Parts explanation for Battery charger

Power Diode bridge

transformer (S2VB20)
(J2405)
2A type is used
This is the as current
transformer capacity. Since
which changes the current to be
AC100V into used is 500mA at
AC24V. 500mA the maximum, it
type is used as a secondary side (24V). is satisfactory also by 1A type.
The charging current is having 100 to
200mA assumed. Therefore, I made it
500mA type in consideration of the margin.

Voltage regulator (LM317) Voltage regulator (7805)

This This regulator is

regulator used in order to
is used in control the charging
order to current.
control the Originally, this
maximum regulator is the
voltage of parts for voltage
charge control. However, in
voltage. this circuit, it is used
This as a circuit which
regulator makes current regularity using the
can make output voltage variable by a property.
resistor. Please look at circuit explanation for
details.
Data sheet for LM317
Data sheet for 7805

The attachment section of a regulator is

connected to the output terminal.
Therefore, in case it attaches in a case, the
sheet for insulation is required.

Variable resister Reverse current prevention diode

 These are the Diode is
variable resisters attached to the
for setting up output circuit so
voltage and that current may
current. not flow
Since much backwards from
current does not a battery.
flow into the variable resister for voltage I am using the type of electric strength
control, it is the usual thing and does not 100V and current capacity 1A.
matter.
The charging current flows into the variable
resister for current control. Therefore, it is
necessary to use a variable resister with big
electric power capacity. I am using 2W type.

Voltmeter Ammeter

This is a This is an
voltmeter for ammeter for
supervising supervising the
output voltage. output current.
The object for The object for
30V is used. 500mA is used.

Aluminum electrolytic capacitor Resistor

These aluminum In order for the

electrolytic charging current
capacitors are to flow into R3,
used in order to it is necessary to
control the use a resistor
ripple voltage with big electric
generated when power capacity. I
AC voltage is rectified and to make it fixed am using the cement resistor of 5W type.
direct current voltage. Other resistors are satisfactory 1/4W.

In the case of the aluminum electrolytic

capacitor, the voltage of the maximum
which can be used is decided. It is
necessary to use the parts of work voltage
higher than the voltage of the circuit to
connect.

Tag block for wiring and Stud Wire rod

There are few In this circuit,

electronic parts since big current
with this does not flow,
equipment. the wire rod of
Moreover, there allowable-
are many parts current 4A is
attached in a used.
case. Therefore, how I fix parts using the
terminal for wiring without using a printed
circuit board is adopted.

Fuse Knob

The fuse is These are the

attached for knobs attached
safety. in the variable
The capacity of resister for
1A is enough. adjusting voltage
and current.
Because
adjustment is not performed frequently, it
is not inconvenient even if it does not use.

Case Metallic
ornaments for
PS-3 made by case
LEAD company is
used as the case. In my case, this
It is 160mm(W), charger is
130mm(D) and attached in the
70mm(H). stick of the iron
on the ceiling of
a garage. Therefore, I formed attachment
metallic ornaments in the upper part of a
case.
 AC100V input Plug and
cable socket for
AC100V
This is AC input
cable of a AC input cable of
charger. a charger can
also wire directly
into a case,
without using a
connector. I am using the connector in
consideration of removal of a charger.

Output cable Plug and

socket for
This is the cable output
which connects
the output of a This cable may
charger to the also wire a
battery of a car. charger directly.
It is not a special
cable. Please
choose according to your environment.

Back panel

This is the back panel.

The panel printed on paper is fixed
with a transparent acrylics board.
1. Step down AC voltage
As we are converting 220V AC into a 5V DC, first we need a step-down transformer to
reduce such high voltage. Here we have used 9-0-9 1A step-down transformer, which
convert 220V AC to 9V AC. In transformer there are primary and secondary coils which
step up or step down the voltage according to the no of turn in the coils.

