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Team: May03-05 Client: Senior Design Faculty advisors: Patterson and Lamont Team members: Richard Musumhi, Pascal Openshaw, Bo Bo Oo, Chris Privitere 17 November 2002
Table of Contents
1. INTRODUCTORY MATERIAL ................................................................................................................ 1 1.1. 1.2. 2. ABSTRACT .......................................................................................................................................... 1 DEFINITION OF TERMS ......................................................................................................................... 1 PROJECT DESIGN ................................................................................................................................. 2 2.1. INTRODUCTION ................................................................................................................................... 2 2.1.1. General Background.................................................................................................................. 2 2.1.2. Technical Problem..................................................................................................................... 2 2.1.3. Operating Environment.............................................................................................................. 2 2.1.4. Intended Users and Uses .......................................................................................................... 2 2.1.5. Assumptions and Limitations ..................................................................................................... 3 2.2. DESIGN REQUIREMENTS ...................................................................................................................... 3 2.2.1. Design objectives ...................................................................................................................... 3 2.2.2. Functional requirements ............................................................................................................ 3 2.2.3. Design constraints ..................................................................................................................... 4 2.2.4. Measurable milestones.............................................................................................................. 5 2.3. END-PRODUCT DESCRIPTION .............................................................................................................. 5 2.4. APPROACH AND DESIGN ...................................................................................................................... 6 2.4.1. Technical approaches ............................................................................................................... 6 2.4.2. Technical design........................................................................................................................ 6 2.4.3. Testing description .................................................................................................................... 7 2.4.4. Risks and risk management ...................................................................................................... 8 2.5. FINANCIAL BUDGET FALL 2002 TO SPRING 2003 ................................................................................ 8 2.6. PERSONAL EFFORT BUDGET................................................................................................................ 9 2.7. PROJECT SCHEDULE ........................................................................................................................... 9 3. CLOSING MATERIAL............................................................................................................................. 9 3.1. PROJECT TEAM INFORMATION.............................................................................................................. 9 3.2. SUMMARY ........................................................................................................................................ 10 3.3. REFERENCES ................................................................................................................................... 10 3.3.1. Web......................................................................................................................................... 10 3.3.2. Books Insert battery book information here ............................................................................. 11 3.3.3. People ..................................................................................................................................... 11
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Appendices
Appendix A: Schematic and description of design Appendix B: Gantt chart for project schedule Appendix C: Battery specifications Appendix D: Data sheet summaries for components
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Introductory Material
1.1. Abstract
Many of today's new electronic devices require rechargeable batteries to function. To be practical, a battery charger should support 120V AC, 220V AC, 50-60 Hz or 12V DC car inputs and be portable. Companies have produced battery chargers that do one or two settings, but very few have all three voltages and current frequencies. Therefore, the team decided to research the current knowledge concerning rechargeable batteries and design a battery charger based on quality and usability principles that would be able to charge using any of the three voltages. The final product should be so efficient that the team could start a business and begin selling the battery chargers. When a large company offers enough money, the business would be sold and the team could start work on another project.
2. Project Design
2.1. Introduction
2.1.1. General Background The battery charger shall be small and portable, and be able to utilize American 120V/60Hz or European 220V/50Hz voltages as well as vehicle cigarette 12V/DC lighter plugs. It shall fast charge one to four AA/AAA NiCad or NiMH batteries in 1-2 hours. 2.1.2. Technical Problem The charger will have one 12V input plug in, with separate adapters for the cars cigarette lighter plug (12V) and the wall outlet plugs (120 or 220 V AC @ 50-60 Hz). The 12V input will then be converted to 12V and 5V for use in the charger. Voltage and temperature sensors on each battery will determine how close each of them is to being fully charged. This data will be fed back to the PIC uP, which will then send signals to regulate the voltage and current on each of the batteries. It will also control LED lights indicating charge, trickle charge, and finished charging on each battery independently. Single batteries could be plugged in at any time and in any state of charge and the battery charger would know when to stop charging them on independent circuits. Even if a battery is completely full before beginning the charge, the battery charger will be able to determine that and terminate the charge accordingly. The charge is terminated by setting a switch, and subsequently if a lower charge is detected the PIC does a trickle charge to fully charge the battery. A crystal will provide the clock for the PIC in order to provide safety timing. 2.1.3. Operating Environment The charger shall be used indoors or in a vehicle. Indoors the charger can plug into a wall outlet that is either 120 or 220 V AC at 50-60 Hz. In the vehicle, the charger requires a 12 V cigarette lighter plug. A plug adapter will be required to plug the charger into a foreign 220V AC source. Due to the temperature limits of the batteries and the environmental limits of the housing and electrical components, the charger is not meant for extreme heat, extreme cold, or wet conditions. 2.1.4. Intended Users and Uses The battery charger is designed for the frequent picture taker or other user of electronic equipment. Batteries frequently run out of power, and the person may be in a different country, driving, or just taking pictures at home. The charger will charge the batteries back as rapidly as possible without doing any damage to them.
