Lead acid battery charger with voltage analyzerr

Mini project 2011

ABSTRACT
Now-a-days maintenance free lead acid batteries are common in vehicles, inverters, and UPS systems. If the battery is left in a poor state of charge, its useful life is shortened. It also reduces the capacity and recharge ability of the battery. For older types of batteries, a hygrometer can be used to check the specific gravity of the acid, which, in turn, indicates the charge condition of the battery. However, you cannot use a hygrometer for sealed type maintenance-free batteries. The only way to know their charge level is by checking their terminal voltage.

Dept. of EEE

1 AWH Engg. College

Lead acid battery charger with voltage analyzerr

Mini project 2011

Chapter 1 INTRODUCTION

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. Today maintenance-free lead-acid batteries are common in vehicles, inverters , and UPS systems. If the battery is left in a poor state of charge, itsuseful life is shortened. It also reduces the capacity and rechargebility of the battery. For older types of batteries, a hygrometer can be used to check the specific gravity of the acid, which, in turn, indicates the charge condition of the battery. However, you cannot use a hygrometer for sealed-type maintenance-free batteries. The only way to know their charge level is by checking their terminal voltage. To their specific users: Universal 12 Volt battery charger
Ability to charge a typical 12 Volt lead-acid battery

Overcharge protection State of charge indicator Affordable We used these requirements as guidelines to implement our product as well as include additional features that we thought are important to the functionality.

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2 AWH Engg. College

Lead acid battery charger with voltage analyzerr

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Chapter 2

BLOCK DAIGRAM
Each individual module was designed and constructed separately. After successful simulation and testing, they were put together to create the finalized version.

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3. CIRCUIT DIAGRAM

3.1 CIRCUIT MODEL

Battery Voltage level to detect are <9.8V >9.8V 11.5V 12.0V 12.5V Select reference voltage in 5 V Choose a zener diode with 5V Dept. of EEE 4 AWH Engg. College

Lead acid battery charger with voltage analyzerr Resistor, Re = 5V/1.25mA = 4k = 3.9k (std) Total current through the voltage level indicator circuit is limited to 0.3mA Total resistance in the divider network = 12.5/0.3mA = 41k = 38k (std) For 12.5 voltage V = (Vcc * R5)/ (Total resistance) 5V= (12.5 * R5)/ (38k) R5= 15.2k = 15k (std)

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For 12 voltage V = (Vcc * (R5+R4))/ (Total Resistance) 5V= (12*(15.2+R4))/(38k) R4=15.83-15.2 =0.63k =680 ohm(std) For 11.5 voltage V= (Vcc*(R5+R4+R3))/ (Total Resistance) 5= (11.5*(15.83+R3))/ (Total Resistance) R3=16.52-15.83 =0.691ohm = 680 ohm(std)

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Lead acid battery charger with voltage analyzerr For 9.8 voltage V= (Vcc*(R5+R4+R3+R2))/ (Total Resistance) 5= (9.8*(16.52+R2))/ (38) R2=19.38-16.52 =2.86k =2.7k (std) Resistor, R1 = Total Resistance (R2+R3+R4+R5) = 38 19.38 k = 18.62k = 18k Resistor R7 to R10 = 5V/ (10mA) = 500ohm = 470 ohm(std)
Trasnsformer 12V, 2A So diode used for rectifier is IN 5408 (4 Nos)

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Dept. of EEE

6 AWH Engg. College

Lead acid battery charger with voltage analyzerr

Mini project 2011

4. COMPONENTS USED
1. 230V AC Primary to 0-12V 2AMP Secondary Transformer 2. Diode IN5402 3. IC LM324 4. PZ1 Piezo Buzzer 5. LED 6. Capacitor 7. Zener Diode 8. Resistor 9. Fuse 10. Crocodile Clips 11. PCB

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Lead acid battery charger with voltage analyzerr

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Chapter 5. COMPONENT DESCRIPTION

5.1. 230V AC Primary to 0-12V 2AMP Secondary Transformer A transformer is an electrical device that transfers energy from one circuit to another by magnetic coupling with no moving parts. A transformer comprises of two or more coupled windings, or a single tapped winding and, in most cases, a magnetic core to concentrate the flux. An alternating current in one winding creates a time-varying magnetic flux in the core, which induces a voltage in the other windings. Transformers are used to convert between high and low voltages, to change impedance, and to provide electrical isolation between circuits. If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (VS) is in proportion to the primary voltage (VP), and is given by the ratio of the number of turns in the secondary (NS) to the number of turns in the primary (NP) as follows:

By appropriate selection of the ratio of turns, a transformer thus allows an alternating current (AC) voltage to be "stepped up" by making NS greater than NP, or "stepped down" by making NS less than NP. In the vast majority of transformers, the windings are coils wound around a ferromagnetic core, air-core transformers being a notable exception. Transformers range in size from a thumbnail-sized coupling transformer hidden inside a stage microphone to huge units weighing hundreds of tons used to interconnect portions of power grids. All operate with the same basic principles, although the range of designs is wide. While new technologies have eliminated the need for transformers in some electronic circuits, transformers are still found in nearly all electronic devices designed for household Dept. of EEE 8 AWH Engg. College

Lead acid battery charger with voltage analyzerr makes long distance transmission economically practical.

