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path: root/docs/CHARGING_ALGORITHM
 ```1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 ``` ``````CHARGING ALGORITHM This doc and a part of the charger implementation (especially voltage courves, remaining time estimation, trickle charge) is written by Uwe Freese. If you miss some information here, write to mail@uwe-freese.de. [INTRODUCTION] This doc describes how the charging works for the recorder. The algorithm can be found in firmware/powermgmt.[c|h]. Debug output is done in apps/debug_menu.c. Charging for the player is done by the hardware and therefore isn't implemented in rockbox. All following information is related to the recorder. [TECHNICAL POSSIBILITIES AJB] - The AJB can read the voltage of the battery (all four cells in series, resulting in about 5V). - We can switch the charging current (about 350mA, constant) on and off. [VOLTAGE COURVES] See http://www.uwe-freese.de/rockbox for some voltage courves taken while charging and decharging an AJB. These voltage courves are implemented as arrays in rockbox. We can then calculate how full the batteries are (in percent) after taking the actual voltage. Both voltage courves (charging and decharging) are used here. [CHARGE OVERVIEW] - If voltage drops under a certain value (with "deep discharge" option on the value is lower), charging is started. - If end of charge is detected, go to top off charge. - Make the batteries completely full. 90 minutes of top off charge (voltage regulation at a high value). - After that, do trickle charge (max. 12 hours with voltage regulation at a lower value). - When trickle charge is done and you did not disconnect or shut off your AJB by now, the AJB decharges normally since it reaches a low voltage and everything starts from the beginning. [NORMAL CHARGE] When charging is started, the charger is turned on. The batteries are charged with a constant current of about 350mA. The charging is stopped for three reasons: - the voltage goes down in a 5 min interval (delta peak, see below) - the voltage goes up only a little bit in an 30 min interval (is mainly constant) - the charging duration exceeds a maximum duration [DYNAMIC MAX DURATION CALCULATION] The max duration is calculated dynamically. The time depends on how full the battery is when charging is started. For a nearly full battery, the max duration is low, for an empty one, it is a high value. The exact formula can be found in the source code. [DELTA PEAK - WHY DOES IT WORK?] Delta peak means to detect that the battery voltage goes down when the batteries are full. Two facts on batteries are the reason why this works: - If the batteries are full, the charging current cannot charge the battery anymore. So the energy is absorbed by heating up the battery. - Each battery has a negative temperature coefficient, that means the voltage goes down when the temperature goes up. NiMH batteries have a smaller delta peak than NiCd, but is is enough for Rockbox to detect that the batteries are full. Related documents on the web: http://www.nimhbattery.com/nimhbattery-faq.htm questions 3 & 4 http://www.powerpacks-uk.com/Charging%20NiMh%20Batteries.htm http://www.angelfire.com/electronic/hayles/charge1.html (soft start idea) http://www.powerstream.com/NiMH.htm (discouraging) http://www.panasonic.com/industrial/battery/oem/images/pdf/nimhchar.pdf http://www.duracell.com/oem/Pdf/others/nimh_5.pdf (discharging) http://www.duracell.com/oem/Pdf/others/nimh_6.pdf (charging) Philips TEA1102/1103/1104 PDFs available at www.philips.com. [TOP OFF CHARGE AND TRICKLE CHARGE] After a normal charge is completed, trickle charging is started. That means charging to keep the batteries full. While trickle charge in other (stand alone) chargers means charging the amount that the battery loses because of self decharging, here it's charging the amount the AJB consumes when it's on. That's because it is not possible to switch off the AJB when charging is done. It goes on again and then the archos firmware charger code would charge again. So we have trickle charge in rockbox. In simple words, rockbox charges about 15 seconds per minute in trickle mode. An AJB consumes 100 mA when it's on and the charging current is about 300mA. So charging 15 s and decharge 45 s will keep the batteries full. But the number of seconds the charger is on in trickle charge mode is also adjusted dynamically (between 1 and 24 sec). Rockbox tries to hold the battery level at 5,65 V (top off charge, that means "make the batteries completely full") for 90 minutes, then a level of 5,45 V. If the voltage drops below the wanted value, rockbox will charge one second more the next minute. If is is greater than this value, is will charge one second less. Trickle charging runs 12 hours after finishing the normal charging. That should be enough for charging the AJB over night and then unplug the charger sometime in this 12 hour trickle charge time. It is not recommended to trickle charge over days, that's because it is stopped after 12 hours. Many chargers do top off and trickle charge by feeding a constant (low) current to the batteries. Rockbox, as described, makes a voltage regulation. That's because the power consumption of the AJB changes when backlight is on/disk is spinning etc. and doing a voltage regulation is the simplest way to charge exactly the needed amount. There are two charge ICs I want to mention here: The Philips TEA1102 and TEA1103 do voltage regulation for NiCd and NiMH at 1,325 V per cell. That would be 5,3 V for four cells, but I think 5,45 V is best for Rockbox with the maximum time of 12 hours. Note that the voltage values are taken in the part of a minute where the charger is off, so the values are a little bit smaller than the actual average of the whole 60 seconds. The Philips TEA1102 top-off charge time (with 0,15 C) is one hour. My test results with trickle charge (battery capacities measured with an external charger): - after normal charge and top off time: 1798, 1834, 1819, 1815 mAh - after normal + top off + trickle charge (12h): 1784, 1748, 1738, 1752 mAh - charged with external charger: 1786, 1819, 1802, 1802 mAh Result: Trickle charge works. :) [REMAINING TIME ESTIMATION] In simple words, it is remaining time = remaining battery energy / power consumption of AJB With using the battery courves described above and a battery capacity (a constant in powermgmt.h), the remaining capacity is calculated. For the power consumption, a usual constant value is used. If the LED backlight is set to always on, it is also considered. [BATTERY LAZYNESS] The battery voltage gives no realistic hint to the actual charging status when the charger was just turned on or off. Assume a 50% full battery and then turn on the charger. The voltage goes up. But the voltage is smaller than the voltage of a 50% full battery when the charging started at 0%. To consider this (and make a better remaining time estimation possible), I implemented the battery lazyness array. It means (in simple words, let's assume the charger is turned on): - if the charger is just turned on, calculate the battery status (percentage) out of the voltage for decharging (even if we actually charge) - after 20 minutes of charging, calculate the battery status out of the voltage courve for charging - inside these 20 minutes, mix the voltage courves (another array in powermgmt.c tells how) [WHICH CHARGING MODE TO USE] (trickle charge on and off not implemented yet!) If you use your AJB connected to the power supply the whole time, select "deep discharge on" and "trickle charge off". If you want to charge your AJB over night and take it with you the next day, select "deep discharge off" (that it starts charging immediately) and "trickle charge on" (that the batteries remain full). A special case: If you fill up the batteries that are still nearly full every night, it is recommended that you make a complete charge cycle from time to time. Select "deep discharge on" and "trickle charge on" and wait till the whole cycle is over (you can speed up the discharging a little bit by turning on the LED backlight). Even if the battery sellers say NiMH cells don't show a memory effect, I recommend making this procedure from time to time (every 10th charging cycle). BUT: Don't recharge the batteries completely every time if you don't have to. ``````