Smart Solar Battery Charger

Design Review
Christine Placek
Philip Gonski
TA: Bob Schoonover
Project #4
C 44!
"ebr#ar$ %%& %''(
I. Introduction
)* Title: Smart Solar Battery Charger
"or o#r project we +eci+e+ #pon b#il+ing a s,art solar batter$ charger*
Rechargeable batter$ #sage has +ra,aticall$ increase+ over the last -ew $ears +#e
to +evices s#ch as cell phones& PDAs& an+ ,p. pla$ers* Cons#,ers ,#st
constantl$ be charging these +evices at ho,e to obtain j#st a -ew ho#rs o- working
-#nctionalit$* /e ,ean to +esign a solar powere+ s$ste, that wo#l+ enable the
cons#,er to charge #p virt#all$ all o- his s,all electronic e0#ip,ent via solar
power* This project has a+vantages -or both the cons#,er an+ the environ,ent*
/e chose to #n+ertake this project beca#se we saw a nee+ in the ,arket -or an
alternative energ$ +evice that can charge +i--erent t$pes o- batteries* Also& this
project will incorporate both o- o#r specialties in lectrical ngineering: power
an+ circ#itr$*
2. Objectives
1#r goal is to #se solar power to charge nickel an+ lithi#,2ion batteries* The #ser
will inp#t the batter$ t$pe* 3sing the o#tp#t o- the solar panel an+ the #ser inp#t&
a ,icroprocessor will +eter,ine the correct voltage an+ c#rrent -or charging that
speci-ic batter$* The charging stat#s will be +ispla$e+ -or the #ser* A te,perat#re
sensor will be #se+ to stop charging i- the batter$ gets too hot*
Benefits:
li,inates nee+ -or ,#ltiple chargers
Provi+es protection o- batter$ -ro, environ,ent
--icient #se o- energ$
o Solar2powere+
o A#to,atic sh#t2o--
Convenient 4 can be #se+ wherever a+e0#ate light is present
Features:
Can charge an$ nickel or lithi#,2ion batter$
Solar2powere+
Displa$s charging stat#s
Te,perat#re ,onitoring
%
II. esign
)* Bloc! iagram




2. "odule escri#tions:
$. %ser In#ut
The operator o- the +evice will choose the che,istr$ o- the batter$ he
wishes to charge* This will +eter,ine the correct voltage that his +evice
nee+s as well as an$ necessar$ c#rrent li,its that nee+ to be s#pplie+ to
co,pensate -or the resistance o- the batter$*
%* "icro#rocessor
The ,icroprocessor is the brain o- o#r +evice* 5t will ,anage the #ser
inp#t an+ also respon+ to the -ee+back loop o- the sensing #nit* Th#s& it
will be able to +eci+e #pon these variables which signals will be sent to the
charging #nit& as well the 6D +ispla$s* 7ost i,portantl$& it will
+eter,ine the voltage an+ c#rrent re0#ire,ents that will have to be ,et -or
each +i--erent t$pe o- che,istr$ that the #ser can inp#t* 5n this sense& it will
control all o- the -#nctionalities o- the +evice*
.* is#lay
This #nit will +ispla$ the c#rrent stat#s o- the batter$ an+ will in-or, the
#ser whether or not it is +one charging* Also& we ,a$ a+apt its
-#nctionalities to incorporate a +ispla$ -or the #ser to see which batter$ is
c#rrentl$ selecte+ -or charging*
4* Charging unit
.
