BATTERY CHARGER USING PUSH-PULL CONVERTER

SHAKIRA FAAIZA BINTI MAZLAN

This thesis submitted in partial fulfilment of the

requirements for the award of the degree of
Bachelor of Engineering
(Electrical)

Faculty of Electrical Engineering

Universiti Teknologi Malaysia

JUNE 2012

ii

iii

Specially dedicated
to my beloved father, mother, brothers, sisters,
to others who encouraged and helped,
and who inspired me
throughout my journey of education

iv

ACKNOWLEDGMENT

First and foremost, Alhamdulillah, thanks to Allah SWT for giving me

strength and good health during the process of this project until it submitted.

Special appreciation to my supervisor, Dr Ahmad Saudi bin Samosir

who has helped me a lot in giving me ideas, opinions and valuable comment
in the making of this project. I am deeply grateful to have him as my
supervisor and also my mentor. His guidance and supervision will help me
in the future life.

Last but not least, thanks to everyone who involved directly or

indirectly in completing this project whether opinion, advice or support
from the beginning of the project until its completion. Thank You So Much

ABSTRACT

Recently, the use of batteries in electrical field or other application

area such as vehicle, back-up power system and others are grows up. To
ensure the lifespan and performance of the batteries, battery chargers need
to be improvised to comply with the characteristics of the battery. In this
project, a battery charger using Push-Pull DC to DC converter was done.
Push-pull converter was chosen to be the DC converter in this project is
because its simplicity and low cost requirement while providing high power
demands. In addition, MOSFET was used as the transistor at the push-pull
converter. Thus, the PWM generator is introduced to trigger the MOSFET
by supplying voltage pulse. IC SG3525 was used in this project at the PWM
generator. At the end of this project, the performance of the developed
battery charger can be seen.

vi

ABSTRAK

Penggunaan bateri di dalam bidang elektrik atau aplikasi lain seperti kereta,
sistem kuasa dan lain-lain sedang membangun. Untuk memastikan jangka
hayat dan prestasi bateri, pengecas bateri haruslah memenuhi kriteria bateri.
Di dalam projek ini, pengecas bateri menggunakan Push-Pull Converter
telah dibuat. Push-pull converter telah dipilih untuk menjadi DC converter
di dalam projek ini kerana ia tidak kompleks dan hanya memerlukan kos
yang rendah walaupun memberi keperluan kuasa yang tinggi. Tambahan
pula, MOSFET digunakan sebagai transistor di push-pull converter. Maka,
PWM generator berfungsi untuk memberi voltan pulse. IC SG3525 telah
digunakan di dalam projek ini. Prestasi pengecas bateri akan dapat dilihat
selepas projek ini selesai.
.

