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Battery Charger Report 6
Battery Charger Report 6
Team Members: Vitaliy Gleyzer ECE Box # 129 Stephen Masullo ECE Box # 221 Jonathan Mulla ECE Box # 250
TABLE OF CONTENTS
1 PROJECT OVERVIEW .................................................................................................................... 1 1.1 1.2 2 2.1 2.1.1 2.1.2 2.2 2.3 2.4 2.5 2.6 3 PROJECT MISSION ........................................................................................................................ 1 PROJECT SOLUTION ...................................................................................................................... 1 MARKET RESEARCH ..................................................................................................................... 3 Identifying the Market............................................................................................................. 3 Exploring Other Markets........................................................................................................ 3 CUSTOMER REQUIREMENTS ......................................................................................................... 5 PRODUCT REQUIREMENTS ............................................................................................................ 6 INITIAL PRODUCT SPECIFICATIONS .............................................................................................. 6 MEETING PRODUCT REQUIREMENTS ............................................................................................ 7 MEETING PRODUCT SPECIFICATIONS ........................................................................................... 8
VALUE ANALYSIS ......................................................................................................................... 10 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.5 METRICS FOR VALUE ANALYSIS ................................................................................................ 10 INDIVIDUAL MODULE ANALYSIS ............................................................................................... 11 Input and Output Connectors Value Criteria ....................................................................... 11 Input Surge Protection.......................................................................................................... 13 Charger Circuit .................................................................................................................... 15 PREFERRED DESIGN APPROACH ................................................................................................. 17 OUR COMPETITION ..................................................................................................................... 18 Soneil 12 Volt 2.5 amp Constant-Current World Charger ................................................... 18 Cliplight 12V 10 Amp Charger............................................................................................. 19 BatteryMinder....................................................................................................................... 19 SBC-6112 Solar Battery Charger ......................................................................................... 20 Defined Criteria.................................................................................................................... 21 Rate Options Using Criteria................................................................................................. 22 Result of the Value Analysis of the Competition................................................................... 23 VALUE ANALYSIS CONCLUSIONS ............................................................................................... 23 Surge Protection ................................................................................................................... 24 Input Voltage Limiting.......................................................................................................... 24 AC/DC Conversion ............................................................................................................... 25 AC/DC Conversion Options ................................................................................................. 25
External AC/DC Converter ........................................................................................................ 25 Internal AC/DC Converter ......................................................................................................... 26 General Description ................................................................................................................... 31 Simulation.................................................................................................................................. 32
PROTOTYPE RESULTS/FINAL DESIGN................................................................................... 38 6.1 MODULE STATUS ....................................................................................................................... 38 6.1.1 AC/DC Conversion ............................................................................................................... 38 6.1.2 Current Surge Protection ..................................................................................................... 38 6.1.3 Charging Circuit................................................................................................................... 39 6.1.4 Battery Indicator................................................................................................................... 39
TESTING........................................................................................................................................... 40 7.1 7.2 7.3 AC/DC CONVERSION ................................................................................................................. 40 CHARGING CIRCUIT ................................................................................................................... 40 BATTERY INDICATOR ................................................................................................................. 40 STRENGTHS ................................................................................................................................ 41 WEAKNESSES ............................................................................................................................. 41 SUGGESTION FOR IMPROVEMENT ............................................................................................... 41 UNIT COST ANALYSIS ................................................................................................................ 42 PRICE SUGGESTION .................................................................................................................... 43 ECONOMIC FEASIBILITY ............................................................................................................. 43
10 11 12 13 14
CONCLUSIONS ............................................................................................................................... 43 APPENDIX A.................................................................................................................................... 45 APPENDIX B .................................................................................................................................... 46 APPENDIX C.................................................................................................................................... 47 APPENDIX D.................................................................................................................................... 48
REFERENCES ........................................................................................................................................... 50
Table of Tables
