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LOW CARBON FOOTPRINT HYBRID
BATTERY CHARGER
FINAL PRESENTATION
Students: Blake Kennedy, Phil Thomas
Advisors: Mr. Gutschlag, Dr. Huggins
Date: May 1, 20081
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PRESENTATION OUTLINE
Project Overview
Design
Buck-Boost
Theory
Design Iterations
Closed Loop Control
Lead Acid Fast Charge IC
Results
Future Recommendations
Questions
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INTRODUCTION
Emphasize efficient energy collection
Photovoltaic arrays
Wind turbine
Minimize utility A.C. energy
Store renewable energy
Charge a mobile battery for vehicular
applications using renewable energy
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PREVIOUS RESEARCH
What has been created by others?
What is new with our project?
All systems combined to charge a vehicle battery
Utilization of battery to battery charging
How can this be done?
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AC Energy
Solar Energy Wind Energy
Max Battery Life
(On/Off)
Select Menu
Min. Charge Time
(On/Off)
Emergency
Charge
Battery Charging
(On/Off)
Percent Battery
Full
Time Remaining
Keypad
Liquid Crystal Display
Key:
= Primary Objective
= Extended Objective (if time permits)
= Power Flow
= Control Signal
Stationary Battery
Stationary Battery Charger
Mobile Battery Charger
Voltage/Current sense leads
Renewable Energy
AC to DC converter
Mobile Battery
Power Control System
Voltage/current sense leads
Microcontroller System
Voltage/Current sense leads
HIGH LEVEL SYSTEM BLOCK DIAGRAM
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LOW LEVEL FLOWCHART
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RENEWABLE ENERGY
7
Photovoltaic (P.V.) Array
BP 350J
50W, 17.5V, 2.9A at max power
Provide sufficient energy
to charge the mobile battery
given worst case conditions
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RENEWABLE ENERGY
8
Mobile Battery Load = 648 kJ
BP 350J Efficiency = 13.22 %
Worst Case: 1.470 sun hours per day
Worst Case Solar Power Energy = 206,449 J/day
Min Number of P.V. Arrays = 2.45 P.V. Arrays
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RENEWABLE ENERGY
Wind Energy
1.2 kWh/day average at 50m
Simulated with D.C. power supply
Southwest Wind Power Air-X
Start up wind speed: 7 M.P.H.
Rotor Diameter: 46 in.
Max Power: 400W @ 28 M.P.H
Vout= 24VDC
Competitive Cost
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LOW LEVEL FLOWCHART
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BUCK-BOOST THEORY
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BUCK-BOOST VERIFICATION
Simulated basic circuit using P-spice
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D1
DMBRF1045
V1
31
0
R4 100
C1
500u
200
V_BATT15Vdc
V2
TD = 0
TF = 1n
PW = 10uPER = 20u
V1 = 0
TR = 1n
V2 = 15
M1
NDP4060/FAI
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
L1
1m
1
2
R3
100
R2
.3
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BUCK-BOOST SCHEME
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Continuous mode- Inductor Current
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BUCK BOOST PSPICE SIMULATIONS
Minimum Input 6V with a 75% Duty Cycle
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BUCK BOOST PSPICE SIMULATIONS
Maximum Input 40V with a 25% Duty Cycle
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BUCK-BOOST IMPLEMENTATION
IR2113 Low-side Driver
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D1
DMBRF1045
V1
31
0
R4 100
C1
500u
200
V_BATT15Vdc
V2
TD = 0
TF = 1n
PW = 10uPER = 20u
V1 = 0
TR = 1n
V2 = 15
M1
NDP4060/FAI
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
L1
1m
1
2
R3
100
R2
.3
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BUCK-BOOST IMPLEMENTATION
IR2113 High-side Driver
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V_BATT15
V2
TD = 0
TF = 10nPW = 25uPER = 50u
V1 = 0
TR = 10n
V2 = 5.0
C1220u
VS
R3100
VBVSVS
D1DMBRF1045
R510000
V_BATT