viii

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

DECLARATION OF THESIS

ii

DEDICATION

iii

ACKNOWLEDGEMENT

iv

ABSTRACT

ABSTRAK

vi

TABLE OF CONTENTS

vii

LIST OF TABLES

LIST OF FIGURES

xi

LIST OF ABBREVIATION AND SYMBOLS

xiii

LIST OF APPENDICES

xiv

INTRODUCTION
1.1

Background of Study

1.2

Problem Statement

1.3

Objectives of Project

1.4

Scope

1.5

Thesis Outline

LITERATURE REVIEW
2.1

Introduction

2.2

Battery Charger

ix

2.3

Battery

2.4

Push-Pull Converter

2.4.1

Analysis when Q1 is Switched On

11

2.4.2

Analysis when Q2 is Switched On

13

2.4.3

Analysis when Q1 and Q2 are

Switched On

METHODOLOGY
3.1

Introduction

18

3.2

Battery Charger Design

20

3.3

MATLAB Simulink Simulation

21

3.4

PCB Design

23

3.5

Hardware Implementation

26

RESULTS AND DISCUSSION

4.1

Introduction

28

4.2

Simulation using MATLAB Simulink

29

4.3

Hardware Implementation

32

4.3.1

PWM Generator

4.3.2

Push-Pull Converter with Resistive

Load Test

4.3.3

32

34

Battery Charger using Push-Pull

Converter

15

37

CONCLUSIONS AND RECOMMENDATIONS

5.1

Conclusion

39

5.2

Recommendations

40

REFERENCES

41

APPENDICES

44

xii

LIST OF TABLES

PAGE

TABLE

TITLE

2.1

Characteristics of Batteries

4.1

Comparison of Charging Capacity

37

LIST OF FIGURES

xiii

FIGURE

TITLE

PAGE

2.1

Constant Current Charging

2.2

Constant Voltage Charging

2.3

Discharging Curve of Lead-acid battery

2.4

Basic Circuit of Push-Pull Converter

10

2.5

Equivalent Circuit when Q1 Switched On

11

2.6

Equivalent Circuit when Q2 Switched On

13

2.7

Equivalent Circuit when Q1 and Q2 Switched

15

Off
2.8

Voltage Waveform for Push-Pull Converter

17

3.1

Flowchart of Project Methodology

19

3.2

Battery Charger Circuit Using MATLAB

21

3.3

Block Parameter Pulse Generator 1

22

3.4

Block Parameter Pulse Generator 2

22

3.5

Pin Connection of IC SG3525

23

3.6

Connection Elements at PWM Generator

24

3.7

Drawing of connection at PWM Generator

24

using PCB Designer

3.8

Connection Elements at Push-Pull Converter

25

3.9

Drawing of connection at Push-Pull Converter

25

using PCB Designer

xiv

3.10

Battery Charger Design

26

3.11

Hardware Implementation of Battery Charger

27

Design
4.1

Voltages when Duty Cycle 40 %

29

4.2

Voltage at Battery when Duty Cycle 40 %

30

4.3

Voltages when Duty Cycle 10 %

31

4.4

Voltage at Battery when Duty Cycle 10 %

31

4.5

PWM Generator generate 50 % Duty Cycle

33

4.6

PWM Generator generate 10 % Duty Cycle

33

4.7

Positions of the Voltages

34

4.8

Voltage Output at Secondary Winding

35

Transformers
4.9

Voltage Output at Diodes

36

4.10

Output Voltages after LC Filtering

36

4.11

Position of Battery at Push-Pull Converter

37

4.12

Readings on 20 minutes charging

38

4.13

Readings on 40 minutes charging

38

xiii

LIST OF ABBREVIATIONS AND SYMBOLS

IC

Integrated Circuit

DC

Direct Current

PWM

Pulse Width Modulation

PCB

Printed Circuit Board

LC

Inductor Capacitor

MOSFET

Metal-Oxide Semiconductor FieldEffect Transistor

VO

Voltage Output

VS

Voltage Source

Duty Cycle

NS

Number of winding at secondary

NP

Number of winding at primary

iL

Changes Current in Inductor

Hertz

Ohm

Microsecond

Period

+ve

Positive

-ve

Negative

xiv

LIST OF APPENDICES

APPENDIX

TITLE

PAGE

Equipment used during project

44

Datasheet IC SG3525A

46

Datasheet MOSFET IRF540

53

CHAPTER 1

INTRODUCTION

1.1

Background of Study

Battery charger is an electrical appliance which restores charge to battery

storage system, electrical vehicles and Uninterrupted Power Supplies (UPS) [1]. A
battery is an item that can produce current flow of electricity and it consist of two
metal plates that are separated from each other which is known as positive (+ve)
and negative (-ve). The plates are made from different types of material to
produce different voltage across them and to allow current to flow out from the
battery. The charge stored in the battery will be gradually reduced and the voltage
across the battery decreased when the current is drawn out from the battery for
electricity application. The battery will reach a point where no more charge can be
taken out. If nothing is done to replace the taken charge, then called flat or dead.

