such as a quasi-constant voltage charging method is used in the present invention. Can be applied.

As described above, the refresh charge is performed by adding a predetermined charge amount to the full charge amount, so that the electrolysis of water in the electrolyte solution of the battery 10 is promoted, and the temperature of the battery 10 (the electrolyte solution) Temperature) is likely to rise. For this reason, there is a concern that the temperature Tm of the battery 10 rises to an abnormal temperature (allowable temperature) and the battery 10 is damaged. Therefore, it is necessary to prevent the battery 10 from rising to an abnormal temperature (allowable temperature). In view of such circumstances, the refresh charge control means 25 performs the following interruption (or switching) / resumption control. As an example, interruption (or switching) / resumption control when the charging operation is performed in the refresh charging current change pattern 54 shown in FIG. 8 will be described with reference to FIGS. In FIGS. 11 and 12, the solid line shows the current change pattern 54 ′ when interrupted (or switched) / restarted, and the broken line shows the current change pattern 54 when proceeded normally without being interrupted (or switched) / restarted. Show.

a) As shown in FIG. 11A, when the detected temperature Tm of the battery 10 reaches a specified warning temperature (a temperature set lower than the abnormal temperature (allowable temperature)), refresh charge control is performed. The means 25 interrupts the charging operation (the charging current I is set to 0A), and resumes the interrupted charging operation after a predetermined time Δt. The predetermined time Δt is set to a time sufficient for the temperature Tm of the battery 10 to return to the normal range. The time Δt is preset and timed by a timer.

b) As shown in FIG. 11B, when the detected temperature Tm of the battery 10 reaches a specified warning temperature (a temperature set lower than the abnormal temperature (allowable temperature)), refresh charge control is performed. The means 25 switches to a charging operation in which the supply current I to the battery 10 is limited. That is, the current I2 is switched to a current I2 lower than the set current I1 of the current change pattern 54 of the refresh charge.

The value of the current I2 after the switching is set to a current value sufficiently low so that the temperature Tm of the battery 10 returns to the normal range. Then, the charging operation before the switching is resumed after a predetermined time Δt as in the case of a).

c) In FIG. 12A, the change in the temperature Tm of the battery 10 is indicated by a broken line. As shown in FIG. 12A, when the detected temperature Tm of the battery 10 reaches a specified warning temperature (a temperature set lower than the abnormal temperature (allowable temperature)), the refresh charge control means 25 Interrupts the charging operation (the charging current I is set to 0A). When the temperature Tm of the battery 10 decreases to a normal temperature, the interrupted charging operation is resumed. Based on the comparison between the detection value of the battery temperature sensor 33 and the threshold value indicating the normal temperature, it is determined that the temperature Tm of the battery 10 has decreased to a normal temperature.

d) As shown in FIG. 12B, similarly to FIG. 12A, the detected temperature Tm of the battery 10 is set to a prescribed warning temperature (a temperature set lower than the abnormal temperature (allowable temperature)). When it reaches, the refresh charge control means 25 switches to the charging operation in which the supply current I to the battery 10 is limited. That is, the current I2 is switched to a current I2 lower than the set current I1 of the current change pattern 54 of the refresh charge.

The value of the current I2 after the switching is set to a current value sufficiently low so that the temperature Tm of the battery 10 returns to the normal range. Then, the charging operation before switching is resumed when the temperature Tm of the battery 10 is reduced to a normal temperature as in the case of c).

In any of the cases a), b), c), and d), the charging completion time is extended beyond the charging completion time when the charging operation proceeds normally without being interrupted (or switched) or resumed. The charge amount should not be changed from the total charge amount when the charge operation proceeds normally without being interrupted (or switched) / restarted. 11 and 12, the time t0 indicated by the alternate long and short dash line is the charging completion time when the charging operation proceeds normally without being interrupted (or switched) / resumed.

When the charging operation is interrupted for a predetermined time Δt, the current change pattern 54 is restarted to extend the charging completion time by the interruption time Δt (see FIGS. 11A and 12A). When the charging current value I is switched to a low value, the shortage of the charging amount caused thereby is applied by further extending the charging time (see FIGS. 11 (b) and 12 (b)).

  The temperature Tm of the battery 10 may be detected individually for each serial module 10b or may be detected as the temperature of the entire battery 10.

  When the temperature Tm of the battery 10 is detected for each module 10b, the charging operation of all the modules 10b, 10b... For all the parallel units is interrupted when the temperature reaches the warning temperature in at least one module 10b. Alternatively, the charging operation of only the module 10b whose temperature has reached the warning temperature may be interrupted. However, if the charging operation of all the modules 10b, 10b... Is interrupted at a time, the temperature Tm of the battery 10 decreases more quickly.

Further, the total charging time is shortened by interrupting the charging operation of all the modules 10b, 10b. This is because the completion of the charging operation is determined by the completion of the charging operation of all the charging modules 10b, 10b.

  3 illustrates the configuration in which the charging operation of all the modules 10b, 10b... Is interrupted at once. However, in the case where the charging operation is interrupted individually for each module 10b, the module in FIG. The charging operation may be performed every 10b (the charging operation is interrupted).