Table 2: Value Analysis Input and Output Connectors .................................................... 13 Table 3: Value Analysis of Input Surge Protection .......................................................... 14 Table 4: Value Analysis of Charging Circuits................................................................. 17 Table 5: Scoring for Criteria ............................................................................................. 22 Table 2: AC/DC External Charger Specification Table .................................................. 26 Table 1: Transformer Specification ................................................................................. 27 Table 2: Bridge Rectifier Specifications.......................................................................... 28 Table 3: Filter Capacitor Specifications .......................................................................... 28 Table 9: Voltage Regulator configuration resistors ......................................................... 34 Table 10: AC/DC Module Status..................................................................................... 38 Table 11: Current Surge Protection Module Status ......................................................... 38 Table 12: Charging Circuit Module Status ...................................................................... 39 Table 13: Battery Indicator Module Status...................................................................... 39 Table 14: Parts list with Bulk Prices................................................................................ 42 Table 15: Unit Cost Calculation ....................................................................................... 43
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Table of Figures
Figure 1: Artist Rendition .................................................................................................. 2 Figure 2: ICP 15W, 12 V Solar Powered Battery Charger .............................................. 4 Figure 3: Vector - Marine 2/6 Amp Battery Charger ......................................................... 4 Figure 4: Feature Matrix for Competitors........................................................................ 20 Figure 5: Functional Block Diagram ............................................................................... 24 Figure 6: Voltage Clamp Circuit Schematic.................................................................... 25 Figure 7: External AC/DC Adaptor ................................................................................. 26 Figure 8: AC/DC Converter Schematic ........................................................................... 26 Figure 9: AC/DC Converter Schematic with 5600uF Capacitor ..................................... 29 Figure 10: Transient Analysis with 5600uF Capacitor .................................................... 29 Figure 11: AC/DC Converter Schematic with 6800uF Capacitor ................................... 30 Figure 12: Transient Analysis with 6800uF..................................................................... 30 Figure 13: Transformer 110/220 V AC Switch ............................................................... 31 Figure 14: Complete Charging Circuit Module ............................................................... 32 Figure 15: Regulator configuration for Charging Circuit Module................................... 33 Figure 16: Vout Switching for Charging Circuit Module................................................ 34 Figure 17: Reference Controlled Switch for Charging Circuit Module .......................... 35 Figure 18: Reference Controlled Switch for Charging Circuit Module with added feedback loop ............................................................................................................ 36 Figure 19: Charging Circuit Module................................................................................ 37 Figure 20: Initial General Project Management Chart..................................................... 45 Figure 21: Initial Module Specific Project Management Chart........................................ 46 Figure 22: End Term Project Management Chart............................................................. 47 Figure 23: Complete Circuit Schematic........................................................................... 48
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1 Project Overview
1.1 Project Mission
With the lack of centralized power grids, car batteries have taken the place of one of the main energy sources available in developing countries. With this in mind, our objective will be to design a cheap, versatile and efficient lead acid car battery charger which will interest and appeal to the cost-minded customer. One of our main incentives in developing this product has been a parallel project, Kinkajou portable LED projector, initiated by the Design that Matters team, who has approached us with a need for a low-cost charger to integrate or combine with their device. After doing market research in their target communities, they have been able to devise a list of particular features that would be essential to making their device practical to their specific users: Universal 12 Volt battery charger Various sources of inputs of electricity - solar panel, pedal generator, and standard AC power (both American and European standards) Ability to charge a typical 12 Volt lead-acid (automotive) battery Overcharge protection State of charge indicator Affordable We used these requirements as guidelines to implementing our product as well as include additional features that we thought are important to the functionality.
This product is available at an average price of $150, and claims to provide battery charging with enough power to run a vehicle full of small appliances. At first, it looks like a perfect one package solution, but with a closer look, there are many disadvantages that are not apparent from the marketing. The most obvious one being, the solar panel will be a useless board without the sun shining in the sky; therefore fruitless during the night, as well as in any densely shaded areas. Second of all, the claim to be able to recharge the battery and run numerous appliances at the same time is somewhat outrages. With a 15W rating and the operating voltage of 15V, the panel can only provide approximately an amp of current at its peak sun condition. This is not very practical, since these conditions are rare, and almost impossible to come by, of course, unless you are living in a desert. These conjectures are confirmed by experienced RV owners who have purchased this product and are dissatisfied with the results. These results were found on a popular forum for RV owners. In addition, this one package deal also excludes the numerous customers who have already invested in solar panel for their or RVs or boats.
We have also found out that there are three major companies that are involved in the production of chargers for the boating industry: Vector, ICP and Guest. Looking through their inventories, we found a second device, which could possibly compete with our product in terms of price and functionality. It is a standalone charger that is available for $39.99 at the online retailer www.boatersworld.com (Figure 4). The charger seems to 4
have most of the desired features plus other extra bells and whistles that make it an attractive buy for an outdoorsman. This charger has multiple outputs that provide for easy trickle charging through aggressive battery charging and jump-starting currents. Because of the price being certainly on the low end of the spectrum for these kinds of products, this could certainly be a possible competitor in the boating industry.
According to the field study preformed by Design That Matters, the electronics industry in Bamako should have sufficient supplies for most of the parts that would be needed to manufacture and repair a battery charger.