Batteries are the major power sources used in renewable generation system,
communication or computer related equipment, and electric vehicles [2, 3]. Battery
is the most critical component in electric vehicles corresponding with the evolution
of electric vehicles such as Plug-in Hybrid Electric Vehicle (PHEV), Hybrid Electric
Vehicle (HEV) and Electric Vehicle (EV). The driving range, cost and weight of the
vehicles completely depend on the battery size and technology. Hence, the battery
charger for the battery is also important. The characteristic of the battery charger
will influence the performance and lifespan of the battery [4, 5].

It is important to design battery chargers which are low cost requirements

while providing high power demands and high performance due to its popularity in
many areas of application.

Considering the ability of push-pull converter that can

perform in a higher power throughput, a battery charger design using push-pull

converter is proposed in this project.

Push-pull converter is a direct current (DC to DC) converter which uses

transformer. The voltage of DC power supply can be changed by the transformer.
The winding ratio of the transformer is fixed. However, the voltage ratios can be
affected by varying the duty cycle of the switching action. In industrial DC power
applications, push-pull converter was approved due to its primary advantages which
is the simplicity of the converter and its capability to scale up to high power
throughput [6].

Converters that have a bidirectional excitation from a transformer normally

will be addressed by the term push-pull. However, this term usually applies to a twoswitch topology with a split primary winding. Capacitor was regularly added at the
output to buffer against the switching noise. In practice, a pair of transistor will be
frequently used as the switches. Both switches must be turned on or turned off
alternately and not simultaneously because it will short out the power supply [6].

1.2

Problem Statement

The criteria for selection of the battery is depend on its size, type, cost,
weight, life cycle, maturity, dependability, availability and efficiency [7]. Different
types of battery will have different charging rate.

The technology of battery

improves at a very fast rate and charging becomes complex because of high currents
and voltage involved in the system and the sophisticated charging algorithms [8]. It
is challenging to develop an advanced charger technology. In this project, a battery
charger will be develop using push-pull converter.

1.3

Objectives of Project

The objectives of this project are:

i.

To study and understand on push-pull converter topology.

ii.

To simulate Pulse Width Modulation (PWM) generator and push-pull DC to

DC converter.

iii.

To design a battery charger by using push-pull DC to DC converter.

iv.

To implement push-pull DC-DC converter for battery charger by using

Integrated Circuit (IC) SG 3525.

1.4

Scope

In order to complete the project, there are guidelines that need to be follow.
First, understanding about the operation of battery charger. Battery criteria such as
size or types will affect the battery charger specifications. The better the battery is,
the more complex the battery charger will be because the battery charger
performance will determined the lifespan of the battery.

In addition, the operation and behaviour of the PWM controller need to be

analyzed so that any problems arising can be avoided. As for transformer, it is not
just to step down or step up the voltage but it is also used to isolate the input voltage
from the output voltage. At the same time, energy from primary winding to the
secondary winding will be transferred.

Furthermore, push-pull converter operation has been studied. There are three
modes of operation which are as follow:
i.

When switch Q1 is switched on;

ii.

When switch Q2 is switched on; and

iii.

When both switches Q1 and Q2 are off.

For all three modes, behaviour of the push-pull converter was analyzed using related
formula.

Lastly, to implement the battery charger hardware using push-pull DC-DC

converter and how the battery charger performs in the charging process. Lead-acid
battery will be used to test the battery charger.

1.5

Thesis Outline

There are five chapters compiled in this thesis.

Chapter 1: Introduction

This chapter contains the background of battery charging and push-pull

converter, problem statement, objective and scope of this project.

Chapter 2: Literature Review

Chapter 2 gives the explanation on the literature review done on battery

charger, battery and analysis of push-pull DC to DC converter.

Chapter 3: Methodology

Chapter 3 describe the methodology of conducting the project. A flow chart

representing the flow of the project is included for better understanding.

Chapter 4: Result and Discussion

The result of simulation and hardware implementation of this project is

shown in chapter 4. This chapter also show the discussion of the result and
performance of the battery charger.

