Low Carbon Footprint Hybrid Battery Charger Project Proposal

LOW CARBON FOOTPRINT HYBRID

BATTERY CHARGER

FINAL PRESENTATION

Students: Blake Kennedy, Phil Thomas

Advisors: Mr. Gutschlag, Dr. Huggins

Date: May 1, 20081

PRESENTATION OUTLINE

Project Overview

Design

Buck-Boost

Theory

Design Iterations

Closed Loop Control

Lead Acid Fast Charge IC

Results

Future Recommendations

Questions

2

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

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?

4

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

5

LOW LEVEL FLOWCHART

6

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

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

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

9

LOW LEVEL FLOWCHART

10

BUCK-BOOST THEORY

11

BUCK-BOOST VERIFICATION

Simulated basic circuit using P-spice

12

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

BUCK-BOOST SCHEME

13

Continuous mode- Inductor Current

BUCK BOOST PSPICE SIMULATIONS

Minimum Input 6V with a 75% Duty Cycle

14

BUCK BOOST PSPICE SIMULATIONS

Maximum Input 40V with a 25% Duty Cycle

15

BUCK-BOOST IMPLEMENTATION

IR2113 Low-side Driver

16

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


IR2113 High-side Driver

17

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


HPCL-3120 High-side driver

18

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


Topology Change

19

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


Optical Isolator with Linear Voltage Regulator

20

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


UA78S40

Universal Switching Regulator Subsystem

Provides PWM Closed Loop Control

21


Inverting Configuration

Vout = 1.25 RC1/(RC2+RC3)

22

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

LOW LEVEL FLOWCHART

23

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

24

STATIONARY BATTERY

25

Optima D31T

Lead Acid

75 Ah,12V

Low cost

No Memory Effect

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

26

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

27

STATIONARY CHARGER SCHEME

BQ2031

Two-Step Voltage Charge

28


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

29


30

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

LOW LEVEL FLOWCHART

31

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

32

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

33

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

34

ACTUAL RESULTS

Buck boost topology, gate drivers, and regulation

works

35

ACTUAL RESULTS

Buck- Boost Results with feedback

36

ACTUAL RESULTS

BQ2031 Indicates it passes qualification tests

Still need to implement gate driver and FET

37

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

38

QUESTIONS?

39

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

40


BQ2031

Configuring Charging Algorithm

41


BQ2031

Voltage and Current Monitoring

42


BQ2031

Voltage and Current Monitoring

N=6 cells

Vflt=13.3V

Vblk=14.0V

Imax=10A

Using Equations

RB1=130KΩ

RB2=50KΩ

RB3=620KΩ

43


BQ2031

Fast Charge cutoff to Trickle Charge

IGSEL = 0

Imin = Imax/10 = 10A/10 = 1A

44


BQ2031

Temperature Sensing

45


BQ2031

Setting Charging Maximum Timeout

Tmto=24hours

R=24hrs/(.5*.1uF)

= 480GΩ

Use largest resistance

possible or open circuit

46


BQ2031

Set switching frequency

Fpwm=100KHz

47

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

48


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

49

Low Carbon Footprint Hybrid Battery Charger Project Proposal

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