10Vdc
VB
M2IRFP240
R410
U1IR2113
123456
7891011
VDDHINSDLINVSSHO
VBVS
VCCCOM
LO
V1
20
0
R2
.3
L1
400u
1
2
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BUCK-BOOST IMPLEMENTATION
HPCL-3120 High-side driver
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VIN
31
6-Vo
5-Vee
3-Cathode
0
2-Anode
Vcc
1
R7100 HCPL3120
M3IRFP240
L1
800u
1
2
PWM
Vee
C1
220u
200
BATT -
R2
.02
8-Vcc
D1DMBRF1045
Vcc
4
7-Vo
Vee
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BUCK-BOOST IMPLEMENTATION
Topology Change
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D41N4744A
12
0
0
M3IRF9520
C2
1n
L1
800u
1
2
C1
220u
200
Neg_Vin
D2DMBRF1045
5V
0
R2
.02
R61k
0
R7520
VIN
31
D1DMBRF1045
PWM
0
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
D31N270
12
0
C4
3300u
50
Pos_VinPos_Vin
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BUCK-BOOST IMPLEMENTATION
Optical Isolator with Linear Voltage Regulator
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M5IRF640
8-Vcc
C1
220u
200
4
C71u
L1
800u
1
2
C82.2u
Pos_Vin
7-Vo
6-Vo
M4IRF9520
R2
.02
3
5-Vee
2
3-Cathode
Neg_Vin
VIN
31
D31N4748
1
0
2-AnodeLM7915
C4
3300u
50
1
PWM
HCPL3120
C2
22n
R64.7
M3IRF9520
D2691120
R9100
-15V
D1STPS20120D
0
R7100
0
R8100
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BUCK-BOOST IMPLEMENTATION
UA78S40
Universal Switching Regulator Subsystem
Provides PWM Closed Loop Control
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BUCK-BOOST IMPLEMENTATION
Inverting Configuration
Vout = 1.25 RC1/(RC2+RC3)
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Ipk Sense 14Driver C 15
4 OpAmp Out
GND 11
3 Emitter
0
2 Diode Pos
UA78S40
PWMCt1470pF
0
RC210K
RC1110K
RC31k
Compare Neg 10
1 Diode Neg
Timing Cap 12
8 Vref OutC3
220uF
Vout
7 Opamp NegCompare Pos 9
6 OpAmp Pos
Vcc 135 OpAmp Vcc
5VSW C 16
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LOW LEVEL FLOWCHART
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STATIONARY BATTERY
Reduces mobile battery charge time
Capacity needed determined by:
What is practical from cost standpoint
Stationary battery decay vs. mobile battery
Must be at least 180Wh
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STATIONARY BATTERY
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Optima D31T
Lead Acid
75 Ah,12V
Low cost
No Memory Effect
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STATIONARY BATTERY CHARGER
Can accept max input values
Voltage: 30V (from renewable energy)
Current: 10A
Charges to maximize life
Provide over current / voltage protection to battery
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STATIONARY BATTERY CHARGER
BQ2031- Lead Acid Fast Charge IC
Automatically detects low current and switches
to trickle charge
Temperature-compensated charging
Automatically detects shorted, opened, or
damaged cells
Provides binary state of charge status
PWM Control
Two-Step Voltage Control
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STATIONARY CHARGER SCHEME
BQ2031
Two-Step Voltage Charge
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STATIONARY CHARGER SCHEME
BQ2031
Stationary battery specific configuration
Switching frequency = 100KHz
Will charge between 32 ⁰ F and 106 ⁰ F
Over current protection = 10A
Voltage regulation = 14.3 V
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STATIONARY CHARGER SCHEME
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R5
1k
M5IRF640
Ipk Sense 14
RB250k
PWM2
8-Vcc
Driver C 15
C1
220u
200
4 OpAmp Out
Pull-Down DSEL10k
16
4
C71u
GND 11
3 Emitter
L1
800u
1
2
C82.2u
0
Pos_Vin
8
7-Vo
2 Diode Pos
UA78S40
PWM
4
6-Vo
M4IRF9520
DSEL= 0 for Mode 1 Display Output (resistor to GND)
TSEL= 0 for Two-Step Voltage Charge (resistor to GND)
QSEL=0 for Two-Step Voltage Charge (resistor to GND)
IGSEL=0 for Imin= 1A
MTO=24hrs Open Circuit for Max
RT1, RT2= Charging stops when greater than 105F and restarts at 85F
RB1, RB2, RB3= Float Voltage=13.3V; IMax=10A; Battery charges at 14V
LED2
R2
.02
CT1n
3
Ct1470pF
MTO-N.C.