Be able to work in temperatures up to 120F 3 different types of input Removable input and output plugs
1) Weigh between 2 and 10 pounds Since our design is intended to be highly portable, the size and weight of our product will need to be small enough for realistic use. We found most chargers on the market to be from 2 to 10 pounds and around 7 cubic inches in dimension. 2) Be at most a cubic 7 inches Battery recharge time is a crucial factor in our design. We decided that a maximum charge time of 12 hours for any given input is required. 3) Charge the battery completely in 12 hours The unstable power grid, along with frequent lightning strikes and other power surges requires that we implement safety measures in our design to combat these problems. 4) Cost at most $50, with a target cost of $25 Although the maximum cost of our design was set to $50, we would like our target cost to be around $25. This lower price will help the marketability of our design, and will make it more competitive in the market. 5) Be able to work in temperatures up to 120F - The harsh environmental conditions of our target market area, Mali have required us to set a maximum operating temperature for our device. 6) 3 different kinds of input The variety of available sources, and the lack of a standard power source in our target market, has required us to accommodate for 3 different kinds of input. 7) Removable input and output plugs For the sake of portability and ease of use, we decided that detachable plugs for input and output would be ideal.
The product requirements our prototype does not meet are: Able to handle spikes from input sources 1) Must not overcharge battery This product requirement is met with the float charge feature. 2) Must indicate charge This product requirement is partial met by our prototype. We have a separate working 4 state battery indicator, but due to time we were not able to incorporate it into the final prototype. 7
3) Must not drain battery This product requirement is met through the use of a high power diode at the output of our prototype, located directly before the battery connection. 4) Cheap and readily available parts This product requirement was met by the simplicity of our design and the components used. 5) Environmental durability With the prototype we have now this product requirement may run into problems. It is an issue that would need to be addressed further if this design was to be taken further. 6) Able to handle spikes from input sources Due to time constraints we were not able to address this issue, therefore our prototype is not protected against voltage or current surges.
The product specifications our product does not meet are: Weigh between 2 and 10 pounds Be at most a cubic 7 inches Handle peak current surges of up to 500 kA
1) Charge the battery completely in 12 hours We estimate that our prototype will charge 80% of a battery in 10 hours when it is connected to AC power. 2) Cost at most $50, with a target cost of $25 We determined our unit price to be $47.75, so depending on how much Design that Matters would sell it for will determine how well we fit this product specification. 3) Three different types of inputs Our prototype was successfully able to charge a battery when connected to 110 VAC, 220 VAC, and a pedal generator. We were not able to test it with a solar cell, but we are confident that it will work with a solar cell that can provide enough voltage and current to charge a 12 volt battery. 4) Be able to work in temperatures up to 120F - With the prototype we have now this product requirement may run into problems. It is an issue that would need to be addressed further if this design was to be taken further.
5) Removable input and output plugs Our prototype has a removable AC cord and two posts for a DC connection. The output has two posts which alligator clips could be connected to, which would then be connected to the battery. 6) Weight between 2 and 10 pounds Due to time constraints we were not able to incorporate any type of housing for the prototype, so the final weight of it is not able to be determined. 7) Be at most a cubic 7 inches Like the weight, this requirement was not able to me determined for the same reasons. 8) Handle peak current surges of up to 500 kA Due to time constraints we were not able to address this issue.
3 Project Organization
3.1
Overall, our initial project time management schedule, which can be found in the Appendix, was changed from our plan because of various external factors. One of the greatest factors in the schedule change was the delay of the ordering of our parts that resulted from a clerical error with our parts list. This delay has caused us to move the building and testing stages of our products a few days back. Also, after completing the research phase, the DC/DC conversion module was dropped from the design. This allowed more time to be allocated to other more important modules, such as the charging circuit.
3.2
Looking back our organization and timing, we believe we made the right decision about using the modular approach to this project. Building separate modules gave the flexibility and tolerance to absorb setbacks and delays. We were able to spend time on the available parts of the project while waiting for components to come in, and not have dependencies without which we could not continue.
4 Value Analysis
The purpose of this section is to analyze our different design options and determine which ones are the most appropriate to meet our goal of creating a unique and competitive solution. This was done by first comparing the different design approaches for each functional component of the battery charger using Value Analysis Matrices to determine feasible and still affordable designs. Then, we went on to perform Value Analysis of our entire product to comparable devices that are already available on the market. This was done to ensure that our efforts of pursuing to design this new device have merit, and there are no other products that are already on the market that can meet the same specifications for a cheaper or better than anything that can be designed by us. After strenuous research on the internet, we were unable to find worthy competitors that would accurately fit within our primary customer requirements. The major shortfall of the available solution is their inflexibility to accept different inputs such as solar panels or pedal generators. Since versatility is an absolute must for our customer, none of these can really match up to the demanding specifications of our product. There were several modules in our initial design that could be implemented in various forms, each with their own specific advantages and disadvantages. The modules were evaluated in terms of cost, ease of repair and portability.
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options where cost could not be estimated because of the lack of knowledge of all the parts that would be required to build it. For these design options we chose to evaluate them based on other important criteria.
