110V UNIVERSAL BATTERY CHARGING PANEL

USING PIC MICROCONTROLLER

A dissertation submitted to the
Department of Electrical Engineering, University of Moratuwa
in partial fulfillment of the requirements for the
degree of Master of Science
by
SWARNA KUMARA VIJITHANANDA
Supervised by: Dr. J.P Karunadasa
Department of Electrical Engineering
University of Moratuwa, Sri Lanka
December 2006
DECLARATION
The work submitted in this dissertation is the result of my own
investigation, except where otherwise stated.
It has not already been accepted for any degree, and is also not being
concurrently submitted for any other degree.
S.K Vijithananda
Date: \\
CM
We/I endorse the declaration by the candidate.
CONTENTS
Declaration I
Abstract IV
Acknowledgement VI
List of Figures VII
List of Tables IX
CHAPTER 1
1.00 Introduction 1
1.10 Requirement of the Project 1
1.20 Project Benefits 1
1.30 Technical Concept & Techniques 2
1.40 Project Tools & Materials 2
CHAPTER 2
2.00 Structure of the Project 12
2.10 Hardware Circuitry 13
2.11 Design of DC-DC Converter 15
2.12 Testing Circuit with 555 Timer 21
2.13 Converter Switching Amplifier Circuits 26
2.14 Overcurrent & Over/Under Voltage Circuits 30
2.20 Software Programming 34
2.21 Introduction to PIC (16F876A) Microcontroller 34
2.22 Analog to Digital Converter (A/D) Module 37
2.23 Operation in PWM Mode 45
2.24 Assembly Programs for A/D Conversion 49
& PWM operation
2.24 (i) A/D Conversion 49
2.24 (ii) PWM Operation 49
II
CHAPTER 3
3.00 Results and Practical Observation 55
3.10 Waveforms of the DC-DC Converter 55
3.20 Voltage variation of the Panel Output 60
3.30 Project Photos 64
CHAPTER 4
4.00 Practical Limitations Challenges & Difficulties 69
4.10 Technical limitations & Challenges 69
4.20 Financial Difficulties 69
CHAPTER 5
5.00 Conclusion 71
5.10 Conclusion and Remarks 71
5.20 Recommendation for Future Developments 71
References 73
Appendix A Definitions of the terms 74
Appendix B Program Codes 77
III
Abstract
Conventional power electronics and electronic control circuits have been replacing by the
intervention of the microprocessors/microcontrollers in modern industrial applications.
This is mainly because with their applications the whole systems becomes more and more
compact while enhancing the durability. On the other even with the more robust
applications hand more accurate & fine operation could achieve by using such modern
programming devices.
This project was origin from based on an actual requirement of designing 1 lOv battery
charging panel (to energize the batteries in spring charge type breakers)for electrical
engineering division of J aya Container Terminal(J .C.T) of Sri Lanka Ports Authority. But
this technique would use to not only to charge batteries of spring charge breakers , but
also batteries widely use in VHF communication hand held sets, explosive detectors,
emergency lamps, etc...
Rechargeable batteries are vital to portable electronic equipment such as laptop
computers and cell phones. Fast charging circuits must be carefully designed and
are highly dependent on the particular battery's chemistry. The most popular types
of rechargeable batteries in use today are the Sealed-Lead-Acid (SLA), Nickel-
Cadmium (NiCd), Nickel-Metal-Hydride (NiMH), and Lithium-Ion (Li-Ion). Li-Ion is
fast becoming the chemistry of choice for many portable applications because it
offers a high capacity-to-size (weight) ratio and a low self-discharge characteristic.
Depending on the battery chemistry the charging characteristics of a battery differs to
each other. In this project simply what I have done is allows the particular battery to
follow its charging characteristic curve when they where you could not find in
conventional charging techniques. The charging process is controlled by the software
program microcontroller (PIC 16F876).Since the battery chemistries are different for
different types of batteries, several sets of programs would have to written to the
controller for each battery given by the manufacturer.
IV
There are some theoretical design calculations included for designing of power
electronics modules. (DC-DC converter, square pulse generator, single rail power & dual
rail power supplies,etc...) Calculations have been done based on highly theoretical facts.
Therefore some practical observations are tends to differ from the theoretical approach.
Most of the theories studied in the power electronic lessons of my M.Sc post graduate were
widely used in doing above mentioned designs.
At the beginning the actual target was to built a battery charging panel of 110V,but due to
some limitations of purchasing of high capacity transformer which suit to this application,
the project was limited to 40V panel only. But the concept, approach & the guide line would
be more or less same for the more advanced systems also.