Selection of proper transformer is very important. Current rating depends upon the
Current requirement of Load circuit (circuit which will use the generate DC). The
voltage rating should be more than the required voltage. Means if we need 5V DC,
transformer should at least have a rating of 7V, because voltage regulator IC 7805 at
least need 2V more i.e. 7V to provide a 5V voltage.

2. Rectification
Rectification is the process of removing the negative part of the Alternate Current (AC),
hence producing the partial DC. This can be achieved by using 4 diodes. Diodes only
allow current to flow in one direction. In first half cycle of AC diode D2 & D3 are forward
biased and D1 and D4 are reversed biased, and in the second half cycle (negative half)
Diode D1 and D4 are forward biased and D2 and D3 are reversed biased. This
Combination converts the negative half cycle into positive.

A full wave bridge rectifier component is available in the market, which consist that
combination of 4 diode internally. Here we have used this component.
3. Filtration
The output after the Rectification is not a proper DC, it is oscillation output and has a
very high ripple factor. We dont need that pulsating output, for this we use Capacitor.
Capacitor charge till the waveform goes to its peak and discharge into Load circuit when
waveform goes low. So when output is going low, capacitor maintains the proper voltage
supply into the Load circuit, hence creating the DC. Now how the value of this filter
capacitor should be calculated. Here is the formulae:
C=I*t/V
C= capacitance to be calculated
I= Max output current (lets say 500mA)
t= 10ms,
We will get wave of 100Hz frequency after converting 50Hz AC into DC, through full
wave bridge rectifier. As the negative part of the pulse is converted into positive, one
pulse will be counted two. So the Time period will be 1/100= .01 Second= 10ms
V = Peak voltage voltage given to voltage regulator IC (+2 more than rated means
5+2=7)
9-0-9 is the RMS value of transforms so peak voltage is Vrms * 1.414= 9* 1.414= 12.73v
Now 1.4v will be dropped on 2 diodes (0.7 per diode) as 2 will be forward biased for half
wave.
So 12.73 1.4 = 11.33v
When capacitor discharges into load circuit, it must provide 7v to 7805 IC to work so
finally V is:
V = 11.33 7= 4.33v
So now C = I * t / V
C = 500mA * 10ms / 4.33 = .5 * .01 / 4.33 = 1154uF ~ 1000uF
4. Voltage Regulation
A voltage regulator IC 7805 is used to provide a regulated 5v DC. Input voltage should
be 2volts more than the rated output voltage for proper working of IC, means at least 7v
is needed, although it can operate in input voltage range of 7-20V. Voltage regulators
have all the circuitry inside it to provide a proper regulated DC. Capacitor of 0.01uF
should be connected to the output of the 7805 to eliminate the noise, produced by
transient changes in voltage.
Mobile Cellphone Battery
Charging Circuit with Explanation

A mobile battery charger circuit is a device that can automatically recharge a mobile phones
battery when the power in it gets low. Nowadays mobile phones have become an integral
part of everyones life and hence require frequent charging of battery owing to longer
duration usage.

Battery chargers come as simple, trickle, timer based, intelligent, universal battery charger-
analyzers, fast, pulse, inductive, USB based, solar chargers and motion powered chargers.
These battery chargers also vary depending on the applications like mobile phone charger,
battery charger for vehicles, electric vehicle batteries chargers and charge stations.

Charging methods are classified into two categories: fast charge method and slow charge
method. Fast charge is a system used to recharge a battery in about two hours or less than
this, and the slow charge is a system used to recharge a battery throughout the night. Slow
charging is advantageous as it does not require any charge detection circuit. Moreover, it is
cheap as well. The only drawback of this charging system is that it takes maximum time to
recharge a battery.