Chapter 5: Conclusion and Recommendations

Chapter 5 obtained the conclusion and recommendation of this project for

future design improvement.

CHAPTER 2

LITERATURE REVIEW

2.1

Introduction

This chapter will elaborate on how battery charger works and characteristics
battery commonly used in electrical application. The three modes operation of pushpull converter will also be describe.

2.2

Battery Charger

Many battery charger strategies have been proposed to charge different types
of batteries. The most popular strategy for battery charger that was used nowadays is
constant-current or constant-voltage charger [9]. Expectation of a battery charger is
to charge the batteries at optimized charging rate and when the battery is fully
charged, it terminates the charging procedure [10]. Battery charger works by feeding
an electric current through the battery for a period of time and store the energy by
resetting the battery chemical to its original state.

Figure 2.1

Constant Current Charging [14]

Figure 2.2

Constant Voltage Charging [14]

Figure 2.1 shows the characteristics of constant current charging while Figure
2.2 shows the characteristics of constant voltage charging.

Process of battery

charging all depend on the characteristics of the battery and the battery charger.
Each battery has its own composition and charging characteristics. Hence, battery
charger must be knowledgably enough to achieve the specific requirements of the
battery [10].

A proper battery charging is important for the battery as it will determine the
maximum life for the battery [11]. Thus, different types of battery charger control
the charging rate in different way.

2.3

Battery

There are a lot of different types of battery used in electric application such as
Nickel Cadmium (Ni-Cd), Nickel Metal Hydride (Ni-MH), and lead-acid battery.
A Ni-Cd battery contains cadmium and a toxic material. It does not been used much
in electrical application nowadays due to its weight that are heavy and it is prone to
the memory effect. Memory effect happen when the battery forgets that it is able
to further discharge because it is constantly partially discharge before charging.

Ni-MH is cadmium-free replacement for Ni-Cd. Thus, they are less affected
form memory effect. It is also offer higher energy density compare with Ni-Cd.
However, Ni-MH battery has problems at very high or very low room temperature.
Even though, it does not contain any heavy metals, it cannot fully recycle.

Nowadays, lead-acid battery is commonly used because of its safety and

reliable characteristics. The applications of lead-acid batteries are in back-up power
supply, emergency lighting equipment, portable electric equipment and vehicles [12,
13]. In this project, lead-acid battery was chosen to be the charging battery due to its
capability to store a large amount of energy at low cost. Thus, charging techniques
are important to prevent from damaging the lifespan of the battery. Table 2.1 shows
the characteristics of these batteries. Figure 2.3 shows the discharging cure of leadacid battery for different currents.

10

Table 2.1
Type
Nominal Operating Voltage
Patent Protection
Price
Security
Green Product
Memory Effect
Energy Efficiency
Cycle Life
Charge Time
Self Discharge

Figure 2.3

2.4

Characteristics of Batteries

Lead-acid battery
2V
No
1
Good
No
No
60 %
400
8 Hours
20 %/Month

Ni-Cd battery
1.2V
No
2
Good
No
Yes
75 %
500
1.5 Hours
30 %/Month

Ni-MH battery
1.2V
No
2.4
Good
Yes
Yes
70 %
500
4 Hours
35 %/Month

Discharging Curve of Lead-acid battery [MATLAB Simulink]

Push-Pull Converter

Push-Pull Converter is a converter that can produce high step-up voltage

ratio. It consists of two transistors that act as switches. Push-pull converter was used
for higher power applications since both switches share the current. The basic
operation of this converter is simple. Basic circuit of push-pull converter is shown in
Figure 2.4 below.

11

Figure 2.4

Basic Circuit of Push-Pull Converter

Each switch, Q1 and Q2, should be able to withstand a reverse voltage due to
the presence of the transformer. The maximum duty cycle for both switches Q1 and
Q2 is 50 %. In addition, push-pull converter is able to generate multiple output
voltages.

There are three mode of operation in the push-pull converter. First, when
switch Q1 is switched on. Next is when switch Q2 is switched on and for the last
mode is when both switches, Q1 and Q2 are switched off.