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("mains") voltage. Transformers are essential for high voltage power transmission, which

5.2.Diode IN5402

A signal diode is one of many types of diodes, which are small components of electrical circuits, manufactured from semiconductors that force electricity to flow in only one direction. Signal diodes which are also sometimes known by their older name of the Point Contact or Glass Diode are physically very small in size compared to their larger Power Diode cousins and control small currents up to about 100mA. Generally, the PN-junction of a signal diode is encapsulated in glass to protect it and they generally have a red or black band at one end of their body to help identify which end is its Cathode terminal.

Silicon diodes are designed to pass very small currents, and have several applications in the signal processing field. The arrow in the symbol of diode points in the direction of conventional current flow through the diode meaning that the diode will only conduct if a positive supply is connected to the Anode (A) terminal and a negative supply is connected to Dept. of EEE 9 AWH Engg. College

Lead acid battery charger with voltage analyzerr

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the Cathode (K) terminal thus only allowing current to flow through it in one direction only, acting more like a one way electrical valve, (Forward Biased Condition). However, we know that if we connect the external energy source in the other direction the diode will block any current flowing through it and instead will act like an open switch, in reverse biased mode.

The characteristics of a signal point contact diode are different for both germanium and silicon types and are given as: Germanium Signal Diodes - These have a low reverse resistance value giving a lower forward volt drop across the junction, typically only about 0.2-0.3v, but have a higher forward resistance value because of their small junction area. Silicon Signal Diodes - These have a very high value of reverse resistance and give a forward volt drop of about 0.6-0.7v across the junction. They have fairly low values of forward resistance giving them high peak values of forward current and reverse voltage. Signal Diodes are manufactured in a wide range of voltage and current ratings. There are bewildering arrays of static characteristics associated with the humble signal diode but the important ones are as follows; maximum forward current, peak inverse voltage and maximum operating temperature. The diode characteristics are shown in Figure.

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5.3.IC LM324 An operational amplifier ("op-amp") is a DC-coupled high-gain electronic voltage amplifier with a differential input and, usually, a single-ended output. An op-amp produces an output voltage that is typically hundreds of thousands times larger than the voltage difference between its input terminals.

5.3.1 Comparator A comparator circuit compares two voltage signals and determines which one is greater. The result of this comparison is indicated by the output voltage: if the op-amp's output is saturated in the positive direction, the non inverting input (+) is a greater, or more positive, voltage than the inverting input (-), all voltages measured with respect to ground. If the op-amp's voltage is near the negative supply voltage (in this case, 0 volts, or ground potential), it means the inverting input (-) has a greater voltage applied to it than the no inverting input (+) 5.4.Piezo Buzzer A buzzer or beeper is an audio signaling device, which may be mechanical, electromechanical, or Piezoelectric. Typical uses of buzzers and beepers include alarms, timers and confirmation of user input such as a mouse click or keystroke

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5.5.LED A light-emitting diode is a semiconductor light source. LEDs are used as indicator lamps in many devices and are increasingly used for other lighting. Introduced as a practical electronic component in 1962, early LEDs emitted low-intensity red light, but modern versions are available across the visible, ultraviolet and infrared wavelengths, with very high brightness.

When a light-emitting diode is forward biased (switched on), electrons are able to recombine with electron holes within the device, releasing energy in the form of photons. This effect is called electroluminescence and the color of the light (corresponding to the energy of the photon) is determined by the energy gap of the semiconductor. An LED is often small in area (less than 1 mm2), and integrated optical components may be used to shape its radiation pattern.LEDs present many advantages over incandescent light sources including lower energy consumption, longer lifetime, improved robustness, smaller size, faster switching, and greater durability and reliability. LEDs powerful enough for room lighting are relatively expensive and require more precise current and heat management than compact fluorescent lamp sources of comparable output.

5.6.Capacitor A capacitor (formerly known as condenser) is a device for storing electric charge. The forms of practical capacitors vary widely, but all contain at least two conductors separated by a nonconductor. Capacitors used as parts of electrical systems, for example, consist of metal foils separated by a layer of insulating film. A capacitor is a passiveelectronic component consisting of a pair of conductors separated by a dielectric (insulator). When there is a potential difference (voltage) across the conductors, a static electric field develops across the dielectric, causing positive charge to collect on one plate and negative charge on the other plate. Energy is stored in the electrostatic field. An ideal capacitor is characterized by a single constant value, capacitance,

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Lead acid battery charger with voltage analyzerr difference between them.

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measured in farads. This is the ratio of the electric charge on each conductor to the potential

5.7.Zener Diode A Zener diode is a type of diode that permits current not only in the forward direction like a normal diode, but also in the reverse direction if the voltage is larger than the breakdown voltage known as "Zener knee voltage" or "Zener voltage". The device was named after Clarence Zener, who discovered this electrical property. A conventional solid-state diode will not allow significant current if it is reversebiased below its reverse breakdown voltage. When the reverse bias breakdown voltage is exceeded, a conventional diode is subject to high current due to avalanche breakdown. Unless this current is limited by circuitry, the diode will be permanently damaged due to overheating. In case of large forward bias (current in the direction of the arrow), the diode exhibits a voltage drop due to its junction built-in voltage and internal resistance. The amount of the voltage drop depends on the semiconductor material and the doping concentrations.

