4 <title>Battery charger and dual power supply unit</title>
5 <!-- 2021-01-03 P 00:39 -->
7 <meta name="viewport" content="width=device-width, initial-scale=1">
8 <meta name="generator" content="Org-mode">
9 <meta name="author" content="Svjatoslav Agejenko">
10 <link href="https://bootswatch.com/3/darkly/bootstrap.min.css" rel="stylesheet">
11 <script src="https://cdnjs.cloudflare.com/ajax/libs/jquery/1.11.3/jquery.min.js"></script>
12 <script src="https://cdnjs.cloudflare.com/ajax/libs/twitter-bootstrap/3.3.5/js/bootstrap.min.js"></script>
13 <style type="text/css">
14 footer {background-color: #111 !important;}
15 pre {background-color: #111; color: #ccc;}
17 <style type="text/css">
18 /* org mode styles on top of twbs */
35 background-color: #f5f5f5;
62 display: inline-block;
74 .bs-docs-sidebar.affix {
77 @media (min-width: 768px) {
83 /* All levels of nav */
84 .bs-docs-sidebar .nav > li > a {
91 .bs-docs-sidebar .nav > li > a:hover,
92 .bs-docs-sidebar .nav > li > a:focus {
95 text-decoration: none;
96 background-color: transparent;
97 border-left: 1px solid #A1283B;
99 .bs-docs-sidebar .nav > .active > a,
100 .bs-docs-sidebar .nav > .active:hover > a,
101 .bs-docs-sidebar .nav > .active:focus > a {
105 background-color: transparent;
106 border-left: 2px solid #A1283B;
109 /* Nav: second level (shown on .active) */
110 .bs-docs-sidebar .nav .nav {
111 display: none; /* Hide by default, but at >768px, show it */
112 padding-bottom: 10px;
114 .bs-docs-sidebar .nav .nav > li > a {
121 .bs-docs-sidebar .nav .nav > li > a:hover,
122 .bs-docs-sidebar .nav .nav > li > a:focus {
125 .bs-docs-sidebar .nav .nav > .active > a,
126 .bs-docs-sidebar .nav .nav > .active:hover > a,
127 .bs-docs-sidebar .nav .nav > .active:focus > a {
132 /* Nav: third level (shown on .active) */
133 .bs-docs-sidebar .nav .nav .nav {
134 padding-bottom: 10px;
136 .bs-docs-sidebar .nav .nav .nav > li > a {
143 .bs-docs-sidebar .nav .nav .nav > li > a:hover,
144 .bs-docs-sidebar .nav .nav .nav > li > a:focus {
147 .bs-docs-sidebar .nav .nav .nav > .active > a,
148 .bs-docs-sidebar .nav .nav .nav > .active:hover > a,
149 .bs-docs-sidebar .nav .nav .nav > .active:focus > a {
154 /* Show and affix the side nav when space allows it */
155 @media (min-width: 992px) {
156 .bs-docs-sidebar .nav > .active > ul {
159 /* Widen the fixed sidebar */
160 .bs-docs-sidebar.affix,
161 .bs-docs-sidebar.affix-bottom {
164 .bs-docs-sidebar.affix {
165 position: fixed; /* Undo the static from mobile first approach */
168 .bs-docs-sidebar.affix-bottom {
169 position: absolute; /* Undo the static from mobile first approach */
171 .bs-docs-sidebar.affix .bs-docs-sidenav,.bs-docs-sidebar.affix-bottom .bs-docs-sidenav {
176 @media (min-width: 1200px) {
177 /* Widen the fixed sidebar again */
178 .bs-docs-sidebar.affix-bottom,
179 .bs-docs-sidebar.affix {
184 <script type="text/javascript">
188 $('.bs-docs-sidebar li').first().addClass('active');
190 $(document.body).scrollspy({target: '.bs-docs-sidebar'});
192 $('.bs-docs-sidebar').affix();
197 <div id="content" class="container">
198 <div class="row"><div class="col-md-9"><h1 class="title">Battery charger and dual power supply unit</h1>
200 <div id="outline-container-sec-1" class="outline-2">
201 <h2 id="sec-1"><span class="section-number-2">1</span> General</h2>
202 <div class="outline-text-2" id="text-1">
204 <li>DISCLAIMER: I DO ELECTRONICS AND 3D DESIGN SOLELY AS A HOBBY. THERE
205 COULD BE ERRORS THAT CAN RESULT IN ALL KINDS OF DAMAGE. USE THESE
206 DESIGNS AT YOUR OWN RISK.
209 <li>This design is released under Creative Commons Zero (CC0) license.