2.1.5. Assumptions and Limitations Assumptions The power sources for 120V, 220V, and 12V are the most common voltages that the charger will need to run on. The user provides a separate adapter for other non-standard power sources. The charger will not charge more than four AA or AAA NiCad or NiMH batteries at a time. The limited number and type of battery was chosen in order to make the device less expensive and more portable. The charger is not meant for extreme cold or wet outdoor conditions. Limitations The budget for battery charger equipment is not to exceed $100. Inexpensive, off-the-shelf rechargeable batteries do not have smart capabilities to aid the charger, and the charger must be able to charge them regardless. The charger must work within the constraints of a cars DC power supply.
2.2.2. Functional requirements Charging The charger shall be able to fast charge up to 4 batteries in 1 hour.
Maintaining Charge The charger shall keep the batteries in a state of full capacity for a long period of time without damaging the batteries. Multiple Voltage Sources The charger shall include adapters to power itself from 120V/60Hz, 220V/50Hz, or 12V DC sources.
Figure 1: Two sample battery chargers from Radio Shack and Energizer.
2.2.3. Design constraints Size The charger should not exceed 4x5x6 inches. Weight The charger shall not weigh more than half a pound. Power adapter The charger power adapters shall have at least 3 feet of cord and a transformer housing no bigger than 2x2x1 inches. See figure 2 below for acceptable adapter sizes.
Heat The charger shall not consume so much power that it generates heat in excess of the temperature limits on the components.
2.2.4. Measurable milestones All components purchased Achieved when there is enough equipment to successfully build the charger. The criteria will be the amount of money spent and the ability to make the charger afterwards. 95% of the equipment must be functional to pass this milestone. Power transformation Using any components available, the power should be turned into something useful to the charging component and the microprocessor. Successful completion is measured through voltage and current reliability. +/- 5% accurate voltage output is required for the transformer to be considered usable. Charging implemented Measured by the ability of the initial prototype to charge NiCad and NiMH batteries successfully in less than 2 hours. Microprocessor coding Evaluated on correct operation, error-free code, and optimizations for battery characteristics. The microprocessor must make the correct decisions for charging 95% of the time for the initial prototype. Housing The basic housing should be able to hold all components other than the power adapters and still have everything function correctly. Testing Testing is successful when the final prototype works correctly in all appropriate situations. Final Report The final report at the end of the year is going to be evaluated by the impression of the course coordinator and the criteria that he/she will use. An A is considered the passing requirement; otherwise the report still needs work. Industrial Review Presentation The industrial review presentation is evaluated on many criteria and overall by the judges' total scores. A 70% satisfaction is the standard for having accomplished the milestone.
batteries will not need to be fully discharged, and will be able to be inserted or removed in any order. For those who travel frequently, it will be able to handle 120 V/60 Hz, 220 V/50 Hz, and 12 V DC power inputs. The charger will be small enough to fit in a travel pouch.
2.4.2. Technical design Plan C was chosen because it provides the most flexibility and options to the team for designing the battery charger. One of the problems with plan A is that the MAX713 has fewer options for setting the voltage drop that terminates the charging. It also does not have input control, for example settings based on whether the batteries are NiMH or NiCad. The same goes for the DS2770, which also has the disadvantage of being more expensive since it is meant to do Lith-Ion cells as well.
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The simplified circuit diagram for the finished charger is shown in figure 3.
A more complete diagram of the battery charger can be found in appendix A. 2.4.3. Testing description Power testing Once the power components are completed, the following must be tested: The 12, 120, and 220V adapters should be able to sustain the load of all four batteries being fast charged. The microprocessor should accurately detect the voltages within 10 mV and set the currents to within 5 mA. The microprocessor should detect four events on each battery line: i. Removal of the battery, which should cause the circuit to be reset. ii. Insertion of the battery, causing the charger to detect the battery characteristics and start charging the battery. iii. Full charge of the battery through temperature difference, when it cuts off the charging.
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iv.