12

2.4.1

Analysis when Q1 is Switched On

An equivalent circuit when switch Q1 is switched on is shown in Figure 2.5.

Primary voltage is equal to the positive source voltage. Thus, diode D1 is in forward
biased and will conduct the current while diode D2 is in reversed biased. The
voltage source is force across the lower primary winding with positive polarity. The
current that flows through diode D1 continues to flows to the output capacitor and
load.

Figure 2.5

Equivalent Circuit when Q1 Switched On

Closing Q1 will establishes voltage at lower primary winding as follow:

VP1 VS

(2.1)

Then, the voltage across P1 is transformed to the three other windings, resulting in
the following:
N
VS1 VS S
NP

(2.2)

13

N
VS 2 VS S
NP

(2.3)

V P 2 VS

(2.4)

VQ 2 2VS

(2.5)

Diode D1 is forward biased and diode D2 is reversed biased, thus:

N
V X VS 2 VS S
NP

N
VL V X VO VS S
NP

(2.6)

V0

(2.7)

Assuming a constant output voltage, voltage across inductor is constant, thus current
increasing linearly in inductor. The change in current in the inductor is:

N
VS S Vo
N
i L i L

P
t
DT
L

iL closed

NS
VS
Vo
N P

DT

(2.8)

14

2.4.2

Analysis when Q2 is Switched On

Figure 2.6 shows the equivalent circuit when switch Q2 is switched on. The
upper primary voltage is equal to negative voltage source. Diode D2 will be in
forward biased and conduct the current and vice versa for diode D1. The voltage
source is forced across the upper primary winding with negative polarity. Hence,
current flows through diode D2 will continue to flow through inductor, capacitor and
load.

Figure 2.6

Equivalent Circuit when Q2 Switched On

Closing Q2 will produce voltage across upper primary winding as follow:

VP 2 VS

(2.9)

The voltage across P2 is transformed to the three other windings, resulting in the
following:

VP1 VS

(2.10)

15

N
VS1 VS S
NP

(2.11)

N
VS 2 VS S
NP

(2.12)

VQ1 2VS

(2.13)

Diode D2 is in forward biased while diode D1 is in reversed biased, thus:

N
V X VS 2 VS S
NP

N
VL V X VO VS S
NP

(2.14)

V0

Current in inductor is linearly increases, thus equation (2.8) applies.

(2.15)

16

2.4.3

Analysis when Q1 and Q2 are Switched Off

An equivalent circuit when both switches are switched off is illustrated in

Figure 2.7 below.

Figure 2.7

Equivalent Circuit when Q1 and Q2 Switched Off

With both switches off, the current at upper and lower primary winding is
zero. The current in the inductor must maintain continuity resulting both diode D1
and D2 becoming forward biased. Inductor current divides into half between the
upper and lower of transformer secondary winding. Voltage across upper and lower
secondary winding is zero, thus:
VX 0

(2.16)

VL V X VO VO

(2.17)

17

Voltage across inductor is VO resulting current will linearly decreases in inductor.

The change current in inductor is:
V
iL
iL

o
t T
L
DT
2

iL open Vo 1 D T
L 2

(2.18)

Net change in inductor current over one period must be zero for steady-state
operation, thus:

iL closed iL open 0
NS

VO
VS
NP
DT VO 1 D T 0

L 2

(2.19)

(2.20)

Solving for Vo,

N
Vo 2VS S
NP

(2.21)

18

Figure 2.8

Voltage Waveform for Push-Pull Converter

19

CHAPTER 3

METHODOLOGY

3.1

Introduction

This chapter elaborates more on the methodology and processes taken in this
project to design the battery charger using push-pull DC to DC converter. Figure 3.1
shows a simple flow chart regarding the steps taken in this project for deeper
understanding. This project methodology is divided into four phases.

