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DESIGN AND CONSTRUCTION OF 12

VOLT AUTOMATIC BATTERY CHARGER

BY

IKEH ANGELA
2006/24375EE

A THE~I S SUBMITTED TO THE DEPARTMENT OF ELECTRICAL AND

OMPUTER ENGINEERING, FEDERAL UNIVERSITY OF
TECHNOLOGY ,

MINNA.
11,·

NOVEMBER, 2010 .

.. '
 DEDICATION

This project is dedicated to the "Almighty God the Father, God the Holy Spirit, the" I AM THAT

I AM" ALPHA and OMEGA . The Beginning and the End, with HIM all things are possible. He has

caused me to laugh to his Glory, and with love to my parents Mr. & Mrs. lkeh Christopher, my beloved

brother & sister (Mr. Francis Ugochukwu Ikeh and Miss maryann Nkulika Ikeh) and Osita Anigbogu &

Family.

ii
 DECLARATION

I, IKEH ANGELA, declare that this work was done by me and has never been presented

e lsewhere I'ur the award of a degree. I also hereby relinquish the copyright to the Federal University of

Technology, Minna.

IKEII ANGELA Mr. Usman N. Galadima

(Student) (Sup~rv.t~')

(~.~~ .. ..I$.:::.!.?:~.1 0 ~'e; 15 /,<..

.................,................... /~tt'>

(Signature and Date) (Signature and Date)

Engr.A.G. Raji External Examiner

(Head of Department)

~c\(~~<Q1;2J:>\) ;),!It
.....................................~.{ I
(Signature and Date) (Signature and Date)

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 ACKWONLEDGEMENT

It is said that "Gratitude is memory of heart" in God, I put my hope and place my trust.

He is the Alpha, Omega and Omniscient worthy of my eternal praise. If God does not build the

house. those who build labour in vain. In my chequered history, he remain my fortrest of hope

.
every hour of grief. I am grateful to the Lord Jesus Christ for the successful completion of my

c'uursc in Electrical and Computer Engineering for he is my strength when I was weak. he lifed

tllC up to where I couldn't reach. I am everything because he loves me.

From depth of my heali [ thank my supervisor Engineer Usman .N. Galadima and Malan

Umar who through their advice and supervision gives this project a meaningful direction. I also

thank my HOD. Engr Raji; and all the Electrical and Computer Engineering Department

lecturers for their contributions toward the laying of fundamental knowledge which is put

together to achieve the aim of this workplace. Their "Keep going" attitude helped me a lot

during the stormy period.

A river that forgets its source wi ll surely dry up. lowe my Father and Mother a big thank

you ror their comments and constructive criticism which have gone a long way in charting the ;

co urse fo r a rich and purposeful project. As a mortal, I am meant to err but, with yoW" words of

cncouragement I have been propelled to higher realms. For all these and other allied reasons I

can only say a big thank you. This I say with a heart full of gratitude.

1\ feast is made laughter and w1l1e makes life merry, but money is the answer for

everything. I'll never forget Mr. Os ita, Mr. Julian, Miss Angela in fact all Anigbogu's Fam 'ly;
thank you would have been an understatement but, no other words to say thank you for your

genuine interest, encouragement, moral, love, caring and particularly financial support. You

motivated me and tell me I can do it and with you solidly behind me, I can move mountains and

climb the ladder of success.

My gratitude to Mr. & Mrs. Joseph Okafor and all the Okafor's Family; for their

encouragement, financial and prayer support: To my brother and sister Francis and Maryann, I

don't know how to thank you for your encouragement, spiritual, physical, moral support. May

God bless you all.

Specially, I would want to acknowledge these special friends of mine for their

' ncouragement and love, Mr. Reuben.C.Erigbuokwu, Musa Umar Bida, Mkpuma Eucharia.U.

Anwser.E, Biodu,Emma and all my Neighbours. Space will fail me to mention every one that

contributed in both little and great ways to this important stage of my like, and only eternity can

reveal how grateful I am to you all and God's richest blessing dwell with you Amen.

lKEHANGELA

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 ABSTRACT
The constant potential mode of charging (using a switching charged capacitor)

across a load as adopted for this project, which was tested on partially run down/

di scharged battery with an expected result.

When charging, a larger amount of current was drawn at first and reducing

progressively until the battery voltage attained the required 12V. The construction and

design is not only to charge but to keep the battery in a charged good condition.

The theory, design, circuit analysis, and circuit diagram with label were provided

to give adequate information about the design.

TABLE OF CONTENTS
..................................................... i
Title Page ....................... ·........ · .. ·.. ·........ ·........ · .. ·........ · .. ·.. .< .

