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CERTIFICATION BY SUPERVISOR
I hereby certify that this project work was carried out under my
supervision. I therefore approve that the work is adequate in scope
and quality for the partial fulfillment of the requirement for the award
of a Higher National Diploma (HND) in Electrical/Electronics
Engineering.
SUPERVISOR:
F. E. YEBOAH
SIGN.
DATE
DEDICATION
This project is dedicated to our beloved parents: Mr. and Mrs.
Kommey, Asiedu, Andoh for their untiring love and support
throughout our educational life. Also, our sincere thanks and
dedication goes to all those who supported us through advices and
finances.
II
DECLARATION
I Kommey, Andoh, Asiedu. Declares that the work was undertaken
whilst in Accra Polytechnic.
I further affirm that, this work so far as I know has not been
submitted to any institution for the award of any certificate and the
source of information has been fully acknowledged
NAME:
SIGN:
Andoh Richmond
III
ACKNOWLEDGEMENT
To GOD be the glory for HIS grace, wisdom, guidance and counsel
which enabled us to produce this work. Our second appreciation
and gratitude goes to our supervisor Mr. F.E. Yeboah the H.O.D. of
Electrical/Electronics Engineering Department whose guidance
enabled us to complete this project
Our profound thanks also goes to Sylvester Delali Dordzi who
through his timeless efforts helped us to build this circuit. Also, to
Calculus, Mrs. Gladys and Mrs. Comfort6 for their financial support
offered us. May the ALMIGHTY GOD bless them.
IV
ABSTRACT
The project in question is a Universal Transformerless Battery
Charger. The charger charges any type of battery irrespective of the
voltage of the battery or the ampage needed by the battery for
charging.
The charger comes with an amp meter which indicated the amount
of current drawn from it as well as a cooling system to maintain less
power loss and ensure maximum performance.
The battery charger charges all kinds of batteries from normal Lead
acid batteries to Gelled maintenance free batteries.
The charger also comes with a volt meter to indicate whether the
battery is fully charged or not.
TABLE OF CONTENTS
CONTENT
PAGE
CHAPTER ONE
1.1
INTRODUCTION
1.2
BACKGROUND
1.3
DEFINATION
1.4
OBJECTIVES
1.5
SIGNIFICANCE OF STUDY
1.6
METHOLOGY
CHAPTER TWO
2.1
STAGES OF OPERATION
2.2
SWITCHING
2.3
17
2.4
RECTIFICATION
30
2.5
SMOOTHING
35
2.6
OVERLOAD PROTECTION
38
CHAPTER THREE
3.1
44
3.2
COMPONENT LIST
45
3.3
CABLE SELECTION
47
3.4
RECORMENDERED LOAD
48
3.5
LIMITATIONS
49
CHAPTER FOUR
VII
CHAPTER ONE
1.1 INTRODUCTION
Over the years charging of automobile batteries has been very
challenging considering the variety of batteries and their charging
requirement. For example Flooded Lead acid batteries and Deep
Cycle maintenance free batteries are totally different. This is
because the flooded Lead acid battery needs more hash power than
the maintenance free batteries. The common method mostly used is
the transformer Rectifier Charger which is not designed to suit a
particular Battery. The transformer or diode would burn instead of
just releasing what ever is available at that time, it would force to
charge the battery and so ending up burning.
But for this project, Universal Transformerless Multi purpose
charge, no matter the number of batteries theres no fears, because
if takes it time to release power for charging according to the type of
batteries connection and the sum up voltage of the Batteries.
1.2 BACKGROUND
Over the last two decades decade, the conversional transformer
charger has been the main system for charging Automobile
batteries.
This charger came with a lot of limitations like
1. Overheating: this was as a result of mismatch between the
rating of the charger and the current drawn by the battery for
charging.
2. High Power loss: this was due to the overheating of the
transformer and the rectifier.
3. Limited Voltage Rating: this is because the output voltage
rating was already determined by the transformer and couldnt
be extended to suit a different voltage rating.
To eliminate this problem, the need for a charging system which is
void of this entire problem was invented. The new charging system
(Universal Transformerless Battery Charger) was invented to
increase the voltage rating range and also help reduce the amount
of power needed to charge an automobile battery.