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Value Analysis Portability: How portable the design is. Very good 5 Good 4 Average 3 Sub-average 2 Poor 1 Versatility: How portable the design is. Very good 5 Good 4 Average 3 Sub-average 2 Poor 1 Durability: How portable the design is. Very good 5 Good 4 Average 3 Sub-average 2 Poor 1 Ease of repair: The ease of repair for the customer. Very Easy 5 Easy 4 Moderate 3 Semi-Difficult 2 Difficult 1 Cost: The approximate cost in US dollars.
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Weight Assignments
Socket Terminal value point 2 1 3 3 5 5 4 2 total 10.00 5.00 12.00 6.00 33.00 33.00 total 9.63 48.15 48.15 0.69 Attached Cords value point 5.54 value point 1.00 0.00 1.00 4.00 Attached Cords total 2.00 0.00 3.00 12.00 17.00 17.00 total 27.70 27.70 0.61 Attached Cords with Terminals value point 8.5 total 409.28 409.28 0.02 value point 2 0 1 0 Attached Cords with Terminals total 4.00 0.00 3.00 0.00 7.00 7.00
Cost I/O
Total
quality/cost
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Value Analysis Ease of use: The ease of design for customer use. Very Easy 5 Easy 4 Moderate 3 Semi-Difficult 2 Difficult 1 Ease of repair: The ease of repair for the customer. Very Easy 5 Easy 4 Moderate 3 Semi-Difficult 2 Difficult 1 Effectiveness: How well the design accomplishes its task. Very Effective 5 Effective 4 Moderately 3 Less 2 Not effective 1 Cost: The approximate cost in US dollars. Weight Assignments
Market value weight 2 2 3 Fuses value point 1 4 5 Total 2 8 15 25 25 total 1 1 1 25 Circuit Breaker value point 1.98 total 1.98 1.98 13.63636364 value point 5 1 5 Circuit Breaker total 10 2 15 27 27
Quality/cost
14
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extra current into the battery, causing overcharge. The ability to harness this current is the key to a successful charger. By monitoring the voltage on the battery, the charge level can be determined, and at a certain point, the current source would need to be folded back to only maintain a trickle charge and prevent overcharging. Multi-stage Constant Voltage/Current Charging Solutions: Both constant voltage and current approaches have their advantages; that is the reason multistage chargers have been developed which combine the two methods to achieve maximum charge time, with minimum damage to the charging cell. An example of a complex, four-stage charger is the Soneil 12 Volt 2.5 Amp Constant Current World Charger. These specifications and explanations for the different stages were taken directly from their website: http://www.4unique.com/battery/soneil/soneil-12v2-5a.htm . Stage 1: Deep Discharge Charging Pulse Mode The Charger starts charging at 0.5V and give pulse current up to 5V. This has effect of removing loose sulphation formed during deep discharge state of the battery. Stage 2: Constant Current Mode (CC) The charger changes to constant current 2.5A. When the battery voltage reaches up to 14.4V, the charging stage changes from (CC) Constant Current to CV (Constant Voltage) mode. Stage 3: Constant Voltage Mode (CV) The charger holds the battery at 14.4V and the current slowly reduces. When the current reaches at 0.5 C (C= Battery Capacity), this point called the Switching Point. The Switching Point is one of the great features of this battery charger that it can adjust the current automatically according to the battery capacity. Other chargers without microprocessors are not capable to adjust the Stage 4: Standby Voltage Mode The charger maintains the battery voltage at 13.8V and current slowly reduces to zero. Charger can be left connected indefinitely without harming the battery. Recharging: If the battery voltage drops to 13.8V, the charger changes from any mode to Constant Current mode and restart charging. The charging cycle will go through Stage 2 to Stage 4. This particular charger has also incorporated some other recharging methods that they have found to optimally charge or treat the battery depending on the level of discharge. As much as multi-stage chargers are enticing in terms of their features, for our purposes, the complexity and the control logic needed to implement this kind of solution would make our project unrealistic given the time and money restraints.
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Value Analysis Simplicity: Very Simple Simple Moderately Less simple Not simple Charge time: Very long Long Fairly long Less long Not long Battery care: Very Good Good Fairly good Less good Not good Weight Assignments
Market Value weight 3 1 1
5 4 3 2 1 5 4 3 2 1 5 4 3 2 1
C voltage total 15 3 4 22 22
Quality/cost
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wrong choice. For the charging module, we decided to go with the constant voltage design. This choice was made not only from the results of the value analysis but also from our research that showed that constant voltage charger design is more compatible with solar panel inputs than the other designs. We obtained this information on the various charging methods from the book Rechargeable Batteries Application Handbook by Technical Marketing staff of Gates Energy Products, Inc. The decision to go with the analog design for the overcharge circuit was decided by the value analysis which showed the lack of feasibility of using a digital approach.
