CHARGER WORK PRINCIPLE & TEST

Prepared By:-
Ajeet (Dep-SQM)

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Working Principal
A mobile charger works on the simple principle of
conversion of AC to DC and Voltage Step down &
regulation work by rectifying and filtering the
electricity with the help of components.

Using the 4 key components which is the transformer,

rectifier, filter & regulator-

 Rectifier
 Transformer
 Filter
 Regulator IC

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Working Principal

Rectifier converts the

Rectifier transformed AC signal
into a pulsating DC.

The Transformer steps

Transformer down voltage to
desirable voltage.

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Working Principal

The Filter eliminates the

fluctuations in order to produce
Filter a relative ripple free DC voltage.

A regulator is an important
device when it comes to
Regulator
power electronics as it controls
the power output.

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Working Principal

Rectifier Filter Transformer Regulator Load

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Working Principal

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Basic components of charger

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Basic components of charger
1.RESISTOR
The resistor is an electronic component that has electrical
friction. This friction opposes the flow of electrons and thus
reduces the voltage placed on other electronic components
by restricting the amount of current that can pass through it.

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Basic components of charger
Resistor as a Fuse Resistor as a Load

An electrical safety device consisting of or including a wire In any electrical circuit we can calculate the load
or strip of fusible metal that melts and interrupts the circuit voltage on a resistor by putting parallel where we
when the voltage exceeds.
want.

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Basic components of charger
2.Rectifier
A rectifier is an electronic device that converts an alternating current into a direct current by using one or more P-N
junction diodes.

A diode allows electric current to flow in one direction only. Types of rectifier defined as below.

A. Half wave rectifier

A half wave rectifier is defined as a type of rectifier that allows only one-half cycle of an AC voltage waveform to
pass while blocking the other half cycle .

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Basic components of charger
B. Full wave rectifier
A full wave rectifier is defined as a rectifier that converts the complete cycle of alternating current into pulsating DC.

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Basic components of charger
B. Bridge wave rectifier
We can define bridge rectifiers as a type of full-wave rectifier that uses four or more diodes in a bridge circuit
configuration to efficiently convert alternating (AC) current to a direct (DC) current.

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Basic components of charger
3.Filter

A filter is a circuit arrangement that is capable of passing certain frequencies while attenuating the rest of the
frequencies. Thus, a filter circuit can pass the desired important frequencies from signals .

Low-pass π filter
High-pass T filter

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Basic components of charger
4.Capacitor
A capacitor stores electrical energy when charged by a source & regulate the voltage.

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Basic components of charger
5.Inductor
The Inductor prevents current from making any sudden changes by producing large opposing voltages. It regulate to
current in charger.

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Basic components of charger
6.IC (integrated circuit) as Voltage Regulator

An integrated circuit is a set of electronic circuits of semiconductor material, usually silicon. Large numbers of transistors
and other electronic components are integrated together on the chip. It is used regulate the voltage.

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Basic components of charger
7.Transformer

Transformer is DC-to-DC converter is an electronic circuit or electromechanical device that converts a source of
direct current (DC) from one voltage level to another. It is a device used in the power transmission of electric energy.

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Basic components of charger
7. Transistor (MOSFET)

Transistor is used mainly for amplification and also to provide constant charging
current. The transformer steps the 230 V down to something close to 5 V while
reducing the current up to (say) 300 to 500 mA. This is then rectified to a pulsating
DC at the frequency of the AC source.

8. PCBA (Printed Circuit Board Assembly)

PCBA stands for Printed Circuit Board Assembly and relates to the component
placement onto the bare board or PCB. Multiple electronic components are
assembled to the circuit board and soldered into position.

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Basic key point for charger manufacturing

• Aging- Aging required with normal voltage 220Volt & High voltage to control the SMT components failure after
assembly of charger, it controlled the component failure. It controlled to reach NG charger at customer end.

• Ultrasonic welding- During assembly we should be do frequent drop test to control the welding cracking of
charger.

• Functional test- As per charger specification, output current & voltage should be same as charger
specification.

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The basic electrical performance requirements
1. Charger input voltage range and frequency
Input voltage range: 100V-240V;
Frequency: 50-60Hz:

2. Charger output characteristics

Including output voltage, current and accuracy, etc., generally represented by the output inflection point diagram.

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The basic electrical performance requirements of
3.Ripple
The ripple is due to the fact that after rectification and filtering, there are some AC components in the DC stable value.
This AC component superimposed on the DC stable value is called ripple. At present, the ripple of the charger is
generally ≤300mV for feature phones, and ≤200mV for smartphones.

4. Short circuit protection

It means that the charger has an automatic short-circuit protection function. When the output terminal is short-circuited,
charger will be in hiccup mode(sense circuit) or low-current output. When the fault is eliminated, the charger
components cannot be damaged, and the work should be normal function.

5. Overcurrent protection
When the current exceeds the maximum value, it plays a protective role for the charger. Generally, the overcurrent point
of the charger is set at 1.1-1.5 times of the rated current.