The charging #nit will react to the inp#t that it receives -ro, the
,icroprocessor* A signal will be sent telling the charging #nit e8actl$ what
is re0#ire+ -or the charging o- the batter$*
!* Solar &anel
5n o#r +esign& the solar panels will -#nction as a power s#ppl$ to o#r
circ#it* 5t will receive light -ro, the s#n an+ convert this to energ$ an+
th#s voltage* This voltage will then be #se+ to operate the 5Cs as well as be
the so#rce o- the c#rrent an+ voltage that the charging #nit will receive*
9* Sensors
Te,perat#re will be ,onitore+ in o#r +evice via the sensors* This is then
,a+e into a -ee+back loop -ro, the batteries to the ,icroprocessor in or+er
to ,ake s#re the circ#it r#ns in an e--icient ,anner within allowe+ li,its*
/e ,a$ also a++ polarit$ checking to ,ake s#re the batter$ is connecte+
the right wa$*
(* Battery
The batter$ in o#r +evice is the en+ b$pro+#ct o- all o- o#r other +evices* 5t
will be a rechargeable nickel2ca+,i#,& nickel ,etal h$+ri+e& or lithi#,2
ion batter$*
'. &erformance (e)uirements
Charge an$ nickel or lithi#,2ion batter$ -ro, '24:
1perates #n+er nor,al s#nlight con+itions
1perates #n+er other light con+itions ;e*g* in+oors<& perhaps with li,ite+
capabilit$
III. *erification
$. Testing &rocedures
Charging #nit o#tp#t
/e will hook #p a -#nction generator to si,#late the s#nlight an+ test the
charging #nit ;the 7A=)!')<* /e will ,onitor the o#tp#t o- the charging
#nit with no batter$ connecte+ to -in+ the ,a8i,#, no loa+ voltages an+
c#rrents* A-ter these ,a8i,#, val#es are -o#n+& we will si,#late b$
#sing vario#s resistances connecte+ at the >batter$ ter,inals> to si,#late
the a--ect o- having the batter$ in place* The voltage an+ the c#rrent going
into the circ#itr$ will be varie+ an+ ,eas#re,ents will be taken at the
BATT o#tp#t o- the 7A=)!') in or+er to +eter,ine whether or not the
correct val#es are being o#tp#tte+* This will also help #s to +eter,ine
whether or not ,#ltiple solar cells will be nee+e+ in or+er to achieve
-#nctional charging since o#r cell o#tp#ts a t$picall$ low c#rrent o-
)'',A* Th#s& this will help #s to +eter,ine e8actl$ what si?e an+ val#es
o- solar cells we nee+ in or+er to achieve no,inal o#tp#t para,eters o- the
7A=)!')*
4
Solar panel o#tp#t
/e will ,eas#re the c#rrent@voltage o#tp#t o- the solar panel -or vario#s
light intensities& #sing +i--erent t$pes o- arti-icial light& as well as s#nlight
at vario#s ho#rs o- the +a$ #sing o#r oscilloscope* B$ +oing this& we can
obtain average val#es -or the c#rrent an+ voltage that o#r solar panel will
o#tp#t to the chips* Th#s& we will be able to see how the chip itsel- will
respon+ to this variance an+ i- we nee+ a +i--erent rating o- solar panel*
/e also will -in+ a wa$ to ,eas#re the light intensit$& either with a light2
intensit$ ,eter or an electronic co,ponent that respon+s to light* Snell>s
6aw will also be applie+ b$ var$ing the angle o- inci+ence between the
panel an+ the s#n* Th#s& we will co,p#te the critical angle at which light
is re-lecte+ instea+ o- absorbe+ b$ the solar cells*
Charge c$cle
/e will ,onitor a batter$ thro#gho#t a charge c$cle& ,aking s#re the
voltage@c#rrent is alwa$s correct an+ that charging is within o#r +esire+
para,eters* "or 6iA an+ Bi batteries we ,#st ens#re that the c#rrent is
aro#n+ the !'',A o#r chip will be progra,,e+ to o#tp#t* The voltage
being o#tp#tte+ -or 6iA batteries ,o+e sho#l+ be aro#n+ 4*% when it is
charge+& while -or Bi batter$ ,o+e& it sho#l+ be aro#n+ 4*C! when
charge+*
Te,perat#re C$cle
/e will connect batteries o- vario#s te,perat#res an+ ,ake s#re the
charging #nit o#tp#ts the correct c#rrent in response to the batter$Ds
resistance change* The 67.! Te,perat#re sensor will be #se+ to ens#re
that the te,perat#re +oes not reach a critical point where the circ#it wo#l+
be +a,age+* Th#s& o#r co,plete circ#it will be s#bjecte+ to +i--erent
te,perat#res to ens#re that the c#rrent an+ voltage being o#tp#t b$ o#r
7A=)!') chip is within charging para,eters o- the batteries*
Special batter$ cases
/e will connect batteries at vario#s states o- being charge+& an+ +ea+
batteries& to ,ake s#re the charger respon+s correctl$ an+ is still able to
reach +esire+ ,a8i,#, charging e--iciencies*
2. Tolerance +nalysis
The ,o+#le that ,ost a--ects the operation o- the +evice is the solar panel* 5- the
solar panel +oes not work& the +evice will not be able to t#rn on or charge batteries
at all* The +evice sho#l+ be able to work over a large range o- light levels& so we
will test to -in+ no,inal light con+itions -or e--ective charging& an+ veri-$ that it
charges #n+er a variet$ o- light con+itions* This will be +one b$ ,onitoring the
charger>s c#rrent an+ voltage o#tp#t #n+er +i--erent ,eas#re+ light intensities*
Angle will also be o- critical i,portance since via Snell>s 6aw there will be an
angle between the cells an+ the s#n at which no power can be o#tp#tte+*
!
