BY A.

SAI SHASHANK

Most modern electrical appliances receive their power directly from the utility grid, a growing number of everyday devices require electrical power from batteries in order to achieve greater mobility and convenience. The system used to draw energy from the grid, store it in a battery, and release it to power a device is called a battery charger system. Battery charger systems often maximize the energy efficiency of their devices to ensure long operation times between charging.

A battery charger is a device used to put energy into a secondary cell or rechargeable battery by forcing an electric current through it. The charge current depends upon the technology and capacity of the battery being charged. A series of power conversion steps must be performed to shape the high-voltage ac electricity from the utility into low-voltage dc electricity that can be accepted by the battery, and the charging process must be controlled so that the battery receives the appropriate amount of current.

Block diagram showing the general configuration battery charger system.

first two stages are functions typically incorporated into ac-dc power supplies. The addition of the third stage controlling the rate of charge of the battery with charge control circuitry is typically what distinguishes a battery charger from an ac-dc power supply
The

Four-layer solid state device that controls current, An SCR consists of four layers of alternating P and N type semiconductor materials. The planar construction is used for low power SCRs

In the normal "off" state, the device restricts current to the leakage current. When the gate-tocathode voltage exceeds a certain threshold, the device turns "on" and conducts current. The device will remain in the "on" state even after gate current is removed so long as current through the device remains above the holding current. Once current falls below the holding current for an appropriate period of time, the device will switch "off". If the gate is pulsed and the current through the device is below the holding current, the device will remain in the "off" state.

The feedback control design of the charger makes it possible for one SCR in the SCR assembly to not function and the charger to still have some output. This condition can be detected by noting the temperature of the separate SCRs and replacing the complete assembly if one of the SCRs feels cold and the other hot. This condition may also suggest its presence by continual melting of the DC fuse

If the applied voltage increases rapidly enough, capacitive coupling may induce enough charge into the gate to trigger the device into the "on" state; this is referred to as "dv/dt triggering." This is usually prevented by limiting the rate of voltage rise across the device, perhaps by using a snubber. "Dv/dt triggering" may not switch the SCR into full conduction rapidly and the partiallytriggered SCR may dissipate more power than is usual, possibly harming the device. SCRs can also be triggered by increasing the forward voltage beyond their rated breakdown voltage (also called as break over voltage), but again, this does not rapidly switch the entire device into conduction and so may be harmful so this mode of operation is also usually avoided. Also, the actual breakdown voltage may be substantially higher than the rated breakdown voltage, so the exact trigger point will vary from device to device. This device is generally used in switching applications.

A transformer is a device that transfers electrical energy from one circuit to another through inductively coupled conductors the transformer's coils. A varying current in the first or primary winding creates a varying magnetic flux in the transformer's core and thus a varying magnetic field through the secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or "voltage", in the secondary winding. This effect is called mutual induction. If a load is connected to the secondary, an electric current will flow in the secondary winding and electrical energy will be transferred from the primary circuit through the transformer to the load. In an ideal transformer, the induced voltage in the secondary winding (Vs) is in proportion to the primary voltage (Vp), and is given by the ratio of the number of turns in the secondary (Ns) to the number of turns in the primary (Np) as follows

The transformer is based on two principles: first, that an electric current can produce a magnetic field (electromagnetism), and, second that a changing magnetic field within a coil of wire induces a voltage across the ends of the coil (electromagnetic induction). Changing the current in the primary coil changes the magnetic flux that is developed. The changing magnetic flux induces a voltage in the secondary coil.

The BC148 equivalent is BC548. The BC548 is a general purpose silicon NPN BJT transistor found commonly in European electronic equipment; the part number is assigned by Pro Electron, which allows many manufacturers to offer electrically and physically interchangeable parts under one identification. The BC548 is commonly available in European Union and Commonwealth Countries and is often the first type of bipolar transistor young hobbyists encounter. The BC548 is often featured in circuit diagrams and designs published in Electronics Magazines such as "Silicon Chip" and "Elektor". As a representative of the large family of bipolar transistors the BC548 provides a "stepping off point" to the use of more esoteric, higher voltage, current or frequency devices for beginners. If the TO-92 package is held in front of one's face with the flat side facing toward you and the leads downward, (see picture) the order of the leads, from left to right is collector, base, emitter.

A simple battery charger based on SCR is shown . Here the SCR rectifies the AC mains voltage to charge the battery. When the battery connected to the charger gets discharged the battery voltage gets dropped. This inhibits the forward biasing voltage from reaching the base of the transistor Q1 through R4 and D2.This switches off the transistor. When the transistor is turned OFF, the gate of SCR (H1) gets the triggering voltage via R1 & D3.This makes the SCR to conduct and it starts to rectify the AC input voltage. The rectified voltage is given to the battery through the resistor R6(5W).This starts charging of the battery. When the battery is completely charged the base of Q1 gets the forward bias signal through the voltage divider circuit made of R3,R4,R5 and D2.This turns the transistor ON. When the Q1 is turned ON the trigger voltage at the gate of SCR is cut off and the SCR is turned OFF. In this condition a very small amount of charge reaches the battery via R2 and D4 for trickle charging. Since the charging voltage is only half wave rectified ,this type of charger is suitable only for slow charging.For fast charging full wave rectified charging voltage is needed.

Topology

Typical Efficiency Range 2 % - 35%

Example Products Cordless phones, power tools Laptop computers, cell phones Golf carts, forklifts Recreational

Market Segment Residential, Commercial Residential, Commercial Commercial, Industrial Commercial,

Relative Cost per Watt Low

Linear

Switch Mode

40% - 60%

High

Ferro resonant

25% - 50%

Low

SCR

30% 55%

Medium

vehicle battery Industrial chargers, forklifts

Battery charger using SCR accomplish all this through three functions: 1) Reducing voltage from the utility level to the lower voltage at which batteries operate, 2) Rectifying ac electricity into dc electricity, and 3) Controlling the low-voltage dc current into the battery

1.Someone should be within range of your voice or close enough to come to your aid when you work near a battery. 2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes. 3. Wear complete eye and clothing protection. Avoid touching eyes while working near batteries. 4. NEVER smoke or allow a spark or flame in the vicinity of batteries. 5. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short circuit battery or other electrical part that may cause explosion.

There are significant opportunities to improve the efficiencies of battery charger systems in use today. At present, inefficiencies in the charger and battery often consume more electricity than the product they power. There are millions of battery charger systems in operation worldwide, and therefore substantial energy savings are achievable by reducing or eliminating these inefficiencies. Several methods can be used to achieve higher efficiency in battery charger systems, including: Higher voltage systems Use of switch mode power supplies Use of synchronous rectification Use of improved semiconductor switches Use of lithium-ion batteries Charge and discharge at lower current rate