1.3 DEFINITION
The Universal Transformerless Battery Charger is a lightweight,
efficient, transformerless battery-charging system especially for use
with electric vehicles and the charging of automobile batteries
wherein a switching regulator (ac capacitor) stores only a fraction of
the energy in each charging pulse, and much of the charging energy
is supplied directly from that power line and never stored in the
charger but is then rectified by a bridge diode to change it from the
AC(alternating current) pulse to DC(direct current) for usage.
1.4 OBJECTIVES
This project is designed to reduce the casualty of Battery Charger
burning because more current was demanded by a battery. If also
seeks to make battery charging easy by making it charge battery
bank arrangements from 12V DC to 220V DC without altering any
change operational wise or replace any component before achieving
the desired output voltage rating needed for charging any battery. It
also seeks to reduce cost and weight of battery charger making it
mobile and cheap.
1.6 METHODOLOGY
220 volts AC is connected in series to a capacitor making the AC tire
which passes through the capacitor to make behave like a pulse
which created when a capacitor charges but are discharge. Since
power cannot pass through the charger but only store electrical
power. The output from the capacitor is series to the rectifier,
changes the power to zero Hz making it conductive for battery
charge. The diode only used power stored in the capacitor. This
procedure continues until capacitor charges to full charge.
All important information needed for this project to takeoff was
acquired form two main source namely primary and secondary
sources.
Primary source were sources were the personal interactions with my
supervisor and workers of a well equipped and well knowledgeable
on this project.
Secondary sources were the research at the library and the internet.
CHAPTER TWO
2.1
STAGES OF OPERATION
Switching
(b)
(c)
Rectification
(d)
Smoothing
(e)
Overload Protection
RELAYS
A relay is an electrical switch that opens and closes under the
control of another electrical circuit. In the original form, the switch is
operated by an electromagnet to open or close one or many sets of
contacts. It was invented by Joseph Henry in 1835. Because a relay
is able to control an output circuit of higher power than the input
circuit, it can be considered to be, in a broad sense, a form of an
electrical amplifier.
OPERATION
When a current flows through the coil, the resulting magnetic field
attracts an armature that is mechanically linked to a moving contact.
The movement either makes or breaks a connection with a fixed
contact. When the current to the coil is switched off, the armature is
returned by a force approximately half as strong as the magnetic
force to its relaxed position. Usually this is a spring, but gravity is
also used commonly in industrial motor starters. Most relays are
manufactured to operate quickly. In a low voltage application, this is
to reduce noise. In a high voltage or high current application, this is
to reduce arcing.
If the coil is energized with DC, a diode is frequently installed across
the coil, to dissipate the energy from the collapsing magnetic field at
deactivation, which would otherwise generate a spike of voltage and
might cause damage to circuit components. Some automotive relays
already include that diode inside the relay case. Alternatively a
contact protection network, consisting of a capacitor and resistor in
series, may absorb the surge. If the coil is designed to be energized
with AC, a small copper ring can be crimped to the end of the
solenoid. This "shading ring" creates a small out-of-phase current,
which increases the minimum pull on the armature during the AC
cycle
1.
2.
3.
4.
10
5.
6.
7.
8.
9.
12
APPLICATIONS
Relays are used:
14
Regulatory approvals
16
CAPACITOR
A capacitor is an electrical/electronic device that can store energy
in the electric field between a pair of conductors (called "plates").
The process of storing energy in the capacitor is known as
"charging", and involves electric charges of equal magnitude, but
opposite polarity, building up on each plate.
Capacitors are often used in electric and electronic circuits as
energy-storage devices. They can also be used to differentiate
between high-frequency and low-frequency signals. This property
makes them useful in electronic filters.
Capacitors are occasionally referred to as condensers. This term is
considered archaic in English, but most other languages use a
cognate of condenser to refer to a capacitor.
Capacitor types
Practical capacitors are available commercially in many different
forms. The type of internal dielectric, the structure of the plates and
the device packaging all strongly affect the characteristics of the
capacitor, and its applications.