I*. Schematics,esign etails
$. Charging %nit

To per-or, o#r charging& we have selecte+ a chip& the 7A=)!')* The 7A=
)!') is an intelligent& constant2c#rrent& constant2voltage& te,perat#re2reg#late+
batter$ charger* 5t can charge 6i& Bi7E& an+ BiC+ batteries all within the
reg#late+ charging para,eters speci-ie+ b$ the +i--erent che,istries o- the batter$*
5t accepts a 4*!2).:olt s#ppl$ with t$pical val#es being aro#n+ !v* This +esign
constraint works well with o#r +esign since we will get appro8i,atel$ 4*!2(: o#t
o- o#r solar cells* This cell pre+o,inatel$ works b$ #sing a+j#stable -ast
charging ,etho+s& which achieves lowest ti,e to charge& b#t also +ecreases the
charge level o- the batter$* 7ost re-erences state that -ast2charging onl$ charges
batteries #p to ('F o- capacit$* Eowever& this is not that i,portant sho#l+ the
#ser +esire to #se his +evice while it is also charging* The cell also #ses topping
o-- techni0#es which increases the batter$ li-e2span* "or clarit$& the pins are
liste+ below with +escriptions in or+er to -#ll$ #n+erstan+ the inner workings o-
the chip an+ o#r +esign*
+. Pin descriptions of 1501
I-& .#in$/
9
Eigh inp#t charger inp#t* This will accept the inp#t -ro, the solar cells in
ter,s o- voltage an+ c#rrent* The voltage level ,#st be between 4*!2
).:olts in or+er to power the logic insi+e the chip* The inp#t c#rrent that
the chip nee+s is aro#n+ 4*!,A which is likewise receive+ -ro, the solar
cells*
I- .#in2/
6ow c#rrent charger inp#t* This is connecte+ to 5BP an+ th#s the solar
cells an+ is #se+ to power the internal 6D1 an+ re-erences* 5B also will
+raw c#rrent when +evice is in sh#t+own
0- .#in'1$'/
S2TI .#in3/
The charging voltage o- the che,istr$ o- the batter$ is reg#late+ via
,o+i-$ing the resistance Rseti which co,es o#t o- the ST5 pin;4<* This
is governe+ via the e0#ation :
RsetiG)'''H;)*4:@5batt<
Th#s& i- we choose to charge the batter$ aro#n+ !'',A or '*!C accor+ing
to so,e re-erences we wo#l+ th#s nee+ a resistance val#e o- aro#n+ %*Ik*
This is liste+ as the opti,al c#rrent that can be #se+ to charge batteries&
since the lower charge c#rrent re+#ces the ti,e at which the cell will
resi+e at 4*%'volts* This was also chosen since o#r solar cells inp#t ver$
low c#rrent into the chip* The lower charge c#rrent re+#ces the ti,e in
which the cell resi+es at 4*%': B$ #sing this low c#rrent& we will also
lose less power to +issipation* Perhaps the greatest reason -or choosing
this low charging c#rrent wo#l+ be the -act that solar cells +o not o#tp#t
a+e0#ate c#rrent that wo#l+ enable #s to charge at an$ -aster rate than
!'',A*
*4 .#in5/ and S24* .#in$3/
Together these #ins o#erate to select the battery voltage that 6ill be
used. They function together according to the follo6ing table:
S24* Connection
Charge "ode GBD :6
6i 4*): 4*%:
Bi7E@BiC+ 4*!: 4*C!:
"ro, this chart& the #ser is given +i--erent options o- voltages that can be
#se+ to charge #p the speci-ie+ batteries* "or o#r +esign& we will be #sing
the option o- connecting the S6: pin to the :6 pin* "ro, research&
