Battery charger and state of charge indicator. Final report

Abstract

The battery charger has a full-wave rectifier in series with a transformer isolated 20 kHz dc-dc converter with high frequency switches which are programmed to actively shape the input ac line current to be a mirror image of the ac line voltage. The power circuit is capable of operating at 2 kW peak and 1 kW average power. The BC/SCI has two major subsystems: (1) the battery charger power electronics with its controls; and (2) a microcomputer subsystem which is used to acquire battery terminal data and exercise the state-of-charge software programs. The state-of-charge definition employed is the energy remaining in the battery when extracted at a 10 kW rate divided by the energy capacity of a fully charged new battery. The battery charger circuit is an isolated boost converter operating at an internal frequency of 20 kHz. The switches selected for the battery charger are the single most important item in determining its efficiency. The combination of voltage and current requirements dictated the use of high power NPN Darlington switching transistors. The power circuit topology developed is a three switch design utilizing a power FET on the center tap of the isolation transformer and the power Darlingtons on eachmore » of the two ends. An analog control system is employed to accomplish active input current waveshaping as well as the necessary regulation.« less