Full charge of the battery through voltage difference, which should cut off the voltage as well.
Usability testing The charger should never overcharge the battery to within 95%, requiring at least 20 batteries to be charged during testing but no more than 100. The charger should be able to finish recharging 2 batteries with 1.5 hours and 4 batteries within 2 hours. Fully discharged 1850 mAh NiMH batteries will be used to verify how long the charger takes. The charger should be able to sustain 10-hour continuous usage on all four batteries without overheating. This will be tested through the use of temperature sensors and switching out discharged batteries as soon as each battery is done charging. End product testing The usability testing is the only part that needs to be repeated for the endproduct testing. 2.4.4. Risks and risk management There are very real risks to the project, but they can be managed. The loss of a critical person on the team is a substantial risk. By documenting research and design materials on paper and/or computer, it would be easier to continue the work of a team member who left. Two people will also be working on each task at a time in buddy pairs. The risk of none of the technical approaches being successful can also be mitigated. Other alternative approaches have been documented in the logbook of each team member, as well as commercial replacements for some of the parts. The team might determine late in the project that a given microprocessor is not useful for the project. This can be avoided by researching the microprocessor well in advance to make sure it does satisfy all the project requirements. Having a backup microprocessor available just in case could help, preferably one that uses similar assembly language. Delays in product shipments for items ordered could delay the delivery and testing of the battery charger. To mitigate this risk, materials and equipment will be ordered much in advance of when they are needed.
Item Student labor Microprocessors 12 V car adapter 120/220V adapter to 12V Wires, resistors, capacitors 4 NiCd batteries 4 NiMH batteries Final housing Digital ICs Total Cost
Estimated cost $0.00 $5.00 $8.00 $15.00 $15.00 $12.00 $12.00 $30.00 N/A $97.00
Revised Estimates Actual Cost $0.00 $6.00 $8.00 $15.00 $15.00 $12.00 $12.00 N/A $21.00 $89.00
2.6.
Privitere, Chris 3311 Birch Stevenson Ames, IA 50013 (515) 572-3591 sabin100@iastate.edu Cpr E Faculty advisors Patterson, Ralph 326 Town Engr Ames, IA 50011-3230 (515) 294 2428 repiii@iastate.edu ECpE Lamont, John 324 Town Engr Ames, IA 50011-3230 (515) 294 3600 jwlamont@iastate.edu ECpE Client E E Senior Design 2215 Coover Hall Iowa State University Ames, IA 50010 (515) 294 2663 ece@ee.iastate.edu Electrical and Computer Engineering Department
3.2. Summary
Battery chargers are an important tool for high-end electronic equipment. There are many chargers on the market, however each of them lacks some features that are useful. By utilizing all the research available on rechargeable batteries and chargers, the group can produce a battery charger that is more convenient, efficient, and long lasting than the ones currently on the market.
3.3. References
3.3.1. Web 3.3.1.1. Charging NiCad and NiMH batteries http://www.rcbatteryclinic.com/seminar.htm http://www.repairfaq.org/ELE/F_NiCd_Battery.html 3.3.1.2. Maxim Part Descriptions and Data Sheets http://www.maxim-ic.com
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3.3.2. Books 3.3.2.1. Handbook of Batteries, third edition. David Linden and Thomas B. Reddy, McGraw-Hill, New York 2002. 3.3.3. People 3.3.3.1. John Oeler, john.oeler@dalsemi.com, (888) 629-4642 followed by asking for Dallas technical support or directly with (972) 371-4448.
3.4. Appendices
Appendix A: Schematic and description of design Appendix B: Gantt chart for project schedule Appendix C: Battery specifications Appendix D: Data sheet summaries for components
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Appendix A
The overall design of the battery charger involves the Microchip PIC controller sending signals to the various chips and receiving inputs from the sensors. Based on this input, the software decided what it should do and sends the binary information out to the DAC or relay switches. See appendix A for details on the components being used.