V
Acknowledgement
Thanks are due first to my supervisor, Dr. J .P Karunadasa, for his great insight,
perspectives, guidance and of humor. My sincere thanks go to the J CT Electrical
engineering staff of J .C.T (J aya Container Terminal) of Sri Lanka Ports Authority for
helping in various ways to clarify things related to my academic works in time with
excellent corporation and guidance. Sincere gratitude is also extended to the people who
serve in the Department of Electrical Engineering office.
I extend sincere gratitude to my superiors, Mr. A.D.T Gunasekara (Chief Electrical
Engineer of Sri Lanka Ports Authority) who made me to be released from my duties to
success this project & Mr.H.A.N.S Fernando (Deputy Chief Electrical Engineer) who
suggested this project concept for this thesis.
Lastly, I should thank many individuals, friends and colleagues who have not been
mentioned here personally in making this educational process success. May be I could
not have made it without your supports.
VI
List of Figures
Figure Page
Figure 1.3.1 Basic Functional Block 3
Figure 1.3.2 Typical Characteristics of Ni-Cd battery 4
Figure 1.3.3 Basic Software Algorithm 6
Figure 1.4.1 Pin Configuration of PIC 16F876A 8
Figure 1.4.2 Demonstration Circuit 10
Figure 1.4.3 PIC Programmer Circuit 10
Figure 2.1.14 Bridge Rectifier 13
Figure 2.1.2 DC-DC Converter Circuit 14
Figure 2.1.3 Single Rail Power Supplies 14
Figure 2.1.4 Dual Rail Power Supplies 14
Figure 2.11 (a) Dimensions of the Core 17
Figure 2.11 (b) Core Loss Curves 19
Figure 2.12 (a) Pin Configuration of 555 Timer 23
Figure 2.12 (b) Pin Data of 555 Timer 25
Figure 2.12 (c) Square Pulse Generator using 555 Timer 26
Figure 2.13 (a) Pin Configuration of TL082 family 27
Figure 2.13 (b) Internal View of TL082 28
Figure 2.13 (c) Frequency & Temperature Characteristics of TL082 28
Figure 2.13 (d) Load & Voltage Characteristics TL082 29
Figure 2.13 (e) Switching Amplifier Circuit 30
Figure 2.14 (a) Figure 2.14-(a) Pin Configuration of TL082 31
Figure 2.14 (b) Typical Characteristics of LM339 (Vcc=15v;Ta =25) 33
Figure 2.14 (b) Comparator Circuit 33
Figure 2.21 (a) Pin Configuration of PIC16F876A 34
Figure 2.21 (b) Demonstration Circuit 37
Figure 2.22(a) ADCONO Register 38
VII
Figure 2.22(b) ADC0N1 Register 40
Figure 11.2 Analog Input Model 42
Figure 11.3 A/D Conversion TAD Cycle 44
Figure 11.4 A/D Result J ustification 45
Figure 2.23(a) CCP Module in PWM Mode 46
Figure 2.23(b) PWM Output 46
Figure 2.23(c) Data of the PI C16F876A 48
Figure 3.0 (a) Voltage across the Primary Winding (Theoretical) 55
Figure 3.0 (b) Voltage across the Primary Winding (Observed) 56
Figure 3.0 (c) Current of the Primary side of the Converter (Theoretical) 56
Figure 3.0 (d) Current of the Secondary side of the Converter (Observed) 57
Figure 3.0 (e) Current through the Secondary Diode 57
Figure 3.0 (f) Duty Cycle 50% 58
Figure 3.0(g) Duty Cycle 35% 58
Figure 3.0 (h) Duty Cycle 10% 59
Figure 3.21(a) Voltmeter reading & desired value vs. time (8 hrs.) 62
Figure 3.21(b) Voltage Error vs. Time (8 hrs.) 63
Figure 3.3 (a) Switching Amplifiers 64
Figure 3.3 (b) Controller Circuit Operate with the main Panel 64
Figure 3.3 (c) Fly-Back Transformer of the Converter 65
Figure 3.3 (d) Overvoltage Comparator Circuit 65
Figure 3.3 (e) Power Transformer Output to the Dual Supply 66
Figure 3.3 (f) Top view of the Panel ' 66
Figure 3.3 (g) 3 Push Buttons Assigned for 3 Battery Types 67
& the Reset Button (left corner)
Figure 3.3 (h) 4 -Bridge Rectifier testing with a Variac 67
Figure 3.3 (i) 3 Sets of Batteries under Charging. 68
Figure Appendix A: (i) Comparator Symbol 75
VIII
List of Tables
Tabl e
Table 1: Operating characteristics of TL082
Table 2: Ratings of the LM339 comparator
Table 3: Analog / Digital channel configuration
Table 11.1: TAD vs. maximum device operating frequency
Table 3.20 Voltmeter reading during eight hours