C6.33u
BATT +
7
5-Vee
0
10
LED2
RT10k- 110k
2
RC210K
6 COM
BATT -
3-Cathode
1
Neg_Vin
9
VIN
31
D31N4748
LED1
1
0
5
Pull-Down TSEL10k
2-Anode
RT219.2k
11
0
LM7915
COM
PWM2
RC1110K
BATT -
3
C4
3300u
50
13
3
R3
1k
RC31k
2
R4
1k
M2IRFP240
Compare Neg 10
VCC 5V
15
1
2
1 Diode Neg
1
PWM
Timing Cap 12
12
HCPL3120
C2
22n
BATT +
R64.7
8 Vref Out
LED3
C3
220uF
M3IRF9520
D2691120
Vout
R9100
7 Opamp Neg
-15V
RT1
9.4k
Compare Pos 9
BQ2031
14
D1STPS20120D
C5.1u
RB3620k
0
R7100
6 OpAmp Pos
Vcc 13
BATT -
0
Pull-Down QSEL10k
R8100
LED3
LED1
5 OpAmp Vcc
5VSW C 16
LM7805
RB1130k
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LOW LEVEL FLOWCHART
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MOBILE BATTERY CHARGER
Accepts energy from stationary battery
Must be capable of outputting
Voltage: 14.9V
Current: 4.8A
The mobile battery charger shall be capable of
charging the mobile battery within at least
12 hours
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MOBILE BATTERY
Panasonic LC-RA1212P for Gaucho 12V lead-acid battery
Rated capacity: 12Ah
Minimal charge time
2 hours 39 minutes
Maximum battery life
2-8 years
250-500 charge cycles
Constant Voltage Charge
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USER INTERFACE
Keypad input
User selects mode of charge
L.C.D. output
Battery charging indicator
Battery charge percentage indicator
Time remaining until battery charged indicator
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ACTUAL RESULTS
Buck boost topology, gate drivers, and regulation
works
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ACTUAL RESULTS
Buck- Boost Results with feedback
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ACTUAL RESULTS
BQ2031 Indicates it passes qualification tests
Still need to implement gate driver and FET
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POTENTIAL IMPROVEMENTS
Implement
Mobile Battery Charger
Microcontroller Feedback
Use switching voltage regulators instead of linear
N-channel MOSFET with floating gate drive on buck-boost
Clean up noise in voltage regulation
Create more protection circuitry
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QUESTIONS?
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STATIONARY BATTERY
Possible battery choicesOptima
Lead AcidLi-Ion Ni-CD Ni-MH
Sealed Lead Acid
Temperature Range (C) 130 to -30 50 to -20 45 to -40 50 to -20 60 to -40
Calendar Life (years) ? 2 to 5 2 to 5 2 to 5 2 to 8
Max Charge Cycles 300+ 1000+ 300 to 700 300 to 600 250 to 500
Discharge Profile Flat Slope Flat Flat FlatSelf Discharge Rate @ 20C (% /mo) Very Low 2 15 to 20 15 to 25 4 to 8
Memory Effect No No Yes Yes NoAbility to Trickle Charge Yes No Yes Yes Yes
Charging Characteristic 2 stageDeep Discharge Yes Yes Yes Yes NoRelatively Quick Charge Yes Yes Yes Yes No
Constant Voltage Or Current Charge
Voltage Voltage Current Current Voltage
Relative Expense/ Capacity Cheap Expensive Moderate Moderate CheapApprox Expense (dollars) 150 < 600 300 350 80
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STATIONARY CHARGER SCHEME
BQ2031
Configuring Charging Algorithm
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STATIONARY CHARGER SCHEME
BQ2031
Voltage and Current Monitoring
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STATIONARY CHARGER SCHEME
BQ2031
Voltage and Current Monitoring
N=6 cells
Vflt=13.3V
Vblk=14.0V
Imax=10A
Using Equations
RB1=130KΩ
RB2=50KΩ
RB3=620KΩ
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STATIONARY CHARGER SCHEME
BQ2031
Fast Charge cutoff to Trickle Charge
IGSEL = 0
Imin = Imax/10 = 10A/10 = 1A
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STATIONARY CHARGER SCHEME
BQ2031
Temperature Sensing
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STATIONARY CHARGER SCHEME
BQ2031
Setting Charging Maximum Timeout
Tmto=24hours
R=24hrs/(.5*.1uF)
= 480GΩ
Use largest resistance
possible or open circuit
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STATIONARY CHARGER SCHEME
BQ2031
Set switching frequency
Fpwm=100KHz
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MICROCONTROLLER REQUIREMENTS
Microcontroller switches IC charging mode
Feedback loop handled by IC
Keypad user input
1 port needed
LCD user output
1 port needed
Port pin IC input
3 pins needed for status
Port pin IC output
1 pin needed for switching modes
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BUCK-BOOST IMPLEMENTATION
IR2113
High and Low Side Driver
Ability to operate at 100KHz
Separate logic supply range from 3.3V to 20V
LO = Vdd = Vbatt = 12-13.5V
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