U1 2 3 4 5 6 7 21 22 23 24 25 26 27 28 9 1 20
C
RC0/T1OSO/T1CKI RA0/AN0 RC1/T1OSI/CCP2 RA1/AN1 RC2/CCP1 RA2/AN2/VREFRC3/SCK/SCL RA3/AN3/VREF+ RC4/SDI/SDA RA4/T0CKI RC5/SDO RA5/SS/AN4 RC6/TX/CK RB0/INT RC7/RX/DT RB1 RB2 OSC2/CLKOUT RB3/PGM RB4 RB5 RB6/PGC RB7/PGD PIC16F872 OSC1/CLKIN MCLR/VPP/THV VDD
11 12 13 14 15 16 17 18 10
DAC
CURRENT SENSOR
BATTERY CELL PIC16F873 10uF CAPACITOR U11 240 6 RESISTOR LM741 7 1 U13 240 6 RESISTOR LM741 10k VOLTAGE SENSOR
7 1
3 + 2 4 5 13.2k
3 + 2 13.2k 4 5
3 + 2 13.2k 4 5
3 + 2 13.2k 4 5
LM741
7 1
10k RESISTOR
B
VOLTAGE SENSOR
10k RESISTOR
RESISTOR
7 1
3 + 2 4 5 13.8k
240 6 RESISTOR
3 + 2 4 5
7 1
U15
7 1
U16
7 1
3 + 2 4 5
LM741
LM741
13.8k
LM741
LM741
10k RESISTOR
A
10k RESISTOR
10k
RESISTOR
A
Title
BATTERY CELL
5 4
10uF CAPACITOR
3
BATTERY CELL
Size Document Number A 10uF CAPACITOR Date: Sunday, November 17, 2002
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ProjectPlan ID 1 Details -4 8 Resource Name Work Pascal Openshaw 128 hrs Work 7h Write Project Plan 8 hrs Work 7h Revise Plan 7 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Have Poster Printed 1 hr Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Learn how to code/use processor 4 hrs Work Work Learn how to interact with8 other hrs components Learn development tools 3 hrs Work Write code 10 hrs Work Debug Code 6 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Order Housing 1 hr Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Chris Privitere 121 hrs Work Review/Make Suggestions 3 hrs Work Revise Plan 7 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work 19 1h 1h 13h 7h 3h 30 22h 41 11h 52 12h 63 17h 74 4h 85 9h 96 19h 107 10h 118
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ProjectPlan ID Details -4 8 Resource Name Work Practice/Rehearse Presentation 2 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Learn how to code/use processor 4 hrs Work Work Learn how to interact with8 other hrs components Learn development tools 3 hrs Work Write code 10 hrs Work Debug Code 6 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Richard Musumhi 100 hrs Work Review/Make Suggestions 3 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Learn how to use power supply 7 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Order Housing 1 hr Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work 19 30 1h 7h 2h 4h 4h 4h 3h 4h 41 52 63 2h 74 85 96 107 118
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ProjectPlan ID Details -4 8 Resource Name Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Diagram PCB 4 hrs Work Make PCB 5 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Bo Bo Oo 99 hrs Work Review/Make Suggestions 3 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Learn how to use power supply 7 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Diagram PCB 4 hrs Work Make PCB 5 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work 19 30 41 52 63 74 4h 4h 3h 85 96 107 5h 118
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ID 1 2 3 4 5 6 7 12 13 14 15 8 9 10 11 19 20 21 25 26 27 28 29 30 31 16 17 18 22 23 24 44 45 46 47 48 32 33 34 35 36 37 38 39 40 41 42 43 49 51 50
Task Name Project Plan Write Project Plan Review/Make Suggestions Revise Plan Components Purchased Research Needed Components Write Purchasing Proposals Design Report Write Design Report Review/Make Suggestions Revise Design Report Poster Layout Poster Error Check Poster Have Poster Printed Power Transformation Learn how to use power supply
12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM Pascal Openshaw Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere
Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Richard Musumhi,Chris Privitere,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo
Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw
Demonstrate power supply to rest of group Microprocessor Coding Learn how to code/use processor Learn how to interact with other components Learn development tools Write code Debug Code Demonstrate Code with components Oral Presentation of Design Report Put together presentation Practice/Rehearse Presentation Charging Implemented Get Microprocessor and transformers to work together Test Board Layout Learn how to make PCB Diagram PCB Make PCB Test PCB Housing Research Housings Order Housing Put Charger into Housing Test Charger in Housing Final Testing Safety Testing Usuability Testing Final Report Write Final Report Review/Make Suggestions Revise Final Report Industrial Review Presentation Practice/Rehearse Presentation Put together Presentation
Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo
Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Richard Musumhi,Bo Bo Oo Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo
Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Richard Musumhi Richard Musumhi,Pascal Openshaw,Chris Privitere,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo
Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Chris Privitere,Pascal Openshaw,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo
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and a plastic gasket. The steel can itself is the negative terminal, which is separated from the positive one by the gasket. (b)Reactions i. For NiCad batteries, the reaction is Cd + 2NiOOH + 2H2 O ? Cd(OH) 2 ? 2Ni(OH) 2 with a discharge going to the right and a charge moving to the left. During the charging process, the positive wafer reaches full charge before the negative and produces oxygen, which then makes its way to the negative wafer and combines with the Cd as follows: 1 Cd + O 2 + H2 O ? Cd(OH)2 . The separator is permeable to the oxygen so that 2 it can pass through to the negative electrode. Charging must be done carefully to avoid the pressure buildup from too much oxygen. The resealable safety valve is there to regulate pressure in case of an otherwise disastrous case of malfunction, high charge rate, or abuse. ii. For NiMH batteries, the charge reaction is MH + NiOOH ? M + Ni ?OH?2 . As with the NiCad batteries, the positive electrode reaches full charge before the negative and produces oxygen. This oxygen then goes to the negative electrode and transforms the MH into M + H2 O . Care must simply be taken to not let the overcharge carry on for longer than the oxygen recombination can handle. (c) Discharge characteristics NiCad and NiMH batteries are typically discharged only to 1.0 V. When multiple battery cells are connected together, it is possible for the one with the lowest initial capacity to be discharged completely and then suffer a polarity reversal. The positive electrode starts to generate hydrogen gas until the positive electrode is saturated, followed by the negative electrode starting to produce oxygen. Overdischarging leads to deterioration of the cell and the opening of the safety valve to reduce the pressure within the battery. However, since only one battery will be discharged at a time in the team's design, overdischarge to negative polarity should not be an issue. The book examines discharge curves for currents up to 8C for the NiCad batteries and 3C for NiMH batteries. On both of these, the only limiting factor should be the amount of heat generated by the reactions. Since both batteries are rated for operation up to 50 deg C, the discharge speed should not be a major problem or could simply be monitored by the temperature sensor. (d)Battery failure causes Reversible failures can be fixed through reconditioning. Irreversible failures cannot be changed back and will eventually cause the battery to cease functioning. i. Reversible failures: The voltage depression or memory effect happens when batteries are continually discharged only partially followed by recharging. Overcharging occurs when a battery is charged at low current for too long. Both are reversible problems that are easily fixed by a few normal charge and discharge cycles. The second problem is not an issue for NiMH batteries because they should not be overcharged to begin with unless the current is at the top-off rate of 0.02C to 0.05C. NiMH batteries have a greater tendency to overheat because the entire charging reaction is
exothermic. For NiCad batteries, only the fully-charged reactions are exothermic. ii. Irreversible failures: These are caused by essentially two causes: Electrolyte loss and short-circuiting. The electrolyte can be lost through the pressure safety valve when the battery is overcharged, or through the normal seals for example at high temperatures. Short-circuits can form because of high temperatures that damage the internal components of the battery. 2. Charging techniques Both batteries are typically charged through the use of the constant-current method. (a) Overview NiCads can use a 0.1C rate for 12 to 16 hours (140%). Most NiCad batteries can be safely charged then overcharged with the C/100 to C/3 rate. NiMH batteries are more sensitive to overcharge, and therefore should be more carefully monitored and rarely use a fixded-time, higher constant current charge to avoid overdoing an only half-discharged battery. (b)Charging rates and their effects on the battery There are typically three charging settings: slow charge, quick charge, and fast charge, corresponding to 12, 5, and 1 hour(s) respectively. i. Temperature curves ii. Voltage curves iii. Cycle life iv.Charge rates (c) Charge termination There are several ways to terminate the charging process, and some are more accurate than others. The main ways of terminating the charging process are through measurements of time, voltage, or temperature. i. NiCad batteries The preferred method of charge termination for NiCad batteries is negative voltage slope with reference to time. ii. NiMH batteries Charge termination through temperature measurement is actually more accurate than with voltage slope, because the downward slope with NiMH batteries is less noticeable than with NiCads.