214 <li>Svjatoslav Agejenko
216 <li>Homepage: <a href="https://svjatoslav.eu">https://svjatoslav.eu</a>
218 <li>Email: <a href="mailto://svjatoslav@svjatoslav.eu">svjatoslav@svjatoslav.eu</a>
230 <li><a href="../../index.html">Other physical projects in this repository</a>
232 <li><a href="https://www.svjatoslav.eu/projects/">Other projects hosted at svjatoslav.eu</a>
240 <div id="outline-container-sec-2" class="outline-2">
241 <h2 id="sec-2"><span class="section-number-2">2</span> Project description</h2>
242 <div class="outline-text-2" id="text-2">
244 I needed dual voltage power supply for my lab that runs on mains
245 electricity (wall power) and slowly charges (use-changing) attached
246 12V Lead-Acid battery. Lead-acid battery in turn provides high current
247 when needed as well as power in portable situations or when mains
248 electricity is not available.
253 <p><img src="make.png" class="img-responsive" alt="make.png">
258 Power supply provides about 13 Volts and 5 Volts simultaneously.
262 <b>!!!WARNING!!!</b> <a href="../alternative%20USB%20layout/">Alternative and incompatible USB wiring/layout</a> is
267 <b>Normal USB devices and cables should not be plugged in! It would
268 damage device/cable and likely power supply.</b>
272 I found USB-A connectors to be easily available, cheap, reliable and
273 functional, so I re-purposed connector for my own needs but I'm using
274 totally incompatible electrical wiring.
279 <p><img src="../alternative%20USB%20layout/schematic.png" class="img-responsive" alt="schematic.png">
284 As seen, it has dual voltage output. Additionally one wire is
285 dedicated to data transmission and can be used with <a href="https://en.wikipedia.org/wiki/1-Wire">1-Wire</a> protocol
289 1-Wire data router/hub is really simple. Power supply simply passively
290 links all data wires together.
294 Power supply uses 3D printed body with lots of holes, for fanless
300 <p><img src="body%20and%20covers/body,%201.png" class="img-responsive" alt="body,%201.png">
305 Various modules are realized on top of prototype PCBs that slide into
306 dedicated rails within the body.
311 <p><img src="body%20and%20covers/body,%202.png" class="img-responsive" alt="body,%202.png">
321 <p><img src="make,%202.png" class="img-responsive" alt="make,%202.png">
326 When cover is closed, it blocks PCB movement:
331 <p><img src="body%20and%20covers/cover.png" class="img-responsive" alt="cover.png">
336 There is still some empty space inside, so why not add dummy cover on
337 top that can be replaced later with add-on functionality/expansion
343 <p><img src="body%20and%20covers/cover%20cover.png" class="img-responsive" alt="cover%20cover.png">
351 <li><a href="body%20and%20covers/body.stl">Body STL file</a>
353 <li><a href="body%20and%20covers/cover.stl">Big cover STL file</a>
355 <li><a href="body%20and%20covers/cover%20cover.stl">Small dummy cover on top, STL file</a>
357 <li><a href="body%20and%20covers/body%20and%20covers.FCStd">Body and covers FreeCAD project</a>
363 <div id="outline-container-sec-3" class="outline-2">
364 <h2 id="sec-3"><span class="section-number-2">3</span> Transformer and AC to DC converter</h2>
365 <div class="outline-text-2" id="text-3">
367 This is where high voltage from mains electricity enters the system.
372 <img src="transformer%20and%20AC%20DC%20converter%20board/schematic.png" class="img-responsive" alt="schematic.png">
376 For safety I kept high voltage section as minimal as possible. That
377 is, wall plug runs straight into transformer. Also I used <a href="https://www.amazon.de/gp/product/B07VGQKM3G/ref=ppx_yo_dt_b_asin_title_o06_s00?ie=UTF8&psc=1">UV hardening
378 glue</a> for extra safety and isolation on PCB.
382 Power on/off switch operates on already reduced voltage of about 30
383 volts. Power switch is located on <a href="#sec-6">indicator panel</a>.