Auto-Turn off Battery Charger

The aim of this project is to automatically disconnect a battery from the mains when
the battery gets fully charged. This system can be used to charge partially discharged
cells as well. The circuit is simple and consists of AC-DC converter, relay drivers and
charge stations.
Mobile Battery Charger Circuit

Circuit Description
In an AC-DC converter section, the transformer step-downs the available AC supply
to 9v AC at 75o mA which is rectified by using a full wave rectifier, and then filtered by
the capacitor. The 12v DC charging voltage is provided by the regulator and when the
switch S1 is pressed, the charger starts working and the power on LED glows to
indicate the charger is on.
The relay driver section consists of PNP transistors to energize the electromagnetic
relay. This relay is connected to the collector of first transistor and it is driven by a
second PNP transistor which in turn is driven by the PNP transistor.

In the charging section, regulator IC is biased to give about 7.35V. To adjust the bias
voltage, preset VR1 is used. A D6 diode is connected between the output of the IC
and a limiting output voltage of the battery up to 6.7V is used for charging the battery.

When the Switch is pushed, it latches relay and starts charging the battery. As the
voltage per cell increases beyond 1.3V, the voltage drop starts decreasing at R4.
When the voltage falls below 650 mV, then the T3 transistor cuts off and drives to T2
transistor and in turn cuts off transistor T3. As a result, relay RL1 gets de-energized to
cut off the charger and red LED1 is turned off.

The charging voltage, depending on the NiCd cell, can be determined with the
specifications provided by the manufacturer. The charging voltage is set at 7.35V for
four 1.5V cells. Currently 700mAH cells, which can be charged at 70 mA for ten hours,
are available in the market. The voltage of the open circuit is about 1.3V.

The shut-off voltage point is determined by charging the four cells fully (at 70 mA for
fourteen hours) and adding the diode drop (up to 0.65V) after measuring the voltage
and bias LM317 accordingly.

In addition to the above simple circuit, the real time implementation of this
circuit based on the solar power projects are discussed below.

Solar Power Charge Controller

The main objective of this solar power charge controllerproject is to charge a battery by
using solar panels. This project deals with a mechanism of charge controlling that will
also do over charge, deep discharge and under voltage protection of the battery. In
this system, by using photo voltaic cells, solar energy is converted into electrical
energy.

Solar Power Charge Controller

This project comprises hardware components like solar panel, Op-amps, MOSFET, diodes,
LEDs, potentiometer and battery. Solar panels are used to convert sun light energy into
electrical energy. This energy is stored in a battery during day time and makes use of it
during night time. A set of OP-AMPS are used as comparators for monitoring of panel
voltage and lead current continuously.

LEDS are used as indicators and by glowing green, indicates the battery as fully charged.
Similarly, if the battery is under charged or over loaded, they glow red LED. The Charge
controller makes use of MOSFET a power semiconductor switch to cutoff the load when
the battery is low or in overload condition. A transistor is used to bypass the solar energy
into a dummy load when the battery is fully charged and it protects the battery from getting
over charged.

Microcontroller Based Photovoltaic MPPT Charge

Controller
The aim of this project is to design a charge controller with a maximum power point
tracking based on a microcontroller

Photovoltaic MPPT Charge Controller

The major components used in this project are solar panel, battery, inverter, wireless
transceiver, LCD, current sensor and temperature sensor. The power from the solar
panels is fed to the charge controller which is then given as output into battery and is
allowed for energy storage. The output of the battery is connected to an inverter that
provides outlets for the user to access the stored energy.
The solar panel, battery and inverter are bought as the off shell parts while the MPPT
charge controller is designed and built by solar knights. A LCD screen is provided for
displaying storage power and other alert messages. The output voltage is varied by
pulse width modulation from the microcontroller to MOSFET drivers. The way to track
a maximum power point by using MPPT algorithm implementation in controller
ensures that the battery is charged at maximum power from the solar panel.

This is how one can make ones own battery charger for the mobile phones. The two
examples mentioned here can make the process easier for you. Moreover, if you have
any doubts and need help for implementing real-time projects and industrial battery
charger circuits, you can comment in the comment section below.