PIC16F87X
28/40-Pin 8-Bit CMOS FLASH Microcontrollers
Devices Included in this Data Sheet:
PIC16F874 PIC16F877
Pin Diagram
PDIP
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RA4/T0CKI RA5/AN4/SS RE0/RD/AN5 RE1/WR/AN6 RE2/CS/AN7 VDD VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL RD0/PSP0 RD1/PSP1 1 2 3 4 5 6 40 39 38 37 36 35 RB7/PGD RB6/PGC RB5 RB4 RB3/PGM RB2 RB1 RB0/INT VDD VSS RD7/PSP7 RD6/PSP6 RD5/PSP5 RD4/PSP4 RC7/RX/DT RC6/TX/CK RC5/SDO RC4/SDI/SDA RD3/PSP3 RD2/PSP2
PIC16F877/874
7 8 9 10 11 12 13 14 15 16 17 18 19 20
34 33 32 31 30 29 28 27 26 25 24 23 22 21
Peripheral Features:
Timer0: 8-bit timer/counter with 8-bit prescaler Timer1: 16-bit timer/counter with prescaler, can be incremented during SLEEP via external crystal/clock Timer2: 8-bit timer/counter with 8-bit period register, prescaler and postscaler Two Capture, Compare, PWM modules - Capture is 16-bit, max. resolution is 12.5 ns - Compare is 16-bit, max. resolution is 200 ns - PWM max. resolution is 10-bit 10-bit multi-channel Analog-to-Digital converter Synchronous Serial Port (SSP) with SPI (Master mode) and I2C (Master/Slave) Universal Synchronous Asynchronous Receiver Transmitter (USART/SCI) with 9-bit address detection Parallel Slave Port (PSP) 8-bits wide, with external RD, WR and CS controls (40/44-pin only) Brown-out detection circuitry for Brown-out Reset (BOR)
PDIP, SOIC
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RA4/T0CKI RA5/AN4/SS VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 28 27 26 25 24 23 22 21 20 19 18 17 16 15 RB7/PGD RB6/PGC RB5 RB4 RB3/PGM RB2 RB1 RB0/INT VDD VSS RC7/RX/DT RC6/TX/CK RC5/SDO RC4/SDI/SDA RA3/AN3/VREF+ RA2/AN2/VREFRA1/AN1 RA0/AN0 MCLR/VPP NC RB7/PGD RB6/PGC RB5 RB4 NC 6 5 4 3 2 1 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 9
PIC16F876/873
PLCC
RC6/TX/CK RC5/SDO RC4/SDI/SDA RD3/PSP3 RD2/PSP2 RD1/PSP1 RD0/PSP0 RC3/SCK/SCL RC2/CCP1 RC1/T1OSI/CCP2 NC
QFP
44 43 42 41 40 39 38 37 36 35 34
12 13 14 15 16 17 18 19 20 21 22
RC7/RX/DT RD4/PSP4 RD5/PSP5 RD6/PSP6 RD7/PSP7 VSS VDD RB0/INT RB1 RB2 RB3/PGM
1 2 3 4 5 6 7 8 9 10 11
PIC16F877 PIC16F874
33 32 31 30 29 28 27 26 25 24 23
NC RC0/T1OSO/T1CKI OSC2/CLKOUT OSC1/CLKIN VSS VDD RE2/AN7/CS RE1/AN6/WR RE0/AN5/RD RA5/AN4/SS RA4/T0CKI
RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL RD0/PSP0 RD1/PSP1 RD2/PSP2 RD3/PSP3 RC4/SDI/SDA RC5/SDO RC6/TX/CK NC
18 19 20 21 22 23 24 25 26 27 282
RA4/T0CKI RA5/AN4/SS RE0/RD/AN5 RE1/WR/AN6 RE2/CS/AN7 VDD VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CK1 NC
7 8 9 10 11 12 13 14 15 16 17
PIC16F877 PIC16F874
RB3/PGM RB2 RB1 RB0/INT VDD VSS RD7/PSP7 RD6/PSP6 RD5/PSP5 RD4/PSP4 RC7/RX/DT
Key Features PICmicro Mid-Range Reference Manual (DS33023) Operating Frequency RESETS (and Delays) FLASH Program Memory (14-bit words) Data Memory (bytes) EEPROM Data Memory Interrupts I/O Ports Timers Capture/Compare/PWM Modules Serial Communications Parallel Communications 10-bit Analog-to-Digital Module Instruction Set
PIC16F873 DC - 20 MHz POR, BOR (PWRT, OST) 4K 192 128 13 Ports A,B,C 3 2 MSSP, USART 5 input channels 35 instructions
PIC16F874 DC - 20 MHz POR, BOR (PWRT, OST) 4K 192 128 14 Ports A,B,C,D,E 3 2 MSSP, USART PSP 8 input channels 35 instructions
PIC16F876 DC - 20 MHz POR, BOR (PWRT, OST) 8K 368 256 13 Ports A,B,C 3 2 MSSP, USART 5 input channels 35 instructions
PIC16F877 DC - 20 MHz POR, BOR (PWRT, OST) 8K 368 256 14 Ports A,B,C,D,E 3 2 MSSP, USART PSP 8 input channels 35 instructions
FEATURES
Unique 1-Wire interface requires only one port pin for communication Provides unique 64-bit serial number to battery packs Eliminates thermistors by sensing battery temperature on-chip On-board A/D converter allows monitoring of battery voltage for end-of-charge and endof-discharge determination On-board integrated current accumulator facilitates fuel gauging Elapsed time meter in binary format 40-byte nonvolatile user memory available for storage of battery-specific data Operating range -40C to +85C Applications include portable computers, portable/cellular phones, consumer electronics, and handheld instrumentation
PIN ASSIGNMENT
GND VSENS+ VSENSVAD 1 2 3 4 8 7 6 5 DQ NC NC VDD
PIN DESCRIPTION
DQ VAD VSENS+ VSENSVDD GND NC Data In/Out General A/D input Battery current monitor input (+) Battery current monitor input (-) Power Supply (2.4V to 10.0V) Ground No connect
