Batteries based on the nickel-metal-hydride (NiMH) and lithium-ion (Li-ion) chemistries have

largely replaced the older nickel-cadmium (NiCd) battery in many of todays applications. Still,
NiCds are the preferred choice when high discharge currents and a rapid recharge cycle (between
one and two hours) are principal concerns.
Precautions must be taken, however, when you try to recharge a standard NiCd cell fast at
current levels that approach or exceed the rated capacity of the battery (called its C-rating). As
the battery becomes fully charged, these high-current levels (at 1C or higher) cause a rapid
increase in electrochemical reaction (oxidation/reduction) within the cell, with a corresponding
rapid increase in both internal cell pressure and temperature.
Therefore, as the cell approaches or exceeds 100% capacity, the high charging current must be
reduced or the cells overcharge safety vent may open, causing gasses to escape with a possible
loss of electrolyte. Additionally, repeated overcharging could degrade the cells lifethe useful
number of charge/discharge cyclesor even render it permanently useless.
One way to avert the potential damage that can result from repeated cell overcharging at high
currents is to monitor the differential temperature TDIFF = TB TA between the batterys surface
temperature (TB) and ambient temperature (TA) and proportionally reduce or taper the charging
current ICH as the differential temperature increases.
Consider a design that must convert a differential temperature rise (battery surface temperature
above ambient) that ranges from 0C to 5C into a charging current that decreases proportionally
from a maximum current level of 1C to 0 A. If the rated capacity of an AA cell equals 600 mAhr,
then 1C equals 600 mA. Equation 1 describes this differential-temperature-to-charging-current
system:

Figure 1a represents the differential temperature-to-charging current system to be designed. Its

main elements are a differential temperature-to-voltage converter and a voltage-to-high-current
converter.
Temperatures TB and TA are monitored separately by standard negative-temperature-coefficient
(NTC) thermistors (10 k at 25C) with corresponding resistance values of RT(B) and RT(A),
respectively (Fig. 2). Both sensor output voltages, VB and VA, are then applied to the inputs of a
basic passive adder created by R2 and R3. At TB = TA = 20C (i.e., TDIFF = 0C) VB = +2.75 V
and VA = -2.75 V, the passive adders output voltage is given by single-ended control voltage VT
= (VA + VB)/2 = (2.75 V + 2.75 V)/2 = 0 V.
When TB rises to 25C due to the initial high charging current of 600 mA and TA remains
constant at 20C (TDIFF = 5C), the sensor voltage VB = +2.50 V and VA = 2.75 V while control

voltage VT = (VA + VB)/2 = (2.75 V + 2.50 V)/2 = -0.125 V. As a result, the output of the
passive adder produces a value for VT that is inversely proportional to TDIFF, (Fig. 1b):

The voltage-to-high-current converter circuitry around IC1, whose output current is directly
proportional to VT, has both scale and offset capabilities and therefore can be designed to deliver
the needed charging current ICH to the battery (Fig. 1c). Circuit performance is described
analytically by:

Before proceeding, we can check the validity of this design by convolving Equation 2 with
Equation 3 to reproduce Equation 1:

Begin the design implementation with TDIFF at 0C where VT = 0 V. VSET is chosen to equal 1.25
V, the maximum charging current is set at 600 mA, and the RSET resistor value is determined by
letting RSET = VSET/ICH = 1.25 V/600 mA = 2 (2 W). When the differential temperature TDIFF
rises to 5C and VT = -125 mV, the value of VSET will have linearly decreased to 0 V, causing
ICH to drop to approximately 0 A, terminating the high-current charge. The performance equation
for this voltage-to-high-current converter is given by.

However, dividing both sides of the equation by RSET yields the more useful form for design:

Final component selection for this converter is accomplished by comparing both offset and scale
terms of the design equation (Equation 3) with the converters corresponding performance
equation terms in Equation 4b. Set feedback resistor R6 to 100 k, 1% and equate offset terms in
Equation 5. Then solve for the value of R5 by choosing 5 V for VREF.

The calculated value of R5 (416.67 k) is approximated by choosing a standard 412 k, 1%

resistor. Finally, calculate the value of R7 by comparing scaling terms in.

The calculated value of R7 is 11.96 k, which can be satisfied with a standard 12-k, 5%
resistor. Circuit performance was simulated and verified by laboratory measurement over
multiple charge/discharge cycles.

2. The voltage outputs corresponding to thermistor resistances RT(A) and RT(B) are summed in
passive adder IC1. This output difference varies from 125 mV to 0 V as the temperature rises
from 0C to 5C..
Reference
Villanucci, Robert S. and Diecidue, Joseph, Intelligent NiCd Charger Avoids Battery Damage
from High Currents, Electronic Design, May 8, 2008, p 51-54,
http://electronicdesign.com/power/intelligent-nicd-charger-avoids-batter...
Robert S. Villanucci, professor (retired), holds an AEng from the Wentworth Institute of
Technology, Boston, Massachusetts, a BSET from Northeastern University, and an MSEE from
Tufts University, Medford, Mass.

Joseph Diecidue, electronics technician, holds a BSEE from the Wentworth Institute of
Technology, Boston, Massachusetts.