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Soft Start and Stop: Starts and stops gradually. No sudden in-rush of current. This protects both the batteries and any other circuits connected to the charger.
OUTPUT: 12 Volt Nominal; 10 Amp DC Set Voltage (cut-off Voltage): 14.7 +/- 0.1 Volt Float Voltage (come-on Voltage): 14.0 +/- 0.1 Volt INPUT: 105 VAC - 120 VAC ; 60 Hz DIMENSIONS: 3-1/2" wide x 2-1/4" tall x 4-1/2" deep 8.75cm x 5.63cm x 11.9cm WEIGHT: 3 lbs.; 1.36kg
4.4.3 BatteryMinder
The third battery competitive battery charger we looked at was the BatteryMinder which is sold on www.vdcelectronics.com. This battery charger is being offered for $59.95 and offers a feature that prevents permanent cell damage due to self discharge and sulphation. Below are the specifications that were found at the merchant site: http://www.vdcelectronics.com/images/Charger%20with%20brain%20saves.pdf 105 130 VAC @ 50/60 Hz Charges/maintains up to 4 batteries at a time Reverse polarity, short circuit and temperature Battery condition/polarity indicators Fully automatic, works with all 12 Volt batteries, a push of a button begins desulphation Prevents permanent cell damage due to self discharge and sulphation 4-3/4L x 3-1/2W x 3H 4 lbs
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BatteryMinder
Features 230/120 VAC Multiple Battery Charging Multistage Charging Direct Wall Plug LED Indicator Fault Protection Overcharge Protection Battery Recovery Size Weight Price
y y
y y
y y y y y y N/A y y y
y y y
4.75x3.5x3 4 lb $59.95
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Charge Time: The charger must be able to charge within the specified time restraint specification of 12 hours Versatility: Ability to use the charger with almost any power source available is important since no standardize power grid will be available in the product environment
Battery Care Considerations: An implicit criteria. Charger must not damage or significantly shorten the life of the charging battery. Fault Protection: Product must be able to handle hazardous, user-inflicted, accidental conditions such as: shorted or inverted inputs. Surge Protection: The unpredictability and low quality of the AC electrical signal, the product also needs to be fully protected against frequent current and voltage spikes.
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5 4 3 2 1
5 4 3 2
5 4 3 2 1
Charge Time (hours): 0-2 3-6 7-9 10+ Surge Protections: Present Not Present
4 3 2 1
Versatility: Excellent 4 Good 3 Fair 2 Bad 1 Fault Protections: Present Not Present
1 0
1 0
Table 4: Scoring for Criteria Weighting Price 5 Size 2 Weight 4 Charge Time 3 Versatility 5 Surge Protection 4 Fault Protection 4 Battery Care Consideration 1
Surge Protection
Fault Protection
Competitors Soneil 12 Volt 2.5 A Cliplight 12V 10A BatteryMinder Solar Battery Charger OUR CHARGER
Battery Care
Versatility
Weight
Price
Size
Weighted Total 75 58 58 53 78
4 4 4 2 5
5 4 3 4 4
5 4 3 5 4
3 1 2 2 4
1 1 1 n/a 1
1 1 1 1 1
2 1 2 1 1
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AC Input DC Input
Battery Indicator
Battery
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Vin
R2 47kohm R5 3kohm R7 1kohm 5 1 2 D1 5.1 V 3 U1 4 LM741 5.1 V D2 R6 1kohm R8 1kohm Q2
Q1
Vout
R1 3kohm
R3 6.8ohm
R4 7.5kohm
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Input Voltage/Frequency Range : Inrush Current : Line Regulation : Load Regulation : Ripple/Noise : Operating Temperature : Storage Temperature : Dimensions (LxWxH) : Approvals :
90~264VAC/47~63HZ 30A max @ 115VAC/50A max @ 230VAC, cold start +/- 1% +/- 5% typical +/- 0.4V min 1% typical 100mV min 0 ~ 40C -10 to 70C 108mm x 66mm x 36mm UL/cUL/ITS-GS/CE
+
C1 6800uF C2 6800uF
Vout -
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Operation: 1. Input signal from the outlet lowered to 16Vrms 2. 16Vrms gets rectified going through the full-bridge rectifier, with 2 diode voltage drop loss (~ 1.4 V) 3. Capacitor is charged to the peak value of the signal 4. Capacitor is discharged by the rest of the circuit until the voltage on the capacitor is not increased by the rectified AC signal wave In our search for the proper transformer, we had to consider many factors such as input voltage, output voltage, output current and price. Since the primary function of a transformer is to step down large AC signals to smaller ones, we needed to make sure that our transformer would handle both 115Vac and 230Vac standards. For output we needed to make sure that our transformer would be able to produce 16 Vrms with a current of at least 3Arms. The output requirements of the transformer come directly from the input requirements of the charging circuit. The transformer that we chose was the Jameco #104408CF Quick Connect Power Transformer from the Jameco online catalog. The cost for a single unit is $12.95. We obtained the specifications in Table 1 from the online catalog.
