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Shortcomings of automatic boost timers (Method C) and current‐sensing automatic systems (Method D)
27 Nov 2021

In the automatic timer control scheme, the duration of the boost charger is pre‐programmed into the charger’s control system. Chargers equipped with automatic boost timers may, under very specific circumstances, provide just the right duration of boost charging. Under all other circumstances, however, such as a different depth of discharge, or when the connected DC load changes, the pre‐programmed and fixed boost time will be either too long or too short. As a result, most recharge cycles will either overcharge the battery or charge it much more slowly than possible with a more sophisticated control system. Throughout a battery's lifetime, the conditions it faces will change. Changing conditions guarantee that chargers employing automatic boost timers will at times both overcharge the battery and, at other times, charge it too slowly.  In other words, automatic timers assure both shortened battery life and inadequate state of charge sometimes. Unfortunately, these two conditions do not average out; undercharging a battery does not undo the damage done by prior overcharge.


Method D, the current‐demand controlled automatic boost, is more advanced than the automatic timer because the duration of boost charging is not pre‐programmed. Instead, the charger automatically adjusts the duration of boost charging to differing depths of battery discharge. This system, however, is not foolproof. The only information available to the charger is current demand, which the charger uses as a proxy for the battery’s state of charge. Adding a DC load ‐ as in increasingly occurring with gensets ‐ to a charging cycle using this approach fools the charger because the charger’s control system cannot differentiate between current demanded by the battery or by the DC load. Adding a DC load thus causes the battery charger to operate at boost voltage longer than the charger would if there were no DC load. As with the automatic timer, the consequence of this relatively simple control scheme is batteries that are either overcharged or that are charged more slowly than possible with a more sophisticated system.


The problems are inherent with both automatic timers and current-controlled automatic boost systems force designers of chargers employing these systems to choose between aggressive recharge profiles that optimize charging speed under ideal conditions or less aggressive charge profiles that result in slower charging but improve battery safety and longevity. The former choice typically results in overcharged, short‐lived batteries. The latter choice typically results in slower charging than ideal, putting the next engine start at risk.

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Conclusion:

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