DESCRIPTION
The DS2438 Smart Battery Monitor provides several functions that are desirable to carry in a battery pack: a means of tagging a battery pack with a unique serial number, a direct-to-digital temperature sensor which eliminates the need for thermistors in the battery pack, an A/D converter which measures the battery voltage and current, an integrated current accumulator which keeps a running total of all current going into and out of the battery, an elapsed time meter, and 40 bytes of nonvolatile EEPROM memory for storage of important parameters such as battery chemistry, battery capacity, charging methodology and assembly date. Information is sent to/from the DS2438 over a 1-Wire interface, so that only one wire (and ground) needs to be connected from a central microprocessor to a DS2438. This means that battery packs need only have three output connectors: battery power, ground, and the 1-Wire interface. Because each DS2438 contains a unique silicon serial number, multiple DS2438s can exist on the same 1-Wire bus. This allows multiple battery packs to be charged or used in the system simultaneously. Applications for the smart battery monitor include portable computers, portable/cellular telephones, and handheld instrumentation battery packs in which it is critical to monitor real-time battery performance. Used in conjunction with a microcontroller in the host system, the DS2438 provides a complete smart battery pack solution that is fully chemistry-independent. The customization for a particular battery chemistry and capacity is realized in the code programmed into the microcontroller and DS2438 EEPROM, and only a software revision is necessary should a designer wish to change battery pack chemistry.
OVERVIEW
The block diagram of Figure 1 shows the seven major components of the DS2438: 1. 2. 3. 4. 5. 6. 7. 64-bit lasered ROM temperature sensor battery voltage A/D battery current A/D current accumulators elapsed time meter 40-byte nonvolatile user-memory
Each DS2438 contains a unique 64-bit lasered ROM serial number so that several battery packs can be charged/monitored by the same host system. Furthermore, other Dallas products featuring the same 1-Wire bus architecture with a 64-bit ROM can reside on the same bus; refer to the Dallas Automatic Identification Data book for the specifications of these products. Communication to the DS2438 is via a 1-Wire port. With the 1-Wire port, the memory and control functions will not be available until the ROM function protocol has been established. The master must first provide one of four ROM function commands: 1) Read ROM, 2) Match ROM, 3) Search ROM, or 4) Skip ROM. These commands operate on the 64-bit lasered ROM portion of each device and can singulate a specific device if many are present on the 1-Wire line as well as to indicate to the bus master how many and what types of devices are present. After a ROM function sequence has been successfully executed, the memory and control functions are accessible and the master may then provide any one of the six memory and control function commands. Control function commands may be issued which instruct the DS2438 to perform a temperature measurement or battery voltage A/D conversion. The result of these measurements will be placed in the DS2438s memory map, and may be read by issuing a memory function command which reads the contents of the temperature and voltage registers. Additionally, the charging/discharging battery current is measured without user intervention, and again, the last completed result is stored in DS2438 memory space. The DS2438 uses these current measurements to update three current accumulators; the first stores net charge for fuel gauge calculations, the second accumulates the total charging current over the life of the battery, and the remaining accumulator tallies battery discharge current. The elapsed time meter data, which can be used in calculating battery self-discharge or time-related charge termination limits, also resides in the DS2438 memory map and can be extracted with a memory function command. The nonvolatile user memory of the DS2438 consists of 40 bytes of EEPROM. These locations may be used to store any data the user wishes and are written to using a memory function command. All data and commands are read and written least significant bit first.