The first phase is to study the operation of PWM Generator and Push-Pull
Converter. The parameter such as switching frequency, timing capacitor, timing
resistor and others will be determined. Second phase is simulation using MATLAB
Simulink and drawing circuit connection using the Printed Circuit Board (PCB)
designer. Battery charger of the design will be simulated and it will be drawn using
PCB designer for hardware implementation purpose.

The third phase which is

hardware implementation where the circuit connections of the battery charger design
is verified to have no errors on the breadboard, and it will be transferred to the PCB.
If there are errors, then the parameters will be calculated again.

Lastly, the

performance of the developed battery charger will be tested by using lead-acid

battery as the charging battery.

20

START
STUDY THE CONCEPT AND
OPERATION OF BATTERY CHARGER
DESIGN AND PUSH PULL CONVERTER
SIMULATION USING MATLAB
DETERMINE THE COMPONENTS USED
CALCULATE SUITABLE PARAMETER
CONSTRUCT PWM CONTROLLER

IMPLEMENT ON PROTOBOARD

TEST USING OSCILLOSCOPE

YES

ERROR
NO

DESIGN TRANSFORMER &

IMPLEMENT ON PROTOBOARD
TEST CIRCUIT

ERROR

YES

NO
TRANSFER CIRCUIT TO PCB
TEST CIRCUIT

TROUBLESHOOT

YES

ERROR
NO
FINISH

Figure 3.1

Flowchart of Project Methodology

TROUBLESHOOT

21

3.2

Battery Charger Design

IC that was chosen to use in this project for the PWM Controller is IC
SG3525. Switching frequency, f s for this project is 100 kHz and Timing Resistor,

RT , 3.3 k . Graph Oscillator Charge Time versus RT in datasheet for IC SG3525

was referred to determine the value of Timing Capacitor, CT . Oscillator charge time
can be determined using equation 3.1.

fs

1
T

100 kHz

(3.1)

1
T

From the graph, the intersection line between oscillator charge time, 10 s
and RT 3.3 k gives 3.3 nF value for CT . For the designated push-pull converter,
MOSFET IRF540 was chosen to be the transistor, 10 mH for the inductor and 220
F for the capacitor. After obtaining all the parameters required, simulation of the
design was conducted.

22

3.3

MATLAB Simulink Simulation

The designated battery charger is simulated using MATLAB Simulink.

Figure 3.2 shows the battery charger circuit simulated using MATLAB Simulink.
PWM generator was generated by using two pulse generators having the same duty
cycle and period but different phase delay. Figure 3.3 and Figure 3.4 shows the
block parameter used in the pulse generator.

The period, T , for both pulse

generators was obtained using the equation 3.1. Due to the characteristic of pushpull converter that must not be turned on or turned off simultaneously, the pulse
generator must have 50 % phase delay with each other. The phase delay is obtained
from the equation 3.2 below.

PhaseDelay

T
2

(3.2)

PhaseDelay
PhaseDelay = 5 s

Figure 3.2

Battery Charger Circuit Using MATLAB

23

Figure 3.3

Figure 3.4

Block Parameter Pulse Generator 1

Block Parameter Pulse Generator 2

24

3.4

PCB Design

PWM generator circuit and push-pull converter was draw using PCB
Designer. Figure 3.5 shows the pin connection of IC SG3525, Figure 3.6 shows the
connection for elements in the circuit for PWM generator and Figure 3.7 shows the
drawing of connection by using PCB Designer.

Figure 3.5

Pin Connection of IC SG3525

25

Figure 3.6

Figure 3.7

Connection Elements at PWM Generator

Drawing of connection at PWM Generator using PCB Designer

To make sure that the battery charger circuit is working, PWM generator was
conducted first followed by push-pull converter.

When PWM generator was

successfully conducted by giving the pulse with different phase that can vary its duty
cycles, push-pull converter battery charger design is initiated.