6. Efficiency
Efficiency = output power/input power * 100%.

7. temperature rise
It refers to the temperature difference between the surface temperature of the charger shell and the test room
temperature. Generally, the temperature rise of the charger is 40°C MAX

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The basic electrical performance requirements
8. Input leakage current
After the charger is connected to the main supply, there is a small voltage between the USB iron shell and the ground,
which is obtained by the formula: voltage/10000, and the general requirement is ≤0.25mA.

9. Backflow current
It refers to adding 5V DC voltage to the output port of the charger, and the current through the charger should be less
than 5mA as observed by the series ammeter.

10. Insulation resistance

Insulation resistance is the most basic insulation index of electrical equipment and electrical circuits. The insulation
resistance of the charger refers to the insulation resistance between the input and the output.

11. High pressure

The highest voltage that the charger can withstand between the primary and secondary. The general product is 3000V,
the time is 60S, and the leakage current is 5mA.

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Test Items
It is done when launch any new model with
the device it will be packed. To check the
fast charging and other key function of
Match With charger like charging time etc.
Device

It is appearance inspection of Cosmetic Functional Test With

Loader
Loader is a device which can
show output voltage, current
charger with 30cm distance & 800-
1200 lux light.
and Visual and power of charger.

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Test Items
1.High
temperature To determine the effect of time ,
8. Constant storage test humidity and temperature, under
temperature 2.Low storage conditions, for thermally
and humidity temperature activated failure mechanisms of
test storage test charger.

• High temperature storage test

• Low temperature storage test
• Temperature impact test
it used to determine the 3.Temperature • High temperature Operation
corrosive resistance of
charger AC pins with
7. Salt spray
test Environmental impact test •
•
Low temperature Operation
Temperature rise test
environment conditions.
test • Constant temperature
and humidity test

4. High
6.Temperature
temperature
rise test 5.Low
Operation
temperature
Operation

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Test Items
The purpose of vibration tests is to
evaluate the effect caused on component
parts by vibration in a specified frequency
range.
Wire interface lifting & body 9.Interface
tensile used to test the life of lifting test 1.Vibration
wire or USB cable. Tumble test and drop test are critical to
& Wire Test
evaluate a product ability to survive the
body tensile 2.Tumble test many bumps and scrapes, it will
test
experience in its life cycle with an end-
It is a test that applies high user.
voltage to assets to 8. HIPOT Test
determine the adequacy of (High Potential
the electrical insulation to test)
withstand voltage transients
and make sure the insulation
Key 3.Drop test

is not marginal performance

Flame test used to test the
7. Flame
test
test
charger housing material.
4. USB plug Bend & sway test used to test
and pull test the life of wire or USB cable.

It is the process of testing a device's

resistance to electrostatic discharge. 6.Esd test
5. Surge test
ESD occurs when two electrically
charged objects contact each other, are The surge test finds shorts and
involved in an electrical short or suffer a insulation weaknesses in coils, windings
dielectric breakdown, resulting in a and transformers
sudden flow of electricity.

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Test Items
During rainy weather customer
used charger so we put the
charger with 90% humidity for 3-
4 hours & test the charger
function to know the failure
sustainability.
In summer season temperature
reached more than 45˚c in India
& customer use charger with
this temperature so we tested
the charger with load in 70˚c
temperature to know the
charger sustainability with this
condition
In High voltage test applied more than
450V for different timing. Its purpose to
know the high voltage sustainability in
charger at user end.
1.Constant high
Tumble test basically used to
voltage till dead
control the handling failure in
the charger at user end, we
2.Tumble test till
7.High checked it to know the maximum
dead
humidity test sustainability till fail. We test it
till dead double or more cycles till dead.
TTD Test
(Test till dead) drop test also used to
control the handling failure
6.High 3.Drop test in the charger at user end,
temperature till dead we checked it to know the
with load test maximum dropping height
till dead sustainability till fail.
4.Voltage
fluctuation till
dead In rural area have AC supply
fluctuation in India so we tested
it to know the failure at
maximum voltage fluctuation in
charger.
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Certification & Marking
Class 2: These appliances are double insulated, have no
grounding requirements for it. This type of electrical
appliances has a high degree of safety and can be used
for appliances that come into contact with human skin.

Indoor Use: This icon indicates that the product is

intended for indoor use.

WEEE: WEEE stands for Waste Electrical and Electronic

Equipment. It is a directive in the European Union that designates
safe and responsible collection, recycling and recovery procedures
for all types of electronic waste.

BIS Logo: Considering how harmful a charger can be for the final
consumer, BIS standards have been introduced to ensure
conformance with Indian safety standards.

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Common failure of Charger
1-Fuse burn
It mainly caused by the high AC voltage applied in charger.

2-Input capacitor leakage

It mainly caused by the high AC voltage applied in charger more
than capacitor specifictions.

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Common failure of Charger
3-IC burn
It mainly caused by the high AC voltage applied in charger.

4-Water damage
It mainly caused by some liquid inserted into charger &
component got short by liquid.

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Common failure of Charger
5-BD Functional fail
when the fuse got burn by high voltage & high voltage applied in
Bridge rectifier then rectifier function got fail.

6-Charger intermittent problem

It mainly caused micro 5pins bend or wire ng connections.

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Common failure of Charger
7-PCBA Track damage
it mainly caused by dropping of charger from more height.

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Thank You !

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