18
AC CAPACITOR
Capacitors do not behave the same as resistors. Whereas resistors
allow a flow of electrons through them directly proportional to the
voltage drop, capacitors oppose changes in voltage by drawing or
supplying current as they charge or discharge to the new voltage
level. The flow of electrons through a capacitor is directly
proportional to the rate of change of voltage across the capacitor.
This opposition to voltage change is another form of reactance, but
one that is precisely opposite to the kind exhibited by inductors.
Expressed mathematically, the relationship between the current
through the capacitor and rate of voltage change across the
capacitor is as such:
21
As you might have guessed, the same unusual power wave that we
saw with the simple inductor circuit is present in the simple capacitor
circuit, too: (Figure below)
23
Capacitive reactance.
24
However, we need to keep in mind that voltage and current are not
in phase here. As was shown earlier, the current has a phase shift of
+90o with respect to the voltage. If we represent these phase angles
of voltage and current mathematically, we can calculate the phase
angle of the capacitor's reactive opposition to current.
25
26
HAZARDS AND SAFETY
Aging Capacitor
The capacitance of certain capacitors decreases as the component
ages. In ceramic capacitors, this is caused by degradation of the
dielectric. The type of dielectric and the ambient operating and
storage temperatures are the most significant aging factors, while
the operating voltage has a smaller effect. The aging process may
be reversed by heating the component above the Curie point. Aging
is fastest near the beginning of life of the component, and the device
stabilizes over time.[2] Electrolytic capacitors age as the electrolyte
evaporates. In contrast with ceramic capacitors, this occurs towards
the end of life of the component.
28
REVIEW:
29
2.4 (c)Rectification
After the capacitor had stored the power it now necessary to rectify
the out put from AC to DC for easy acceptance by the battery for
charging.
Rectification
The purpose of the rectifier section is to convert the incoming
ac power source via the capacitor to change it to some kind of
pulsating dc. That is, it takes current that flows alternately in
both directions as shown in the first figure to the right, and
modifies it so that the output current flows only in one direction,
as shown in the second and third figures below.
The circuit required to do this may be nothing more than a
single diode, or it may be considerably more complex.
However, all rectifier circuits may be classified into one of two
categories, as follows:
30
Full-Wave Rectifiers.
The more common approach is to manipulate the incoming ac wave
so that both halves are used to cause output current to flow in the
same direction. The resulting waveform is shown to the right.
Because these circuits operate on the entire incoming ac wave, they
are known as full-wave rectifiers.
Rectifier circuits may also be further classified according to
their configuration, as we will see below.
31
Bridge Diode
A bridge diode or bridge rectifier is an arrangement of four diodes
connected in a bridge circuit that provides the same polarity of
output voltage for any polarity of the input voltage. When used in its
most common application, for conversion of alternating current (AC)
input into direct current (DC) output, it is known as a bridge rectifier.
The bridge rectifier provides full wave rectification from a two wire
AC input (saving the cost of a center tapped transformer) but has
two diode drops rather than one reducing efficiency over a center
tap based design for the same output voltage.
Full-wave Rectifier
The half-wave rectifier chopped off half our signal. A full-wave
rectifier does more clever trick: it flips the - half of the signal up into
the + range. When used in a power supply, the full-wave rectifier
allows us to convert almost all the incoming AC power to DC. The
full-wave rectifier is also the heart of the circuitry that allows sensors
to attach to the RCX in either polarity.
A full-wave rectifier uses a diode bridge, made of four diodes, like
this:
So, if we feed our AC signal into a full wave rectifier, we'll see both
halves of the wave above 0 Volts. Since the signal passes through
two diodes, the voltage out will be lower by two diode drops, or 1.2
Volts.
AC Wave In:
34
2.5 (d)Smoothing
Most circuits will require 'smoothing' of the DC output of a rectifier,
and this is a simple matter since it involves only one capacitor, as
shown below
35
Ripple
If the voltage peaks from the rectifier were not continually charging
up the capacitor, it would eventually discharge and the output
voltage would decrease all the way down to 0V. The discharging
that does occur between peaks gives rise to a small 'ripple' voltage.
The amount of ripple is affected by a combination of three factors:
36
the more charge it can store, and the slower it will discharge.