388 <p><img src="transformer%20and%20AC%20DC%20converter%20board/make,%201.png" class="img-responsive" alt="make,%201.png">
393 DC current of about 30 volts is then routed to <a href="#sec-4">Main board</a>.
398 <p><img src="transformer%20and%20AC%20DC%20converter%20board/make,%202.png" class="img-responsive" alt="make,%202.png">
403 <a href="https://www.amazon.de/gp/product/B07RLQH5TR/ref=ppx_yo_dt_b_asin_title_o07_s00?ie=UTF8&psc=1">Single sided prototype PCB is used</a>.
408 <div id="outline-container-sec-4" class="outline-2">
409 <h2 id="sec-4"><a id="ID-65d68227-4bf2-4c4f-b4d3-c390bc6a9c34" name="ID-65d68227-4bf2-4c4f-b4d3-c390bc6a9c34"></a><span class="section-number-2">4</span> Main board</h2>
410 <div class="outline-text-2" id="text-4">
412 This is logically main board because it appears to be central hub that
413 connects all components. It also houses 2 <a href="https://www.amazon.de/gp/product/B072MQYJ93/ref=ppx_yo_dt_b_asin_title_o04_s00?ie=UTF8&psc=1">adjustable DC-DC Step Down
414 voltage converters</a>.
419 <p><img src="main%20board/main%20board,%201.png" class="img-responsive" alt="main%20board,%201.png">
424 High-level schematic of entire device:
425 <img src="main%20board/schematic.png" class="img-responsive" alt="schematic.png">
429 As seen from schematic, ~30 volts DC from transformer board is routed
430 into first step-down converter that reduces it to about 15V. Reduced
431 voltage is then directed to <a href="#sec-5">Current limiter circuit</a>. Current limiter
432 loses about 2 volts. Now we have current and voltage limited power at
433 about 13 volts. This power is used to charge connected 12V Lead-Acid
434 battery. Also the same power is routed to <a href="#sec-7">connector terminal</a> to be
435 consumed by connected devices.
439 As seen from this schematic, device is not meant to provide high
440 current for long periods of time. Instead it gets comparatively
441 limited current to charge the battery and feed devices with low
442 current requirements. Occasional current spikes are backed up by
443 battery that stays in use-changing mode.
447 Also about 13V output voltage is approximate and depends on connected
448 battery charge level.
452 Second Step-Down converter reduces voltage even further to quite
453 precisely 5V DC. This resulting voltage is also routed to <a href="#sec-7">connector
458 Both 13V and 5V lines are also routed to <a href="#sec-6">indicator panel</a> for
463 There is single on/off switch. In off position, it disconnects battery
464 and transformer from the system effectively powering everything down.
468 On schematic above, some wires are annotated with numbers from 1
469 to 13. This corresponds to output pins on the board.
474 <p><img src="main%20board/main%20board,%202.png" class="img-responsive" alt="main%20board,%202.png">
479 <div id="outline-container-sec-5" class="outline-2">
480 <h2 id="sec-5"><a id="ID-afc22d23-9bc4-421c-9cac-e0ce34bd36bc" name="ID-afc22d23-9bc4-421c-9cac-e0ce34bd36bc"></a><span class="section-number-2">5</span> Current limiter</h2>
481 <div class="outline-text-2" id="text-5">
484 <img src="current%20limiter/schematic.png" class="img-responsive" alt="schematic.png">
488 Simple LM317 based current limiter is used. I used 4.7 ohm
489 resistor. It provides about 265 milliamps of current. See <a href="http://www.reuk.co.uk/wordpress/electric-circuit/lm317-current-calculator/">calculator</a>.
494 <p><img src="current%20limiter/current%20limiter,%201.png" class="img-responsive" alt="current%20limiter,%201.png">
499 Thermal paste below and UV hardening glue on top is used to attach
500 LM317 to the heatsink. There is also jumper-like solution on top
501 right. This is handy to attach multimeter tap to verify/monitor
502 current during initial device calibration.
506 If attached battery is really empty, significant voltage drop can
507 occur in LM317. Heatsink is needed to dissipate that power.