Terminals: Input voltage: Output voltage: VA Cap: Terminal size: Size: Weight: Quick Connect, Solder 115/230VAC 16VCT@3.5A 56.0 0.187" 2.00"L x 2.70"W x 2.30"H 1.8 lbs.
Following the transformer output, the next stage in the AC/DC conversion process involved inverting the negative cycles of the AC input. This process requires the use of a full wave rectifier diode bridge. We determined the required specifications for the bridge rectifier based on the input voltage and current. We determined that our rectifier would have to be able to handle the peak voltage of 22.6V along with voltage spikes from a dirty line, as well as the 3 amps that the charging circuit would be pulling with some head room for current spikes. The rectifier that we chose is the KBPC6005 Bridge Rectifier by International Rectifier. We found this rectifier in the Digikey online catalog with the part number KBPC6005-ND with a single unit cost of $1.80. The specifications in Table 2 were obtained from the online catalog.
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The filter capacitors from the input voltage and the maximum ripple voltage allowed by the charging circuit. The capacitor would have to be able to handle the peak input voltage of 22.6V along with headroom for voltage spikes from a dirty line; it would also have to be able to maintain a ripple voltage that would not dip below 17 volts at any time. The capacitor that we chose is the Jameco #115431 6500uF@50V capacitor from the Jameco online catalog. The cost for the single unit is $3.49. We obtained the specifications below from the online catalog.
OPERATING TEMPERATURE RANGE: leakage current: Tolerance: Capacitance: Size (DxL): 40 DEGREES C TO +85 DEGREES C MAX. 0.02CV (uA) or 3mA whichever is smaller +/-20% 6800uF@50V x 51mm (dimensions and lead spacing may vary)
The simulation of our AC/DC conversion module consisted of a modeled AC input after the transformer, a bridge rectifier, a filter capacitor and a current source to model the load. The reason why we went with a modeled AC input, was because of the lack of the specific transformer which we would need to step down the 220VAC wall source. Our model for the AC input consisted of 16Vrms at 50Hz, which would be the output of the transformer. We tested for different known values for the capacitor to see how they would affect the output. The current source that we used to model the load was determined to be 3Amps because that is the maximum current that the charging circuit will draw due to the internal current limiting of the voltage regulator. We computed the required capacitor values using the formula: dv I =C dt I = 3Amps. This is the maximum load current of the charging circuit, so the worst case would be if the circuit pulled this amount of current. dv = 22.6V- 17V, this is the amplitude of the input signal minus the minimum voltage required by the charging circuit. This gives us the minimum distance that the ripple voltage can be at from the peak. dt = 1/100Hz, because the frequency of the rectified signal is twice the frequency of the input. We chose the 50Hz of the European signal for analysis, because it is the worst case scenario since there would be more time for the capacitor to discharge.
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C = 53571.4 uF. Since the calculated value is not a common value we chose the next highest value, 5600uF. We chose a higher value because higher capacitor values decrease the ripple voltage. While searching for parts we found a 6800uF capacitor with a better voltage rating and a lower price than most of the 5600uF capacitors that we found. The simulations below display the outputs of the simulated transient analysis for the circuit with both capacitors.
AC/DC Converter Schematic with 5600uF Capacitor
V1 22.63V 16.00V_rms 50Hz 0Deg 2 4 2 D1 1 C2 5600uF 1 I1 3A 0 3 MDA2501 7
Figure 5 shows the 5600uF capacitor, and the corresponding transient analysis simulation is given by Figure 5.
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Figure 6 uses the 6800uF capacitor and the output of the simulated transient analysis from Figure 7. Note the smaller ripple voltage in this graph, compared to the previous simulation.
Transformer Configuration As it can be seen in Figure 13, the transformer switches between 110 and 220 VAC utilizing a double pole double throw toggle switch. The toggle switch works by switching the dual primary transformer from a series configuration, 220 VAC, to a parallel configuration, 110 VAC.
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U1 LM350
Vin
R7 0.1ohm
D1 Schotkey
+ Battery -
To Charge Indicator
Figure 14: Complete Charging Circuit Module
The circuit is not very tolerant to resistor changes, therefore low tolerance 1% resistors would probably preferable.
5.1.5.2 Simulation
The simulation was slowly built up piece by piece to ensure proper simulation of the complete circuit, as well as catch any simulation problems that might be encountered.