Therefore, smoothing capacitors are normally electrolytic
capacitors with values over 470F.
peaks from the rectifier, the more often the capacitor will be
charged, and the lower the ripple voltage will be.
If you want to calculate the ripple voltage, you can use this
formula...
2.6
Since the output power of the charger for charging has limitations, it
is important to protect the out put against overloading.
The input of the charger is protected with an appropriate circuit
breaker to prevent the charger from drawing more than 10 Amps.
When the charger draws 220V at 10A the maximum output power
would be
Voltage x Current =
CIRCUIT BREAKER
A circuit breaker is an automatically-operated electrical switch
designed to protect an electrical circuit from damage caused by
overload or short circuit. Unlike a fuse, which operates once and
then has to be replaced, a circuit breaker can be reset (either
manually or automatically) to resume normal operation. Circuit
breakers are made in varying sizes, from small devices that protect
an individual household appliance up to large switchgear designed
to protect high voltage circuits feeding an entire city.
38
ORIGINS
An early form of circuit breaker was described by Edison in an 1879
patent application, although his commercial power distribution
system used fuses. Its purpose was to protect lighting circuit wiring
from accidental short-circuits and overloads.
OPERATION
All circuit breakers have common features in their operation,
although details vary substantially depending on the voltage class,
current rating and type of the circuit breaker.
The circuit breaker must detect a fault condition; in low-voltage
circuit breakers this is usually done within the breaker enclosure.
39
40
42
43
CHAPTER THREE
3.1
Pulse
Changer
Capacitor
220
Volts AC
Source
Rectifier
To
Battery
220V IN
+Ve
F1
D1
C2
0V
D2
C3
C1
RLY1
0V
S1
S2
44
3.2
COMPONENT LIST
PARTS
220VAC brushless Fan
AC light
C1,C2
QUANTITY
1
1
2
DESCRIPTION
Force Air Cooling system
Power on indicator
450uF 50VAC AC capacitor
C3
450V/330UF
S1,S2
F1
current
Measuring Output Current
8811 MEXICO 8278909
1
2
DC.
Measuring Output voltage
60Amps connectors
5 Grill
1
1
DC output connection
Cover for FAN
Heatsink
45
DC cable
Battery tags
RLY1
DC output connection
DPDT Switch
single pole double throw
switch with10Amps contact
NOTE:
R
RESISTOR
CAPACITOR
TRANSFORMER
D -
DIODE
TRANSISTOR
ZD-
ZINER DIODE
COMPONENTS SELECTION
For this project the rectifier is to be selected carefully because they
determine the output current and the use of inferable quality would
prevent max output.
46
3.3
CABLE SELECTION
47
CHAPTER FOUR
4.1
LIMITATIONS
48
4.2
CIRCUIT CONSTRUCTION
This circuit was first divided into two parts and each stage was
carefully tested with electronics schematic stimulation software and
then assembled.
This circuit was finally tested after all the two parts were puts
together to check and correct its short falls.
Much consideration was given to meter readings or voltages and
current.
49
4.3
50
4.4
PRECAUTIONS
51
4.5
CONCLUSION
The use of this type of charger can be dangerous and also friendly
provided it is used correctly.
This charger can be used to charge any battery no mater the
voltage or current demanded.
The use of this could reduce cost, since it is void of burning as
compared to the chargers which uses transformers.
52
SUMMARY
53
RECOMMENDATIONS
54
REFERENCES
1.
2.
Credits to:
The Great Battery Shootout" by Dave Etchells
AN913: Switch-Mode, Linear, and Pulse Charging
Techniques for Li+ Battery in Mobile Phones and
PDAs" Maxim 2001
A New Pulse Battery Charger" by Jean-Michel Cour
fast pulse battery charger" patent 2003
Battery charger with current pulse regulation"
patented 1981 United States Patent 4355275
Pulse-charge battery charger" patented 1997 United
States Patent 5633574
Pulse Maintenance charging."
The pulse power(tm) battery charging system"
Negative Pulse Charge, or "Burp" Charging: Fact or
Fiction?"
Tech Brief: Negative Pulse Charging Myths and Facts
and Negative Pulse Charging: Myths and Facts
55