After repeated experiments, the author has produced a reliable fast charger for electric bicycles. The circuit is shown in the figure.
Schematic diagram of self-made electric bicycle fast charger
1. Circuit characteristics
1. After the output voltage is set (for example, 36V), if the pole plate of the battery is disconnected and disconnected, causing a group of batteries to fail or a short circuit, the battery terminal voltage will be reduced or zero, and the charger will have no output current.
2. If the voltage of the charged battery deviates from the set voltage, such as the set voltage is 36V, the 24V, 12V, 6V batteries are mistakenly connected, and the charger has no output current. If the setting is 24V, the 36V battery is mistakenly connected, because the charger output voltage It is lower than the battery voltage, so it cannot charge the battery.
3. If the two output terminals of the charger are short-circuited, the trigger circuit of the thyristor SCR in the charger cannot work, so the thyristor does not conduct, and the output current is zero.
4. If the positive and negative poles of the battery are mistakenly reversed during use, the thyristor trigger circuit is reversely terminated, there is no trigger signal, the thyristor is not conductive, and the output current is zero.
5. The use of pulse charging is conducive to extending battery life. Since the low-voltage alternating current is pulsating DC after full-wave rectification, the thyristor will be turned on only when its peak voltage is greater than the battery voltage, and when the pulsating DC voltage is in the valley area, the thyristor will reverse bias and stop to the battery. Charging, so what flows through the battery is pulsating direct current.
6. Fast charging, full stop. Because the voltage across the battery is low at the beginning of charging, the charging current is large. When the battery is about to be sufficient (36V battery terminal voltage can reach 44V), as the charging voltage becomes closer to the peak value of the pulsating DC output voltage, the charging current will become smaller and smaller, and it will automatically become trickle charging. When the voltage across the battery is charged to the peak value of the rectified output, the charging process stops. After testing, the three-segment electric vehicle battery 36V (12V / 12Ah three-serial series), the charger can be fully charged in just a few hours.
7. The circuit is simple and easy to make, requiring little maintenance and repair.
Second, the circuit principle
The AC220V mains is stepped down by the transformer T1, and after D1-D4 full-wave rectification, it is supplied to the charging circuit for operation. When the output terminal is connected to the set charged battery according to the correct polarity, if each half-wave peak value of the rectified output pulsating voltage exceeds the output voltage of the battery, the thyristor SCR is triggered to conduct through the collector current of Q, the current Charge the battery via SCR. When the pulsating voltage is close to the battery voltage, the thyristor is turned off and the charging is stopped. Adjust R4 to adjust the turn-on voltage of transistor Q. Generally, R4 can be adjusted from large to small to turn on Q to trigger the thyristor (turn on). In the figure, the light-emitting tube D5 is used as a power supply instruction, and D6 is used as a charging instruction.
3. Component selection
The power transformer can be a BK200 type control transformer, and the output voltage can be used as a 36V block, or a 4090 type 200V toroidal transformer can be used. The secondary voltage is 22Vx2 or 20V & TImes; 2 block series. The 4090 type ring transformer used by the author has three secondary voltages of 24Vx2, 12Vx2, 0-6-23V. If the 24Vx2 gear is connected in series (48V), the output voltage is too high and the charging current is too large (for 36V electric vehicle battery) When charging, the average charging current measured by the ammeter on the string is about 1.5-1.8A, which is the average value. At this time, the peak current can reach more than 5-7A). To reduce the output voltage of the transformer, the remaining 12V & TImes; 2 and O- 6V two sets of coils are connected in series in the primary coil, which reduces the secondary output voltage to 40V at no load and 36V at full load (when the average charging current is 1.2A), which can be used. Because the market price of the 4090 toroidal transformer is only about 23 yuan. Can reduce production costs. Fans can also wind the transformer by themselves.
In addition, the rectifier full-bridge D1-D4 in the circuit can choose 8-10A square full-bridge, with a circular mounting hole in the middle, which can be installed on the aluminum plate for heat dissipation. The thyristor can use 1OA / 100V gold seal unidirectional thyristor, and fix it with the rectifier bridge on the same heat dissipation aluminum plate with a nut. Trigger transistor Q parameters are Vceo≥60V, IM = 1A, 2SB536, B564, B1008, B1015 or 2SA684, A720 and other tubes can be selected. R6 is used for current limiting protection. If the secondary output voltage of the transformer is appropriate and the charging current (average value) does not exceed 1.5A, this resistor can also be omitted.
If the charger is used to charge batteries of other voltages (such as 24V, 12V, etc.), the secondary output voltage of the transformer can be selected as 22V-26V, 12V-14V, etc., and the resistance of R2 and R5 can be appropriately reduced , Can also use the band switch to control the secondary AC voltage and resistance conversion, so that the charger has a greater range of use.
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