Rizal Technological University

Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

12V-24V Automatic Battery Charger

A proposal for DC-DC Application

In partial fulfillment for the subject ECE553L

Prepared by:
Pajudpud, Marie Claire B.
Palisoc, Loren Dawn
Pandes, Camille
Ponce, John H.
Quinoñes, Monique

Submitted to:
Engr. Odilon Yangco

CEIT – 05 – 902E
GROUP 6
 Rizal Technological University
Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

INTRODUCTION
Power electronics is the application of solid-state electronics to the
control and conversion of electric power. In modern systems the conversion is
performed with semiconductor switching devices such as diodes, thyristors and
transistors. In contrast to electronic systems concerned with transmission and
processing of signals and data, in power electronics substantial amounts of
electrical energy are processed. An AC/DC converter (rectifier) is the most
typical power electronics device found in many consumer electronic devices,
e.g. television sets, personal computers, battery chargers, etc. The power range
is typically from tens of watts to several hundred watts. In industry a common
application is the variable speed drive (VSD) that is used to control an induction
motor. The power range of VSDs start from a few hundred watts and end at
tens of megawatts.
The power conversion systems can be classified according to the type of the
input and output power:
• AC to DC (rectifier)
• DC to AC (inverter)
• DC to DC (DC-to-DC converter)
• AC to AC (AC-to-AC converter)

A DC-to-DC converter is a class of power supply which converts a source of

direct current (DC) from one voltage level to another. They can essentially step-
up, step-down or invert a DC voltage. It is a type of electric power converter.
Power levels range from very low (small batteries) to very high (high-voltage
power transmission). It is also used in portable electronic devices such as
cellular phones and laptop computers, which are supplied with power from
batteries primarily, and that's our proposal for module 2 Such electronic devices
often contain several sub-circuits, each with its own voltage level requirement
different from that supplied by the battery or an external supply (sometimes
higher or lower than the supply voltage). Additionally, the battery voltage
declines as its stored energy is drained. Switched DC to DC converters offer a
method to increase voltage from a partially lowered battery voltage thereby
saving space instead of using multiple batteries to accomplish the same thing.
 Rizal Technological University
Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

PRINCIPLE:

LM338 devices or electronic components are adjustable, three-terminal,

positive-voltage regulators capable of supplying more than 5 A over an output-
voltage range of 1.2 V to 32 V. This component includes time-dependent
current limiting, thermal overload protection, and safe operating area protection.
Overload protection remains functional even if the ADJUST terminal is
disconnected. The current limit circuitry allows peak currents of up to 12 A to be
drawn from the regulator for short periods of time. This allows the LM338 to be
used with heavy transient loads and speeds start-up under full-load conditions.
Under sustained loading conditions, the current limit decreases to a safe value
protecting the regulator. Also included on the chip are thermal overload
protection and safe area protection for the power transistor. Overload protection
remains functional even if the adjustment (ADJ) pin is accidentally
disconnected.

WORKING / IMPLEMENTATION OF PROPOSAL FOR DC-DC

APPLICATION:

DC to DC is a type of converter that works very efficient. It helps to change

one level/voltage of DC into another level/voltage of DC. It can be used as
switching mode regulators to convert a DC voltage, normally unregulated, to a
regulated DC output voltage. If you look at the circuit below, the circuit switches
off the current to the battery as soon as the battery reaches full charge. An
illuminated LED at the output indicates the fully charged condition of the battery.
 Rizal Technological University
Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

HOW IT WILL WORKS?

 Fundamentally the voltage control and regulation is done by the versatile,

work horse IC LM 338.

 An input DC supply volt in the range of 30 is applied to the input of the IC.
The voltage may be derived from a transformer, bridge and capacitor
network.

 The value of R2 is set to get the required output voltage, depending upon
the battery voltage to be charged.

 If a 6volt battery needs to charged, R2 is selected to produce a voltage of

around 7 volts at the output, for a 12volt battery it becomes 14 volts and for
a 24volt battery, the setting is done at around 28 volts.

 The above settings take care of the voltage that needs to be applied to the
battery under charge, however the tripping voltage or the voltage at which
the circuit should cut off is set by adjusting the 10 K pot or preset.

 The 10K preset is associated with the circuit involving the IC 741 which is
basically configured as a comparator.
 Rizal Technological University
Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

 The inverting input of the IC 741 is clamped at a fixed reference voltage of 6

via a 10K resistor.

 With reference to this voltage the tripping point is set via the 10 K preset
connected across the non-inverting input of the IC.

 The output supply from the IC LM 338 goes to the battery positive for
charging it. This voltage also acts as the sensing as well as the operating
voltage for the IC 741.

 As per the setting of the 10 K preset when the battery voltage during the
charging process reaches or crosses the threshold, the output of the IC 741
goes high.

 The voltage passes through the LED and reaches the base of the transistor
which in turn conducts and switches off the IC LM 338.

 The supply to the battery is immediately cut off.

 The illuminated LED indicates the charged condition of the connected

battery.

PCB DESIGN:
We made the PCB design and used etching technique.
 Rizal Technological University
Boni Avenue, Mandaluyong City

College of Engineering and Industrial Technology

Electronics and Communications Engineering Department

EQUIPMENTS WITH SPECIFICATION:

 LM338  Potentiometer 10K Ω
 C1 0.1 µF  1N4007
 104 µF,10v Capacitor  2N2219
 R1 240 Ω  6V Zener Diode
 R2 2.2K Ω  3.3V Zener Diode
 4.7K Ω  IC 741 Op-Amp
 10K Ω

COSTING:
ITEMS/EQUIPMENTS QUANTITY PRICE (PHP) TOTAL (PHP)
LM338 1 250 250
0.1 µF Capacitor 1 3 3
104µF, 10V
1 3 3
Capacitor
240 Ω 1 2 2
2.2K Ω 1 2 2
4.7K Ω 1 2 2
10K Ω 1 18 18
2N2219 2 38 76
3.3V Zener 1 10 10
6v Zener 1 8 8
IC 741 OP Amp 2 150 300
POT 10K Ω 1 20 20
1N4007 1 3 3
TOTAL PRICE: 697