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R1 223.3ohm
The input to the regulator was chosen to be at least two volts higher above the set output voltage. In Figure 9., the resistor values were chosen so that the voltage regulator is configured to the output 14.5V DC for testing purposes only. An interesting note, the simulator applies a 1.3V potential between the adjustment and the output pins. This somewhat varies from the specification of the LM350, which tries to maintain 1.25V across the same pins. Using the simulators voltage across R1, the voltage was calculated to be 14.5V: Vout = 1.3V + (1.3V/R1)*R2 This was confirmed by the simulation.
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R1 10ohm
V1 17.2V
Adding a transistor will act as a switch to ground, and therefore vary the equivalent resistance of R3 which will provide control over the voltage regulator. When the switch is turned on, R4 is connected to ground, putting it in parallel with R3. This lowers the equivalent resistance of both resistors, and therefore lowers the voltage across both of them. Since the voltage is lower, the total output voltage is brought down the same amount. The voltage on the first stage needed to be 14.7V or 2.45 V/Cell and during the float state, 13.8V or 2.3V/Cell. The current through R1, R5 and R2 is 1.25V/250Ohms=.005 A The output voltages were calculated to be: Transistor State OFF ON R3||R4 1000 820 VR3 5.0 4.1 Vout 14.7 13.8
Simulating the circuit, the output voltage was measured to be 14.2V when the transistor was completely on, and 15.1V when it was completely off. This .4V difference is due to the fact that the potential difference between the adjusting terminal and the output pin is 1.3 rather 1.25; therefore producing a larger current, which increasing the output voltage. Another possible source of discrepancy could be the voltage drop across 34
the transistor, which does not completely pull the resistor to ground when it is on, and also has leakage currents.
R1 10ohm
V1 17.2V
V2 12V
The current through R1 and R5 was calculated to be 5 mA. Breaking the 250Ohm resistor into 240Ohm resistor in series with a 10Ohm, provides a 50mV reference below the output voltage. This reference is used as the negative input for the comparator, and the battery voltage as the positive input. Whenever the battery charge is greater than the reference point, the comparator turns on the transistor, and therefore lowers the output voltage to the float charger state. This phenomenon was observed as predicted in the simulations.
Step 4: Providing Feedback through the Current Sensing Resistor This final step was to build the complete circuit. It proved to be a challenging task. Even though logically the circuit seemed to make sense and did not vary significantly from the previous one, we were unable to get the expected output. After numerous hours of trying to appease the simulator, we came to the conclusion that our analysis is probably correct and that the feedback loop through the current sensing
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resistor R6, added enough complexity to the circuit that the simulator did not provide us with an accurate answer.
V1 17.2V
V2 12V
Figure 18: Reference Controlled Switch for Charging Circuit Module with added feedback loop
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To Charging Circuit
R1 2kohm R2 10kohm LED1
LM324
R5 160ohm
R6 7.5kohm
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Our AC/DC conversion module worked as expected. It outputs the correct voltage, and can handle the load simulating a dead battery. We have 2 different options for future implementation, one is an external AC/DC converter design which includes a transformer, bridge rectifier and filter capacitor, the second option is an external AC/DC adapter.
This module has not been fully implemented into our design yet, because of time issues. We are confident that if we did implement it, it would work as expected.
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The charging circuit module works completely as expected, but there is an inherent design problem. Since the charger is built around a linear regulator, heat dissipation creates a major problem if not addressed properly, especially in warm climates such as Malis.
The battery indicator module works independently and indicates the status of the battery while its not charging. Since the battery voltage level during charge does not correspond to the actual voltage of the battery, as we found out during testing, the indicator would not accurately represent the actual charge of the battery. The indicator would need to be modified to indicate the actual status of the battery.
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7 Testing
7.1 AC/DC Conversion
We tested our AC/DC converter with an oscilloscope in three stages. The first stage was the transformer connected to a load. We measured the output and confirmed that it would meet our voltage requirement. The second stage was the transformer hooked up to the rectifier and to a load. We verified the inversion of the negative cycle of the ac input. The third stage was the transformer with the rectifier and filter capacitor. In this stage we measured the ripple voltage to make sure it met our voltage requirements.
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8.1 Strengths
Charging Circuit o Successful 3 stage charging o Reasonable charging time ~80% of dead battery in 10 hours (wall outlet) o Overcharge protection o Works with 110/220 VAC and DC pedal generator Fault protection o Output can be shorted without causing damage to the circuit Will not discharge battery Simple design o Easy to repair Will not be heavier than 3 pounds with metal casing Detachable AC cord for replacement for both 110 and 220 AC plugs
8.2 Weaknesses
Heat Dissipation o Hot to the touch o Lower lifespan of components o In hotter temperatures (Mali) this becomes more of a problem Lack of voltage spike protection Solar panel input not tested Charge indicator does not work with charging circuit
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9 Economic Analysis
During various stages of our project we have needed to consider the economic aspects of our design. From the first product specification stage where we set the precedent of a low product cost as a critical requirement, to the various design cuts and revisions based on part pricing, we have kept the cost in serious consideration.
