Charger IC

ColorMaker

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I am looking into building a NiMH battery charger. 12 volt 1a to 4a. My research concluded there are a few companies than make charger IC's that targets Dv and DT cutoff but most do not have the ability to charge at more than 1a. I was looking at the possiblity of using a PIC processor to detect DV and be able to select the charge current. Has anyone attempted such a design ? Any links on DV would we great.

JM
 
I've never done it, but it should be very feasible and sounds like an interesting project. Experimenting with programmable microcontrollers is on my list of fun things to do at some point.

Here are a few ideas:

You will need to be able to measure the cell voltage down to mV precision. To reduce noise it typically helps to use over-sampling. That is, you take, say, ten voltage readings in quick succession and average them to get the value you will use.

If you measure the voltage slope, I have always thought that the normalized dV/dC would be a better choice than dV/dt (where C is the charge supplied). To compute slopes some filtering is definitely needed to further smooth out noise, and you'd have to experiment with filter parameters for that.

To obtain the -dV termination point, you would record the maximum voltage ever seen and store that in a register. Then when and if the currently measured voltage is less than the maximum by the preset amount (3 - 10 mV typical), you terminate the charge.

One thing to note with high charging currents is that the cells will start to heat up significantly by the time that the -dV signal is detected. For cooler charging it would be nice to terminate before -dV. For an idea on this, search the back threads for a discussion of the inflexion point termination algorithm. This could be implemented well in a microcontroller and would give you an advantage over off-the-shelf chargers or ICs.
 
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I have 10 years experience with Pic Microcontroller and wirting the code should not present a problem, Understanding the technique on DV however may be more complicated. I have searched through the threads for hours and have not found a complete description on how DV is detected, Is DV a fast drop ms, us, Seconds, minutes ?
If you are looking to get started check out Microchip.com. They have a great selection of demo boards. I plan on using Pic18F2331 for the project.

We manufature a variety of Battery powered LED lights and I want to design a charger system that will identify the capacity of the battery in the device and automatically set the charge rate. Its a one charger fits all. Our devices use 12 volt batteries from 2600ma to 10a.
 
Exactly how -dV is detected is likely to be a bit proprietary. In the normal way of things, any published information you find may not be the "best" or "optimal" implementation. Manufacturers may well have refined things by their own research.

A lot of proprietary detail probably goes into sampling and smoothing algorithms to get reliable measurements.

In my own estimation (just guesswork, not authoritative), the -dV is detected as I indicated, as an absolute drop from the maximum without any time constraint.

How will you detect the capacity of the battery? An internal resistance measurement perhaps?

Many people here have been discussing microcontrollers for incan voltage regulation. The direction has been towards AVR rather than PIC. Can you say how they compare in features and application?
 
Capacity detection is not a problem. We manufacture the devices to be charged and we plan on an ID system when the charger is connected. Never used AVR. The Pic has a 16 bit AD converter and with a voltage divider 3-10 Mv detection should not be a problem. I assume the charger is disconnected while sampling battery voltage, At what intervals should the sample take place is the question. I have also read several methods of charging PWM and Current charging are some examples.

JM
 
Many chargers apply a pulsed charging current. In other words they might apply the full charging current for 0.9 seconds, then disconnect and wait 0.1 seconds for the open circuit voltage to stabilize, measure the battery voltage, and then start the next 0.9 second pulse.

It's quite up to you how frequently you sample the voltage. 1 s, 5 s, 10 s, it's all the same. The -dV signal is a persistent signal, it's not an instantaneous signal you can miss if you don't happen to sample at the right time.
 
Something else to watch for is a false -dV signal. Sometimes an unwanted -dV signal can happen early in the charge. You may need to apply a time or voltage threshold below which you ignore any -dV before you start looking for the right one. (And if you apply a time threshold, you have to make sure you don't cook already charged cells that are put back on charge...)

How about using an off-the-shelf IC but combine it with a current mirror circuit to increase the charging current above 1 A?
 
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I have read about the false -Dv and I plan on a timer. The ID system we plan to use may be able to prevent double charge, Still under design.
The IC devices I looked at both MaxIC and National used current sensing direct from battery terminals so I assumed if I altered charge current it would give false readings. Did you have a chip in mind that would be more suitable for eaternal current control ?

By the way Thank you for your help ! its been educational.
Here is what I do www.ColorMaker.net

JM
 
I'm sorry, the current mirror idea was just a theoretical suggestion for something to investigate. I couldn't tell you if it actually is possible in practice.
 
Hello JM,

There is a wealth of information in this thread, but it takes some effort to work your way through it.

Some of these chargers are very interesting.

Tom
 
What device are they using to monitor the charger results ?

Meter View software is very cool I want one! Where can I get it or is there a better meter since the post ?

JM
 
Capacity detection is not a problem. We manufacture the devices to be charged and we plan on an ID system when the charger is connected. Never used AVR. The Pic has a 16 bit AD converter and with a voltage divider 3-10 Mv detection should not be a problem. I assume the charger is disconnected while sampling battery voltage, At what intervals should the sample take place is the question. I have also read several methods of charging PWM and Current charging are some examples.

JM

Can you point me out on pic that has 16BIT ADC please?

zega
 
Can you point me out on pic that has 16BIT ADC please?

zega

10 bit, my mistake. More than enough for monitoring. Use 2 ADC with voltage dividers for wider ranges.
I use Pic16 and Pic18 series.
 
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