26

Metal-Oxide Semiconductor Field-Effect Transistor (MOSFET) was used as

switching for the converter. The primary winding, N p of the transformer have 20
turns and for the secondary winding, N s it is 30 turns. Figure 3.8 shows the
connection of the push-pull converter to the load (battery) while Figure 3.9 shows the
drawing of the connection of the push-pull converter using PCB designer before
implementing it together with PWM generator.

Figure 3.8

Figure 3.9

Connection Elements at Push-Pull Converter

Drawing of connection at Push-Pull Converter using PCB Designer

27

3.5

Hardware Implementation

The main focus of hardware implementation is on transferring the design

circuit from the breadboard to PCB. By using SG3525 IC as reference, battery
charger design using push-pull converter can be designed as shown in Figure 3.10
below.

Figure 3.10

Battery Charger Design

The implementation of PWM generator and push-pull converter on PCB was

done by following the right procedure and steps. Firstly, the circuit connection as in
Figure 3.7 and Figure 3.9 was printed out on art paper. PCB was obtained from
laboratory technician. The size of the PCB will be determined by the size of the
drawn circuit. The board was cleaned by using rubber eraser. The design was
transfer to PCB by laminating the art paper with PCB using thermal transfer
machine.

28

Next, the board was put in a bucket of water for 15 minutes to make it easier
to tear the art paper from the board. Then, the board was dried using blow dryer. To
remove the unwanted copper on the board, chemical etchant machine was used. The
board was left for 6 minutes and washed using water after that. Again, the board was
dried using blow dryer.

Holes for the leads component were drilled on the board using a suitable
needle size. After all components was arranged and place on the board, the leg of the
component was soldered onto the board carefully. Figure 3.11 below show the result
of the implementation of battery charger using push-pull converter.
Lead Acid Battery

PWM Generator

Figure 3.11

Push-Pull DC to DC Converter

Hardware Implementation of Battery Charger Design

29

CHAPTER 4

RESULT AND DISCUSSION

4.1

Introduction

In this chapter, results obtained from the simulation of MATLAB Simulink,

PWM generator, push-pull converter with resistive load test and the performance of
the battery charger will be discussed. The result will be divided into two parts as
follow:
i.

Result of simulation; and

ii.

Result of hardware implementation.

a. Output of PWM generator;
b. Output from push-pull converter with resistive load test; and
c. Performance of the battery charger.

The result for each part will be discussed together with the result shown.

30

4.2

Simulation using MATLAB Simulink

Simulation of battery charger using MATLAB Simulink was conducted by

using the parameter that was discussed in Chapter 3. Two results were obtained
when the duty cycle is 10 % and when the duty cycle is 40 %. Figure 4.1 (a) shows
the voltage waveform at the secondary winding while Figure 4.1 (b) shows the
voltage after diode for duty cycle 40 %. Voltage at the battery during this duty cycle
is shown in Figure 4.2.

Figure 4.1

Voltages when Duty Cycle 40 %

31

Figure 4.2

Voltage at Battery when Duty Cycle 40 %

To compare the battery charging characteristics, the duty cycle was reduced to 10 %.
Figure 4.3 (a) shows the voltage at the secondary winding while Figure 4.3 (b) shows
the voltage after diode. Battery voltage measurement was shown in Figure 4.4.

32

Figure 4.3

Figure 4.4

Voltages when Duty Cycle 10 %

Voltage at Battery when Duty Cycle 10 %

33

Comapring Figure 4.2 and Figure 4.4, we can see that battery will be charged
at a higher rate if duty cycle is high due to higher pulse width. In addition, the time
taken for the battery to start charging when duty cycle is 40 % was faster compare
with when duty cycle is 10 %.

4.3

Hardware Implementation

Result for the PWM generator will be discussed followed by the result of
push-pull converter with resistive load test. Then, the performance of the battery
charger will be discussed.

4.3.1

PWM Generator

The input voltage for PWM circuit is 12V. The duty cycle was adjusted to
get 50% of the pulse signal. Figure 4.5 and Figure 4.6 shows the output pulses that
obtained from the PWM generator when the duty cycle is 50 % and 10 %
respectively.