$12.9500 $10.4900
Table 14: Parts list with Bulk Prices For distribution we used a UPS Shipping calculator to find the price for bulk shipping using estimated weight of a single unit times the bulk number. We assumed that many of the parts. Because the maximum allowable weight per package is 70kg ,roughly 154.3 pounds, our bulk rate is 85 units per package. This calculation gave us a shipping cost of around $29.75 per unit. This shipping number seems extremely high, so we assumed that
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with complete bulk shipping of 1000, and cheaper distribution alternatives such as freight shipping, our estimated distribution cost would be around $10. We decided that for the final product, we would recommend PCB layout for the board. This solution is ideal because it provides a cheap and easy assembly process for this product. With a PCB board, the entire unit can be assembled locally at a much cheaper cost. Searching online at http://www.pcbpro.com we found a quote for $2.62 a board for 1000 5x3 in. boards after 5 weeks. We assumed that all the product assembly would be done in Mali by the local electronic component shops. For this we assumed an hourly wage of $5 and estimating about an hour to assemble.
Parts Manufactur Distribution Assembly Unit Cost $29.75 $3.00 $10.00 $5.00 $47.75
10 Conclusions
We were able to accomplish our main goal, and that is design a working prototype for a 12V lead-acid battery. In this project we have learned more then just how to make a simple universal battery charger and drawing upon our EE knowledge from our previous classes. We experienced our first taste of design and major project management. Along with these
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specific skills, we also improved our time management and team work skills. Through our design project we experience many success and failures in the process, and have had to make a lot of important design decisions. With more time we could have taken our rough design and brought it to usable standalone charger.
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11 Appendix A
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12 Appendix B
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13 Appendix C
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14 Appendix D
Solar Panel / Pedal Generator Input
U1 LM350 Vreg IN OUT R1 10ohm R6 0.1ohm R8 2kohm R9 10kohm
Bus
T1
2 D4 4 1
Switch
D1 Schotkey
LED1 U2
+ Battery -
C1 6800uF
C2 6800uF R2 2.3kohm
R3 220ohm R10 1.5kohm 3 R5 251kohm Q1 R4 1kohm R7 1kohm D3 4 5.1 V 5 1 LM741 R11 570ohm U3 2 D2 5.4 V
1 3 2 U4 1 3 2
R12 160ohm
R13 7.5kohm
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15 Appendix E
DTS180330UC-P5P-ET Design That Matters Attn: Jonathan Mulla
QUOTATION
e-mail:
jonmulla@wpi.edu
Description: Switching Desktop power supply, 90~264VAC/47~63Hz Universal input. 18VDC@ 3.3A output, with a 6-foot output cord terminating to a 2.1mm x 5.5 mm x 9.5mm center positive DC power plug. Includes AC Power Cord. This unit is UL/cUL/TUV/CE/CB/FCC/BSMI/EK/PSE/NORDIC Approved. Part Number: DTS180330UC-P5P-ET Quantity: Quantity: 1K pcs 2K pcs Price: $18.25/unit (Minimum Order Quantity) Price: $17.87/unit
First Delivery: 10~12 weeks via Sea freight, ARO/ or approval of credit. Delivery time may be reduced to 5~6 weeks by Air freight at an additional cost. Standard Terms: 1. Terms: 1%/10 days, Net 30 days on approved credit. 2. FOB: Beaverton, Oregon. 3. Customers PO must acknowledge that Orders are non-cancelable and non-returnable. 4. This quotation is in USD, and is valid for 60 days from date of issue unless withdrawn prior to acceptance. 5. CUI Inc. requires customer approval of a sample unit prior to acceptance of a production order. If you have any questions or comments, call me at any time. Thank you for your interest in CUI products. Sincerely, Heather J. Roley NE Regional Sales Manager
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16 References
RV owners forum: http://www.trailerlife.com/cforum/index.cfm/fuseaction/thread/tid/683429/gotomsg/683 780.cfm Boaters World: www.boatersworld.com Battery Stuff.com: http://www.4unique.com/battery/soneil/soneil-12v2-5a.htm Battery Mart: http://www.batterymart.com/battery.mv?p=ACC-12103 Battery Minder: http://www.vdcelectronics.com/images/Charger%20with%20brain%20saves.pdf PCB Pro.com: http://www.pcbpro.com Powerstream.com: http://www.powerstream.com/PV-Control.htm
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