,ost 6i batteries are charge+ to 4*% volts with a tolerance o- A@2 *'!:@cell*
Ea+ we connecte+ this pin to GBD& the charge wo#l+ have been re+#ce+
b$ )'F total& $et the total li-espan o- the batter$ wo#l+ increase* This is
(
,ostl$ relate+ to the -act that ,ost o- o#r re-erences citing #sing aro#n+
4*% volts to charge #p lithi#, ion batteries* 6ikewise& this sho#l+ also
help +ecrease the total charging ti,e b$ allowing the batter$ to reach
charge+ levels 0#icker* "#ll charge is attaine+ a-ter the voltage threshol+
has been reache+ an+ the c#rrent has +roppe+ to .F o- the rate+ c#rrent or
has levele+ o--* Re-er to appen+i8 -or charge c$cle graph*
T"+7 .#in8/
This is the ti,e li,it place+ on the chip to ens#re ,a8i,#, sa-et$ -ro,
overcharging the batter$& as well as i,proving e--icienc$* 5- T7A= is
connecte+ to gro#n+& the charge ti,e is .hrs& i- -loating& 4*!hrs& an+ i-
connecte+ to :6& 9hrs* "or o#r +esign& we will leave T7A= -loating to
achieve a ,e+ian val#e o- charging to ti,e to leave plent$ o- roo, -or
error in o#r +esign*
F%44I .#in9/
This selects the val#e o- the top2o-- c#rrent -or the batter$ charging as a
percentage o- -ast2charge c#rrent* 5n o#r +esign we will +esign -or .'F
top2o-- o- ,a8i,#, c#rrent since this will 0#icken the ti,e* To achieve
this val#e& the connection is le-t -loating*
T2"& .#in:/
The operation o- this pin -#nctions to reg#late the ,a8i,#, +ie2
te,perat#re reg#lation point -or ther,al control* /e chose to leave this
connection -loating& which& accor+ing to the +ata sheets& will set the
reg#lation to ))!C which sho#l+ be ,ore than eno#gh roo, -or o#r +esign
to operate in stan+ar+ con+itions*
"O2 .#in;/1 C<02- .#in$=/
71D an+ CEGB are #se+ to select which t$pe o- batter$ is being
charge+* The ,icroprocessor will sen+ the correct signals to these pins
+epen+ing on what t$pe o- batter$ the #ser has selecte+*
"O2 .C<02-/> ."O2/>
6i Charge ' '
Bi7E@BiCD ' )
Disable ) '
Bo batter$ ,o+e ) )
+CO? .#in$$/
AC1J o#tp#ts low i- the voltage on 5B is between 4*% an+ 9*%!: an+
greater than the batter$ voltage b$ at least '*):* Th#s& AC1J checks to
,akes s#re the inp#t voltage is within an acceptable range to charge the
batter$* AC1J is connecte+ to the ,icroprocessor& which will give an
error ,essage i- the inp#t voltage ;i*e*& the solar panel o#tp#t< is not high
eno#gh* The spec re0#ires that AC1J has a )''k p#ll#p resistor*
I
B+TT .#in$2/
1#tp#t o- chip to be connecte+ to batter$ being charge+* Re0#ire+ b$ spec
to have a )'#" capacitor -or o#tp#t voltage stabilit$* 1#tp#ts 4*)4I2
4*%!%: -or 6iA batter$& 4*I!2!*'!: -or Bi* Charge c#rrent varies& b#t is
ro#ghl$ !%!,A -or both batter$ t$pes +#ring -ast charging ,o+e*
(42 .#in$5/
R6D is connecte+ to the ano+e o- an 6D whose catho+e is p#lle+ high*
/hen the batter$ is charging& R6D goes low& t#rning on the 6D*
R6D o#tp#ts )',A& taken into consi+eration in the calc#lations -or
power@c#rrent nee+e+* R6D ,a$ be connecte+ to the ,icroprocessor i-
we +eci+e to in+icate charging stat#s in so,e wa$ besi+es an 6D*