  As described above, when the temperature Tm of the battery 10 reaches the warning temperature (a temperature that does not reach the abnormal temperature (allowable temperature)) during the refresh charging, the charging operation is interrupted or supplied to the battery 10. Switching to the charging operation in which the current I is limited, the temperature Tm of the battery 10 is lowered, and then the interrupted charging operation is restarted or the charging operation before the switching is restarted. Can be prevented. Further, refresh charging is resumed from the middle of the charging operation without being reset to the initial state of the current change pattern 54 or 55 of the refresh charging, so that the refresh charging can be continuously performed until the charging operation is completed. .

In the above description, the refresh charging is automatically performed under a certain condition as described above (when the number of counts by the counting means 26 reaches a specified value).

However, in order to manually instruct the refresh charge, a refresh charge button is provided on the charge operation panel 40, and the refresh charge control means 25 is instructed to perform the refresh charge in response to the pressing operation of the refresh charge button. Similarly to the above-described embodiment, the control means 25 may be configured to control the charging current I and perform the refresh charging operation.

In such a configuration, when the temperature Tm of the battery 10 reaches the warning temperature in the same manner as in FIGS. 11 and 12, the charging operation may be interrupted / resumed. In this case, similar to the above-described embodiment, an effect that the battery 10 can be prevented from reaching an abnormal temperature and an effect that the refresh charge can be continued without being reset are obtained.

  DESCRIPTION OF SYMBOLS 1 Battery type forklift, 10 battery, 20 Controller with charging function, 22 Normal charge control means, 23 Rapid charge control means, 24 Rapid complementary charge control means, 25 Refresh charge control means, 26 Count means, 33 Battery temperature sensor, 40 Charging Operation panel, 41 Normal charge button, 42 Quick charge button, 43 Quick supplement charge button, 44 Stop button

Claims (8)

A battery charged by an external power source;
Full charge instruction means for instructing full charge of the battery;
A full charge control means for controlling the current supplied from the external power source to the battery and performing a charge operation until the full charge amount is reached when full charge instruction is instructed by the full charge instruction means;
Counting means for counting the number of times the charging operation has stopped before the battery reaches the full charge amount;
When the number of times counted by the counting means reaches a specified number, and the full charge instruction means instructs the full charge of the battery, the current supplied from the external power source to the battery is controlled to further increase the full charge amount. A battery charging device for an industrial vehicle, comprising: a refresh charging control unit that performs a charging operation up to a refresh charging amount including a predetermined charging amount. A battery charged by an external power source;
Full charge instruction means for instructing full charge of the battery;
A full charge control means for controlling the current supplied from the external power source to the battery and performing a charge operation until the full charge amount is reached when full charge instruction is instructed by the full charge instruction means;
Auxiliary charging instruction means for instructing auxiliary charging of the battery;
Counting means for counting the number of times the charging operation has stopped before the battery reaches the full charge amount;
When the number of times counted by the counting unit is less than the specified number, and when the auxiliary charging instruction unit instructs the auxiliary charging of the battery, the current supplied from the external power source to the battery is controlled and the full charge amount is determined. Supplementary charging control means that performs charging operation up to a small supplementary charging amount,
When the number of times counted by the counting means reaches a specified number, when full charging instruction is instructed by the full charging instruction means or auxiliary charging of the battery is instructed by the auxiliary charging instruction means, the external A battery for an industrial vehicle, characterized by comprising refresh charge control means for controlling a current supplied from the power source to the battery and performing a charging operation up to a refresh charge amount obtained by adding a predetermined charge amount to the full charge amount. Charging device. Charging operation stop instruction means for instructing stop of the charging operation is provided,
3. The battery charging device for an industrial vehicle according to claim 1, wherein the counting means counts the number of times of stopping the charging operation including the number of times that the charging operation has been stopped in accordance with an instruction from the charging operation stop instructing means. . 3. The number of counts by the counting means is cleared to zero when the battery is charged up to a full charge amount or when the battery is charged up to a refresh charge amount. The battery charger for industrial vehicles as described. Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and interrupts after a predetermined time. The battery charging device for an industrial vehicle according to claim 1 or 2, wherein the charging operation is restarted or the charging operation before switching is restarted. Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and the battery temperature is normal. 3. The battery charging apparatus for an industrial vehicle according to claim 1, wherein when the temperature is lowered to the temperature, the interrupted charging operation is resumed or the charging operation before switching is resumed. A battery charged by an external power source;
Refresh charging instruction means for instructing refresh charging of the battery;
When refresh charging of the battery is instructed by the refresh charging instructing means, the refresh charging is performed so that the current supplied from the external power source to the battery is controlled to reach the refresh charging amount obtained by adding a predetermined charging amount to the full charging amount. Control means;
Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and interrupts after a predetermined time. A battery charging device for an industrial vehicle, wherein the charging operation is restarted or the charging operation before switching is restarted. A battery charged by an external power source;
Refresh charging instruction means for instructing refresh charging of the battery;
When refresh charging of the battery is instructed by the refresh charging instructing means, the refresh charging is performed so that the current supplied from the external power source to the battery is controlled to reach the refresh charging amount obtained by adding a predetermined charging amount to the full charging amount. Control means;
Battery temperature detection means for detecting the temperature of the battery,
When the detected battery temperature reaches the specified warning temperature, the refresh charge control means interrupts the charging operation or switches to a charging operation in which the supply current to the battery is limited, and the battery temperature is normal. A battery charging device for an industrial vehicle, wherein when the temperature drops to a temperature, the interrupted charging operation is resumed or the charging operation before switching is resumed.

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