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Figure 4.5

Figure 4.6

PWM Generator generate 50 % Duty Cycle

PWM Generator generate 10 % Duty Cycle

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Saw tooth waveform was produced at leg 5 of the SG 3525 IC and the signal
will be compared with feedback voltage at leg 1 (inverting input). When the
feedback voltage is high, SG 3525 IC will regulate the PWM width so that the output
voltage will be maintained at required value. Variable resistor, 50 k, was used in
the circuit to vary the PWM width manually.

4.3.2

Push-Pull Converter with Resistive Load Test

The testing was done by using resistor, 68 as the load and the push-pull
converter was inserted with output from the PWM generator. Figure 4.7 shows the
position for the voltages in push-pull converter.

Figure 4.7

Positions of the Voltages

Figure 4.8 illustrate voltage across transformer at the secondary winding, V s .

For figure 4.9, voltage across each diodes ( VD1 , VD 2 ) and the combination voltage of
these diodes, V X were shown. To get a DC Voltage at the output, LC Filter was
inserted at the output. Mean voltage for the output is 8.93 as shown in Figure 4.10.

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Figure 4.8

Voltage Output at Secondary Winding Transformers

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Figure 4.9

Figure 4.10

Voltage Output at Diodes

Output Voltages after LC Filtering

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4.3.3

Battery Charger using Push-Pull Converter

Voltage output obtained from the design is 16.8 V. It is higher than the
battery voltage which is 12 V. Lead acid battery was replaced as the load to test the
performance of the developed battery charger using push-pull converter. By using
single phase power analyzer, the reading for the voltage across the battery and the
amount of current flow in the battery while charging can be recorded. To compare
the result, the charging time was in 20 minutes and 40 minutes.

Figure 4.11

Position of Battery at Push-Pull Converter

Figure 4.11 above illustrate the connection of the battery to the charger at the
output of push-pull converter. Table 4.1 below shows the comparison of charging
capacity between these two time limits.

Table 4.1

Comparison of Charging Capacity

Time (Minutes)

Before Charging (V)

After Charging (V)

20

9.666

11.708

40

9.767

12.027

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From the table, when the time of charging increases the capacity of the
battery voltage also will increases. Figure 4.12 and Figure 4.13 below show the
reading when charging time is 20 minutes and 40 minutes respectively.

20min

Figure 4.12

Readings on 20 minutes charging

40min

Figure 4.13

Readings on 40 minutes charging

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CHAPTER 5

CONCLUSION AND RECOMMENDATIONS

5.1

Conclusion

As a conclusion of this project, the entire main objective that had been
mentioned before has been achieved. Battery charger using push-pull DC to DC
converter has been successfully design.

During the design phase of the battery charger, there are some problems
faced. First, component that is sensitive to heat must be handle with extra care when
soldering them or when testing. For example in this project, MOSFET get heated
easily while testing or soldering which sometimes can cause damage to the
MOSFET. Heat sink was used to protect the MOSFET.

Furthermore, the connectivity of the circuit must always be checked before

testing to avoid any short circuit that can damage not only the component but also the
whole system.

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As a lesson learned, to produce such electrical system there are a lot of safety
measures that need to be taken into consideration to protect both the electrical project
equipment and also the person doing it.

5.2

Recommendations

These are some recommendations for improvement of this project. First,

better filter need to be done so the circuit will produce less noise and spike.

Next, this developed battery charger can be modified to a more sophisticated

battery charger by installing the trickle charger mode. Trickle charging is when the
charger detects a battery is fully charge, thus 5% of charging rate compare to the
normal rate will be given to the battery.

Lastly, LCD display can be put on the charger so that it can measure the
temperature difference, voltage across and current flow in the battery. This will
contribute to the lifespan of the battery.

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Appendix A

Equipment

DC Power Supply

Single Phase Power Analyzer

46

Oscilloscope

Multimeter

47

Appendix B

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Appendix C

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57

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