042 .#in$8/
Sa,e as R6D& b#t t#rns 6D on when batter$ is +one charging* C#rrent
not taken into consi+eration in calc#lations beca#se G6D will onl$ sink
c#rrent when no charge c#rrent is being o#tp#tte+* Th#s& chip o#tp#t
c#rrent when batter$ is +one charging is trivial*
B. Calculations for 1501 (values from spec)
)!') nee+s
Batter$
charging nee+s
R6D nee+s
;batter$ charging in+icator<
4*!29*%!:
;ass#,e !<
4*%: -or 6iA
4*C!: -or Bi
):
4*9,A !%!,A )',A
'*'%./ %*9/ '*')/
Total power #sage: %*9../
Charger e--icienc$: %*)/@%*9../ G I'F
2. Solar &anel
"or o#r +esign we chose to #se 17 >"le8ible Solar Cell> ,o+el n#,ber 7PT92
)!'* This appeare+ to the cheapest ,o+el we can -in+ that pro+#ce the a+e0#ate
voltage we nee+* 5t has the properties:
*oltage: 8.= *
Current: $==m+
*oltage .oc/: :.= *
Current .sc/: $2=m+
Thic!ness: =.2mm .: mil/
Total Si@e: $$3mm A $5=mm .3.5 A 5.; inches/
+#erture Si@e: $==mm A $5=mm .'.; A 5.; inches/
Beight: 3.8g .=.$o@/
C
Th#s& the I: ,a8i,#, voltage sho#l+ be ,ore than eno#gh to power a
chip that re0#ires greater than 4*!: to operate its internal logic* Also& the
solar cell is ver$ s,all -or co,parable o#tp#ts& being onl$ 4*!K b$ !*CK
Ass#,ing o#t+oor average solar -l#8 is )'''/@,
%
& we can calc#late an
esti,ate+ o#tp#t voltage that o#r solar cell will provi+e since it is liste+ as
!F*
Th#s we have )'''/@,
%
8 ;*), 8 *)!'< 8 *'!G *(!/ in con+itions o-
best operating s#nlight
Ass#,ing in+oor average solar -l#8 wo#l+ be appro8i,atel$ )'F o- the
,a8i,#,& we can th#s calc#late si,ilar +ata ass#,ing a solar -l#8 o-
)''/@,
%
Th#s we have )''/@,
%
8 ;*), 8 *)!'< 8 *'!G *'(!/ in+oors
'. Tem#erature Sensor
Bickel an+ lithi#, batteries are sensitive to te,perat#re an+ sho#l+ not be
charge+ i- their te,perat#re is over 4!LC* To sa-eg#ar+ against this& we will #se
a te,perat#re sensor ;place+ ne8t to the batter$< that will sh#t o-- the charger i-
the te,perat#re is too high* /e are #sing the 67.! te,perat#re sensor which
o#tp#ts a voltage proportional to te,perat#re* :o#t G ': A )',:@LC* The
critical te,perat#re is 4!LC& when the sensor o#tp#ts )',:@LC H 4!LC G '*4!:*
An op2a,p co,parator ;7A=C')C< will be #se+ to +etect this voltage& an+ will
o#tp#t a high i- the te,perat#re is above 4!LC* The ,icroprocessor will +etect
the op2a,p o#tp#t an+ sh#t +own the charger i- the te,perat#re is too high* The
val#es o- R) an+ R% will +epen+ on the precise voltage o#tp#tte+ b$ the solar
panel& which will be +eter,ine+ -ro, testing:
;:solar 4 '*4!:<@R) G '*4!:@R%
;:solar 4 '*4!<@'*4! G R)@R%
)'
Power #se+ b$ te,p sensor:
9#/ ;co,parator chip< A 4(#/ ;67.!< G !.#/
3. "icro#rocessor
The ,icroprocessor will per-or, the -ollowing -#nctions:
Select batter$ t$pe: check the batter$ t$pe that was selecte+ -ro, the switch an+
give the correct o#tp#t to pins 71D an+ CEGB o- the )!')*
Te,perat#re sh#to--: when the te,perat#re sensor gives a high o#t ;te,perat#re
o#t o- range<& sen+ signal to 71D an+ CEGB to stop charging*
Solar panel check: pin AC1J o- the )!') gives a low when the )!') has proper