5.8.Resistor

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A resistor is a two-terminalpassiveelectronic component which implements electrical resistance as a circuit element. When a voltage V is applied across the terminals of a resistor, a current I will flow through the resistor in direct proportion to that voltage. This constant of proportionality is called conductance, G. The reciprocal of the conductance is known as the resistance R, since, with a given voltage V, a larger value of R further "resists" the flow of current I as given by Ohm's law:

5.9.Fuse (2.5 AMP) A fuse is a type of sacrificialovercurrent protection device. Its essential component is a metal wire or strip that melts when too much current flows, which interrupts the circuit in which it is connected. Short circuit, overload or device failure is often the reason for excessive current. A fuse interrupts excessive current (blows) so that further damage by overheating or fire is prevented. Wiring regulations often define a maximum fuse current rating for particular circuits. Overcurrent protection devices are essential in electrical systems to limit threats to human life and property damage. Fuses are selected to allow passage of normal current and of excessive current only for short periods

5.10 Crocodile Clips

A crocodile clip (or spring clip) is a temporary electrical connector, named for its resemblance to a crocodile's jaws. Functioning much like a spring-loaded clothespin, the clip's two tapered, serrated jaws are forced together by a spring to make them grip a metal object. One of the jaws usually has either a wire permanently attached or a 4 mm banana plug inserted into it, for connection to an electrical circuit. The clip may be partly covered by a plastic shroud or "boot" to prevent accidental short-circuits.
5.11. PCB

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Lead acid battery charger with voltage analyzerr

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Printed circuit board, or PCB, is used to mechanically support and electrically connect electronic components using conductive pathways, tracks or signal traces etched from copper sheets laminated onto a non-conductive substrate. It is also referred to as printed wiring board (PWB) or etched wiring board. A PCB populated with electronic components is a printed circuit assembly (PCA), also known as a printed circuit board assembly (PCBA). Printed circuit boards are used in virtually all but the simplest commercially-produced electronic devices. PCBs are inexpensive, and can be highly reliable. They require much more layout effort and higher initial cost than either wire wrap or point-to-point construction, but are much cheaper and faster for high-volume production; the production and soldering of PCBs can be done by totally automated equipment

Dept. of EEE

15 AWH Engg. College

Lead acid battery charger with voltage analyzerr

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Chapter 6 WORKING
When the circuit is connected to the battery and push switch S2 is pressed (withS1 open), the battery voltage is sampled by the analyzer circuit. If the supply voltage sample applied to the non-inverting input of an op-amp exceeds the reference voltage applied to the inverting inputs, the output of the op-amp goes high and the LED connected at its output Lights up. The different levels of battery voltages are indicated by LED1 through LED4. All the LEDs remain lit when the battery is fully charged (above 12.5V). The buzzer connected to the output of IC1 also sounds (when S2 is pressed with S1 kept open) as long as the voltage of battery is above9.8V. If the voltage level goes below 9.8V, the buzzer goes off ; this indicates that its time to replace the battery. The status of LEDs for different battery voltages is shown in the table.

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16 AWH Engg. College

Lead acid battery charger with voltage analyzerr

Mini project 2011

The circuit can be assembled on a general- purpose PCB or a bred board. Use 4mmwire and crocodile clips to connect the charger to the battery. A 2.5-amp fuse connected to the output of the charger protects the analyzer circuit against accidental polarity reversal.

Chapter 7 RESULT
The circuit presented here can replenish the charge in a battery within 6-8 hours. It also has a voltage analyzing circuit for quick checking of voltage before start of charging, since overcharging may damage the battery. The voltage analyzer gives an audio-visual indication of the battery voltage level and also warns about the critical voltage level at which the battery requires immediate charging. The status of LEDs for different battery voltages is shown in the table.

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17 AWH Engg. College

Lead acid battery charger with voltage analyzerr

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Chapter 8 CONCLUSION
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 than 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 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.

Dept. of EEE

18 AWH Engg. College

Lead acid battery charger with voltage analyzerr

Mini project 2011

BIBILOGRAPHY

1. RV owners forum: http://www.trailerlife.com/cforum/index.cfm/fuseaction/thread/tid/683429/gotomsg/683 780. cfm 2. Boaters World: www.boatersworld.com 3. Battery Stuff.com: http://www.4unique.com/battery/soneil/soneil-12v2-5a.htm 4. PCB Pro.com: http://www.pcbpro.com 5. Powerstream.com: www.powerstream.com/PV-Control.htm
6. Datasheet

www.datasheet.in

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Lead acid battery charger with voltage analyzerr

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ANNEXURE

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Lead acid battery charger with voltage analyzerr

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CONTENTS

Introduction 1 Block Diagram Circuit Diagram Components used Component Description Working Result Conclusion Bibliography Annexure ` 16 17 13 14 15 2 3 6 7

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