MINISTRY OF HIGHER EDUCATION

AIN SHAMS UNIVERSITY FACULTY OF ENGINEERING 3 YEAR MECHATRONICS DEPARTMENT

RD

Power Electronics

Battery Charger Project

Documentation

Submitted to: Dr\Osama Shawky

Ain Shams University Industrial Electronics Department 3rd Year Mechatronics Industrial Power Electronics Project 2010-2011 Battery Charger Project

This is the documentation for the Ni-Cd battery charger device. The device circuits consist of 4 circuits (AC-DC converter circuit, Charging circuit, Temperature difference detection 1st charge terminating circuit & Timer 2nd charge terminating circuit).

1-AC DC converter circuit Function: Transformer is used to change AC supply magnitude then Converts AC supply to DC supply through rectifying bridge to use this DC voltage later in battery charging process. Components: Transformer 220/16 V. Bridge rectifier.

2- Charging circuit Function: Adjustment Buck (Voltage regulator) is used to step down the voltage form the supply to charge the battery with variable voltage & constant current. As the battery is charged by time. The voltage upon it increase so a feedback signal is sent back to the buck, so the buck adjusts the out voltage in order to keep the current constant. Components: LM 2575 Adjustment Buck Chip. BY399 (Fast acting diode for the buck). 68mH inductance. LM358 OP-AMP. 100mF capacitor to smooth V-in. Different power resistors.

Buck critical inductor current For max Voltage

No. of batteries to be charged =9.6/1.2=8 batteries. Max voltage from batteries Eb=8*1.5=12 V A constant current of Io= 600 mA is required from the buck so the buck output voltage is: Vo = Eb + 0.05 0.6 = 12.003 V And the input DC voltage Vin=20 V, so the duty ratio D = V o = 0.6
in

F= 52 KHz, L=136 H So the critical inductor current can be calculated: Iob = Iob = 1 1 1 Vo 1 D 2 L f

1 1 1 12.003 1 0.6 = 339.5 mA 2 136 106 52 103

The operating current is 0.6 mA so it is in continuous conduction mode.

For min. voltage

Min voltage from batteries Eb=8*0.8=6.4 V A constant current of Io= 600 mA is required from the buck so the buck output voltage is: Vo = Eb + 0.05 0.6 = 6.403 V And the input DC voltage Vin=20 V, so the duty ratio D = V o = 0.32
in

F= 52 KHz, L=136 H So the critical inductor current can be calculated: Iob = Iob = 1 1 1 Vo 1 D 2 L f

1 1 1 6.403 1 0.32 = 307.8 mA 2 136 106 52 103

The operating current is 0.6 mA so it is in continuous conduction mode.

3-Temperature Difference Detection Circuit Function: This circuit is used as a protection for the battery from over charging heat effect by detecting difference between the battery temperature & the ambient. There are two sensors in this circuit the first measures the battery temperature while the second measures the ambient, when the temperature sensor detects 5 degree Celsius difference between battery & the ambient the comparator turns on and helps in Turning OFF the whole charging operation. Components: LM35 Temperature Sensor Chip. LM358 OP-AMP. Different resistors. 78L05 Voltage regulator.

T Detector circuit calculations

The ambient sensor measures 25C assumingly, and the circuit comparator is needed to trigger when the output voltage of the battery sensor which is equal to 300 mV when the battery is fully charged, but the output voltage of the ambient sensor is only 250 mV, so an Op-amp non-inverting summer is used to add 50 mV to the ambient sensor output. Vo = Vt 1 + Vo = Vy Vsensor + R1 R2 Rf Rg 1+ Rf (1) Rg

R1 R 2 R1 + R 2

And to get 0.05 V from the circuit Vin=5 V, a voltage divider made of two resistances is used. 5 0.05 0.05 0 = Ra Rb Rb = 0.01 Ra

So two resistances with this ratio are used (for example Rb=9.1 K, Ra=470 K) By substituting Vy=0.05 V in Equation (1): Vo = 0.25 0.05 + 1 106 1 106 0.5 106 2 = 300 mV

Now this value is compared with the output of the battery sensor via a +ve feedback comparator usually called Schmitt trigger due to latching effect. The battery sensor output voltage (Vb) at the +ve input and Vo at the ve input of the comparator, the comparator remains off as long as the value of Vb is less than 300 mV. But when Vb reaches 300 mV the comparator triggers and latches due to the +ve feedback, so it doesnt turn off if the value of Vb becomes less than 300 mV again, and the charging operation of the power circuit is terminated.

V+ve = Vb V+ve = 300

Rf R1 + Vin R1 + R f R1 + R f

1 106 39 103 + 5000 = 476.42 mV 1.039 106 1.039 106

4-Timer Circuit. Function: This circuit is used as a protection for the battery from over charging by Turing OFF the whole charging operation after a set period of time almost equal to 90 minutes. To adjust the circuit to give output after 90 minutes leg 15 is used and the value of the variable resistance is adjusted accordingly. The yellow and green leads are used as an indication that the circuit is properly operating, for example if leg 15 turns 1 after 90 minutes which equals to 5400 seconds, then the yellow lead will turn on after 5400/64 =84.4 seconds, the green lead turns on and off as an indication of the counting of the 4060 IC.

The circuit output is considered as the shutdown signal which is connected to the (on/off) leg of the buck.

Components: 4060B (14 stage ripple carry binary counter/divider and oscillator) chip (Time Counter). 100nF, 22uF Capacitors. Different resistors (To adjust oscillation Frequency). Variable Resistance. 1N4148 diode (To latch circuit output). LEDS (Green & Yellow)(Time indicators).

Reference for Data sheets: http://www.scribd.com/document_collections/2759379