inp#t voltage -or charging& high otherwise* The ,icroprocessor will sh#t o-- the
charger i- AC1J is high* /e will also possibl$ inter-ace ,ore 5@1 with the
AC1J signal an+ the ,icroprocessor& -or e8a,ple signaling to the #ser i- the
inp#t voltage is not within the correct range ;perhaps ,eaning the solar panel
nee+s ,ore light<*
5. I,O
5n or+er -or the correct batter$ ,o+e be sent to the ,icroprocessor to operate on&
the #ser ,#st -lip a single p#ll2+o#ble throw switch to t#rn the +evice on or o--&
an+ then another single2p#ll +o#ble throw switch that will select either lithi#, or
nickel batter$ che,istr$* Th#s& the correct signal will be sent to the
,icroprocessor which will co,,#nicate to the 7A=)!') to pro+#ce the correct
,o+e*
5n or+er to solve the proble, o- +ebo#ncing& which is when the o#tp#t o- a switch
Mbo#ncesD be-ore reaching a stea+$ state high& we will #se the 7A=9I)I +#al
switch +ebo#ncer* This +evice accepts eight inp#ts -ro, the switches& an+ o#tp#ts
two +ebo#nce+ o#tp#ts* These signals will th#s be sent to o#r ,icroprocessor -or
anal$sis an+ then it will o#tp#t the correct signals to the 7A=)!') charging 5C*
1#r +esign will also have two 6Ds to in-or, the #ser o- charging stat#s: a green
6D to in+icate charging -inishe+ an+ a re+ 6D to in+icate charge in progress*
))
MAX6818
See R6D an+ G6D pins on )!') -or ,ore in-or,ation*
8. &o6er Considerations
Total power nee+e+ G )!') power ;%*9../< A te,p sensor power ;!.#/< A #P
power ;)/< A switch power ;.'#/< G .*9..'I/
*. Cost and Schedule
$. Cost +nalysis
a. 4abor
;N.!@ho#r< H %*! H ;)% ho#rs@week< H ;)% weeks< H % people G N%!&%''
b. &arts
&art Cuantity &rice Status
Power"il, 7PT92)!' Solar Panel ) N.' 5n Ro#te
7icrocontroller;P5C)9"I((A< ) N)' 1n Ean+
7A= )!') 5C ) N.*!) 5n Ro#te
67.! Te,perat#re Sensor ) N'*9C 1n Ean+
7A=C')C ;voltage co,parator< ) N'*!I 5n Ro#te
7A= 9I)( ;+ebo#ncer< ) N%*'! 5n Ro#te
Resistors& capacitors )' N)*'' 1n Ean+
6D % N'*.' 1n Ean+
SPDT switch % N)*'' 1n Ean+
Protoboar+ ) N%' 1n Ean+
Eo#sing ) N)! Designing
6T )(9( Charging Cable ) N!*9'
Pen+ing
Decision
Total .&arts/ D E:;.9'
Total.&artsF4abor/DE252:;.9'
2. Schedule
)%
Bee! Tas!
%@4 4 %@)' /rite proposal& research
%@)) 4 %@)( /ork on sche,atics& research parts
%@)I 4 %@%4
"inali?e sche,atic& calc#lations& or+er
parts
%@%! 4 .@.
B#il+ charging #nit& test with -#nction
generator
Christine: learn P5C progra,,ing
Phil: or+er a++>l parts i- nee+e+
.@4 4 .@)'
Phil: test solar panel O sensors
Christine: progra, P5C
.@)) 4 .@)(
Phil: a++ solar panel an+ sensors to
charging #nit
Christine: inter-ace all parts with P5C
.@)I 4 .@%4 ;spring break< Prepare -or ,ock +e,o
.@%! 4 .@.)
Phil: tolerance anal$sis
Christine: +esign PCB
4@) 4 4@(
Tro#bleshooting& testing
Phil: b#il+ ho#sing
Christine: sol+er parts to PCB
4@I 4 4@)4 /ork on +e,o& presentation
4@)! 4 4@%) /ork on presentation& -inal paper
4@%% 4 4@%I /ork on -inal paper
General +ivision o- labor:
Christine: progra,,ing& la$o#t& sol+ering
Phil: solar panel& sensors
Both: charging #nit& 5@1
P
*I. +##endiA
).
)4