512 <p><img src="current%20limiter/current%20limiter,%202.png" class="img-responsive" alt="current%20limiter,%202.png">
517 Note: resistor gets hot too.
522 <div id="outline-container-sec-6" class="outline-2">
523 <h2 id="sec-6"><a id="ID-c9a69490-f920-4a31-b32e-b101bfc3d01b" name="ID-c9a69490-f920-4a31-b32e-b101bfc3d01b"></a><span class="section-number-2">6</span> Indicator panel</h2>
524 <div class="outline-text-2" id="text-6">
527 <p><img src="indicator%20panel/indicator%20panel,%201.png" class="img-responsive" alt="indicator%20panel,%201.png">
532 Basically 2 digital DC voltmeters and main on/off switch.
537 <p><img src="indicator%20panel/indicator%20panel,%202.png" class="img-responsive" alt="indicator%20panel,%202.png">
547 <p><img src="indicator%20panel/indicator%20panel.png" class="img-responsive" alt="indicator%20panel.png">
552 <li><a href="indicator%20panel/indicator%20panel.stl">STL file</a>
554 <li><a href="indicator%20panel/indicator%20panel.FCStd">FreeCAD project</a>
560 <div id="outline-container-sec-7" class="outline-2">
561 <h2 id="sec-7"><a id="ID-e33940bd-652f-4ec0-b53b-1c03e16941c8" name="ID-e33940bd-652f-4ec0-b53b-1c03e16941c8"></a><span class="section-number-2">7</span> Connector terminal</h2>
562 <div class="outline-text-2" id="text-7">
565 <img src="connector%20terminal/schematic.png" class="img-responsive" alt="schematic.png">
569 As seen above, most of the USB connectors are used to deliver dual
570 power output and 1-wire data connectivity, except one on the bottom
571 right. This is used to attach 12V battery. Some capacitors are thrown
572 in as well to stabilize against smaller current spikes.
576 Electrically schematic is realized using smaller prototype PCBs.
581 <p><img src="connector%20terminal/make,%201.png" class="img-responsive" alt="make,%201.png">
587 Those PCBs are wired to central small PCB that acts as a hub:
592 <p><img src="connector%20terminal/make,%202.png" class="img-responsive" alt="make,%202.png">
597 PCBs are held together by being sandwiched between front panel:
602 <p><img src="connector%20terminal/front%20panel.png" class="img-responsive" alt="front%20panel.png">
607 and smaller back-end plate:
612 <p><img src="connector%20terminal/back%20panel.png" class="img-responsive" alt="back%20panel.png">
622 <p><img src="connector%20terminal/make,%203.png" class="img-responsive" alt="make,%203.png">
631 <li><a href="connector%20terminal/front%20panel.stl">front panel STL</a>
633 <li><a href="connector%20terminal/back%20panel.stl">back panel STL</a>
635 <li><a href="connector%20terminal/connector%20terminal.FCStd">FreeCAD project</a>
641 <div id="outline-container-sec-8" class="outline-2">
642 <h2 id="sec-8"><span class="section-number-2">8</span> Calibration</h2>
643 <div class="outline-text-2" id="text-8">
645 Since device uses adjustable step-down modules, these need to be
646 calibrated to provide correct output voltage. It is important that
647 battery receives proper charging voltage otherwise either no charging
648 occurs or battery starts gassing out and gets destroyed.
652 See here for more details: <a href="https://www.powerstream.com/SLA.htm">https://www.powerstream.com/SLA.htm</a>
662 </div><div class="col-md-3"><nav id="table-of-contents">
663 <div id="text-table-of-contents" class="bs-docs-sidebar">
665 <li><a href="#sec-1">1. General</a></li>
666 <li><a href="#sec-2">2. Project description</a></li>
667 <li><a href="#sec-3">3. Transformer and AC to DC converter</a></li>
668 <li><a href="#sec-4">4. Main board</a></li>
669 <li><a href="#sec-5">5. Current limiter</a></li>
670 <li><a href="#sec-6">6. Indicator panel</a></li>
671 <li><a href="#sec-7">7. Connector terminal</a></li>
672 <li><a href="#sec-8">8. Calibration</a></li>
677 <footer id="postamble" class="">
678 <div><p class="author">Author: Svjatoslav Agejenko</p>
679 <p class="date">Created: 2021-01-03 P 00:39</p>
680 <p class="creator"><a href="http://www.gnu.org/software/emacs/">Emacs</a> 26.1 (<a href="http://orgmode.org">Org-mode</a> 9.1.9)</p>