____________________________Features
o Buffered Voltage Outputs o Double-Buffered Digital Inputs o Microprocessor and TTL/CMOS Compatible o Requires No External Adjustments o Two- or Three-Wire Cascadable Serial Interface o 16-Pin DIP/SO Package and 20-Pin LCC o Operates from Single or Dual Supplies
MAX500
______________Ordering Information
TEMP. RANGE PIN-PACKAGE ERROR (LSB) PART MAX500ACPE 0C to +70C 16 Plastic DIP 1 MAX500BCPE MAX500ACWE MAX500BCWE MAX500BC/D MAX500AEPE MAX500BEPE MAX500AEWE MAX500BEWE MAX500AEJE MAX500BEJE MAX500AMJE MAX500BMJE MAX500AMLP MAX500BMLP 0C to +70C 0C to +70C 0C to +70C 0C to +70C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -55C to +125C -55C to +125C -55C to +125C -55C to +125C 16 Plastic DIP 16 Wide SO 16 Wide SO Dice* 16 Plastic DIP 16 Plastic DIP 16 Wide SO 16 Wide SO 16 CERDIP 16 CERDIP 16 CERDIP 16 CERDIP 20 LCC 20 LCC 2 1 2 2 1 2 1 2 1 2 1 2 1 2
________________________Applications
Minimum Component Count Analog Systems Digital Offset/Gain Adjustment Industrial Process Control Arbitrary Function Generators Automatic Test Equipment
________________Functional Diagram
SRO VREFC AGND DGND VSS VDD LDAC VREFA/B VREFD
_________________Pin Configurations
VOUTB
TOP VIEW
V OUT B 1 16 V OUT C 15 V OUT D 14 V DD
DATA BUS
INPUT REG B
DAC REG B
DAC B
MAX500
MAX500
SDA 8
DIP/SO
For free samples & the latest literature: http://www.maxim-ic.com, or phone 1-800-998-8800
A15 A8
ADDRESS BUS A0 82C55 PA0 A1 PA1 CS PA2 WR D7 D0 PA3 . . SCL SDA LDAC LOAD*
MAX500
A15 A0
ADDRESS BUS
8085/ 8088
WR ALE AD7 AD0 EN LATCH
ADDRESS DECODE
6809/ 6502
R/W OR E
ADDRESS DECODE
6821 6521 PA0 C32 PA1 R/W PA2 E DB7 PA3 . . DB0
MAX500
7 D0
DATA BUS
* CONNECT LOAD TO P1.3 FOR 3-WIRE MODE OR CONNECT LOAD TO VDD FOR 2-WIRE MODE
* CONNECT LOAD TO P1.3 FOR 3-WIRE MODE OR CONNECT LOAD TO VDD FOR 2-WIRE MODE
___________________Chip Topography
V OUT B V ss V OUT A V OUT D V DD V OUT C
18 V DD 17 V REF C
MAX500
LDAC 10
SDA 11
LOAD 12
SCL 13
DGND
DGND
LCC
Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time.
12 __________________Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 (408) 737-7600 1996 Maxim Integrated Products Printed USA is a registered trademark of Maxim Integrated Products.
Schematic Diagram
DS009341-1
DS009341-7
(Continued)
Note 2: For operation at elevated temperatures, these devices must be derated based on thermal resistance, and Tj max. (listed under Absolute Maximum Ratings). Tj = TA + (jA PD).
Note 3: For supply voltages less than 15V, the absolute maximum input voltage is equal to the supply voltage. Note 4: Unless otherwise specified, these specifications apply for VS = 15V, 55C TA +125C (LM741/LM741A). For the LM741C/LM741E, these specifications are limited to 0C TA +70C. Note 5: Calculated value from: BW (MHz) = 0.35/Rise Time(s). Note 6: For military specifications see RETS741X for LM741 and RETS741AX for LM741A. Note 7: Human body model, 1.5 k in series with 100 pF.
Connection Diagram
Metal Can Package Ceramic Dual-In-Line Package
DS009341-2
DS009341-5
Order Number LM741H, LM741H/883 (Note 8), LM741AH/883 or LM741CH See NS Package Number H08C Dual-In-Line or S.O. Package
Note 9: also available per JM38510/10101 Note 10: also available per JM38510/10102
Order Number LM741J-14/883 (Note 9), LM741AJ-14/883 (Note 10) See NS Package Number J14A Ceramic Flatpak
DS009341-6 DS009341-3
Order Number LM741J, LM741J/883, LM741CM, LM741CN or LM741EN See NS Package Number J08A, M08A or N08E