Battery charger – battCharger V1


I am proud to introduce you now my newest electronic hardware:

battCharger – a free and open hard- and software design to evaluate buck-converters charging a battery.

battCharger.jpg
[more]

battChargerPCB.jpg

The hardware circuit consists foremost of a secondary switched micro-controller driven buck-converter. An Arduino Micro board controls the output levels, while it is measuring voltage, current and temperature.
The main reason to build this “monster” was that most manufacturers do not free the source code and schematics. What if a “new” battery technology is out and the manufacturer does not update it’s firmware any more?

With the battCharger no problem: Source code is available for public.

The battCharger can charge battery types like Ni-Cd, Ni-Mh, Li-ion and Lead acid. Although it is designed for charging batteries, the battCharger has a power supply mode and an electronic load mode because the main hardware design consists of a power supply.

The software is currently mostly functional and following features are implemented:

Charger mode:

  • Charge

    Batteries are charged within given parameters: Voltage, current, capacity, cells, temperature, battery type. A security shutdown occurs if over-/undervoltage, -temperature and overcurrent is detected, or a timeout is reached.

  • Discharge

    Batteries are discharged within given parameters: Voltage, current, capacity, cells, temperature, battery type. A security shutdown occurs if over-/undervoltage, -temperature and overcurrent is detected.

  • Charge/Discharge/Charge
  • Charge/Discharge/Charge cyclic (for Ni-Cd batteries)
  • Measure resistance

    The resistance is measured by discharging at 0,1C for 20 seconds and by discharging afterwards at 1C for 20 seconds. If finished, the resistance will be calculated. (DC load method, http://batteryuniversity.com/learn/article/how_to_measure_internal_resistance)

Power supply mode:

  • CV/CC mode

Electronic load mode:

  • CC mode

Hardware

  • Channels: 2
  • Maximum current per channel: 8A
  • Maximum voltage: 36V
  • Maximum power sum: 200VA
  • Maximum capacity: 200Ah
  • Maximum discharge/load power per channel: 50W
  • Power supply topology: Secondary switched buck converter (with transformers)

External data acquisition tools
The USB UART of the Arduino Micro can be grabbed with any tool understanding serial communications. A GUI is developed to inspect electrical loads, sources and batteries. Remote SSH connection is supported.
Also an email alert function is implemented.

battChargerGUI.png

The soft- and hardware sources are available at: http://bazaar.launchpad.net/~tuxstef/mrsd/trunk/files/head:/BattCharger/

Two PCBs were manufactured by Eurocircuits and one of them is now under stress-test. Note that a new PCB release will be publicated to patch some errors.

Further on more info will be presented onto this site.