..................................................Ii
Dedication Page .......................... ·.. ·.. · .. · .. · .. ·........ · .. · .. · .. ·.. ··

. Page ............................................................
Declaration : ....................................................iii

. Ie d gemen t .............................................................................................................iv
Ack now

Abstract ...............................................................................................................................v

Table of contents .......................................................................·........................................vi

LIST OF FIGURES

Fig 3.1 A typical dc power supply ................................................................................. 17

Fig 3.2 The circuit diagram of the full wave rectifier ................................................. 18

Fig 3.3 Output of 0 1 and 0 3 ......... .................................................................................. 18

Fig 3.4 Output of 02 and 0 4 .......................................................................................... 19

Fig 3.5Complete Circuit Diagram .................................................................................29

LIST OF TABLES

Table 4.5 Result of Charging ........................................................................................32

Table 4.6 Result of Discharging...................................................................................32

CHAPTER ONE .............................; ....................................................................................1

GENERAL INTRODUCTION .............................................................................................. 1

1.1 INTRODUCTION .........................................................................................................1

1.2 Project Aim and Objectives .....................................................................................3
1.3 Features of the project .........................................................................,.................. 3

vii
1.4 Limitation .................................................................................................................... 3

CHAPTER TWa .................................................................. ................................. ............... 4

LITERATURE REViEW .......................................................................................................4

2.1 Batteries in Existence .............................................................................. ... ............... 4

2.1.1 Nickel Cadmium ....................................................................................... ............... 4

2.1.2 Gel Cell ..................................................................................................................... 4

2.1.3 Lead Acid ............................................................................................................ ..... 4

2.2 Fast Charging ........................... :.................................................................................. 5

2.2.1 Constant Current Fast Chargers ........................................................................... .5

2.2.2 Constant Voltage Fast Chargers ................................................................... :........ 5

2.3 Low Rate Charging ......... :............................................................................................6

2.4 Trickle Charging ..........................................................................................................6

2.6 Background information ............................................................................................6

2.6.1 Power Supply ............................................. .............................................................. 7

2.6.2 Thyristors ...........................·....................................................................................... 7

2.6.3 Battery ......................................................................................................................8

2.6.4 Light Emitting Diode Indicators ............................................................................. 9

2.6.5 Voltages ....................................................................................................................9

2.6.6 Amp-Hour (current} ...............................................................................................10

2.7 CHEMICAL REACTIONS IN LEAD ACID BATIERy ... ................................................. 10

2.7.1 Discharging ............................................................................................................. 10

2.7.2 Charging ..................................................................................................................11

2.8 Battery Rating ............................................................................................................ 12

2.9 Electromotive Force .............., ................................................................................... 13

viii
2.10 Reversible Cells ........................................................................................................ 13

2.11 Battery Charging ...................................................................................................... 13

2.12 Vo ltage on Discharge .............................................................................................. 14

2.13 Voltage on Charger .............................................................................:.................... 15

2.14 Constant Voltage Fast Chargers ........................................................................... 15

CHAPTER THREE ........................... ,................................................................................... 17

..

3.0 Design of Power Supply Unit.. ................................................................................ 17

3.1 The Charging Circuit ................................................................................................. 22

3.1;1 Thyristors (BT136) .................................................................................................. 22

3.2 The Control Circuit ...................................................................................................23

3.2.1 Zener Diode ... .........................................................................................................23

3.3 The 12V Battery Charger ......................................................................................... 23

3.3.1 Capacitor ................................................................................................................24

3.4 Resistor ......................................................................................................................25

3.5 Light Emitting Diodes (LED) ...................................................................................... 26

3.6 Construction .........................·......................................................................................27

3.7 Conceptual Mode of Operation ............................................................................... 27

3.8 Complete Circuit Diagram ......................................................................................... 29

CHAPTER FOUR .................................................................................................................. 30

TESTS, RESU LTS AN D DISCUSSION ...................... ,............................................................ 30

4.1 Testing ...........................................................................................................................30

4.2 Indications of fully Charged Battery .........................................................................30

ix
4.2.1 Gassing ......... ... ..............................................................................~ ............................ 30

4.2.2 Voltage ...................................................................................................................... .31

4.2.3 Specific Gravity of the Electrolyte ....................................... ......... .......................... 31

4.3 Packaging .............................. ................................................... ........................... .......... 31

4.4 Discussion of Results ........................... ........................... ,............................................31

4.7 Battery Operation in H'igh and Low Temperature ............................ ;...................... 33

4.7.1 Low Temperature, ................................................................................ ......... .......... 33

4.7.2 High Temperature ..............•.....................................................................................33

CHAPTER FiVE ..................................................................................................................... 36

CONCLUSION AND RECOMMENDATION ..................................... ,.................................. 36

5.0 Conclusion ...................................................................................................................36

5.1 Recommendation ........................................................................................................36

REFERENCES .......................................................................................................................37