A medium-high power battery charger

Abstract

The utility model discloses a kind of middle high-power battery charger, belong to charger field, including power supply circuit, DC regulated power supply circuit, signal processing circuit and switching power supply circuit;The power supply circuit one end is connected with external commercial power, and the other end of power supply circuit and DC regulated power supply circuit are connected;The input end of power supply circuit and signal processing circuit is connected, and the output end of signal processing circuit and DC regulated power supply circuit are connected;Power supply circuit and switching power supply circuit are connected.The utility model can greatly improve power, while efficiency is greatly improved, the utility model has almost no loss without obvious temperature rise, efficiency is improved very obviously, the utility model's flyback topology PWM is modulated by pulse width, reduces duty cycle and can realize 1000W within small power supply full range output.

Description

Technical Field

[0001] This utility model relates to the field of chargers, specifically a medium-to-high power battery charger. Background Technology

[0002] Traditional lead-acid and lithium battery chargers with a power of 200W or more are currently designed using dual-transistor forward or LLC half-bridge topologies, which result in complex circuits and unsatisfactory cost and size.

[0003] Existing charger circuits, due to the narrow input voltage range of LLC topologies, require the addition of PFC circuits for voltage boosting and regulation under wide input voltage range conditions to ensure reliability. This complexity results in very high costs. Furthermore, the limited gain range of LLC topologies also prevents them from achieving a wide voltage range output. However, when the battery is over-discharged, the voltage may even drop to zero volts, at which point the circuit cannot activate the battery for charging. Utility Model Content

[0004] The purpose of this utility model is to provide a medium-to-high power battery charger to address the problems mentioned in the background section.

[0005] To achieve the above objectives, this utility model provides the following technical solution: A medium-to-high power battery charger includes a power supply circuit, a DC regulated power supply circuit, a signal processing circuit, and a switching power supply circuit. The power supply circuit is connected to an external mains power source and is connected to the DC regulated power supply circuit via a bridge rectifier BR1 and a transformer T1. The power supply circuit is also connected to the switching power supply circuit. The power supply circuit is connected to the input terminal of the signal processing circuit via an internally configured PWM controller U2, and the output terminal of the signal processing circuit is connected to the DC regulated power supply circuit.

[0006] As a further embodiment of this utility model: the power supply circuit includes switch K4-B, fuse F1, varistor MOV1, bridge rectifier BR1, transformer T1 input side, optocoupler U4-A, optocoupler U9-A, optocoupler U14-B, PWM controller U2, transistor TR10, transistor TR9, diode D8, MOSFET Q9 and inductor L3-A; One end of switch K4-B in the power circuit is connected to the live wire of the mains power; the other end of switch K4-B is connected to one end of varistor MOV1. The neutral wire of the mains power is connected to one end of the fuse F1, and the other end of the fuse F1 is connected to the other end of the varistor MOV1. A capacitor C4 is connected in parallel across the two ends of the varistor MOV1; The two ends of the varistor MOV1 are connected to the two input ports 2 and the two output ports 3 of the bridge rectifier BR1. The two output ports 1 and 4 of the bridge rectifier BR1 are connected in parallel with a capacitor C7. The output port 1 of the bridge rectifier BR1 is connected to one end of the input side of the transformer T1; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R48, the other end of the resistor R48 is connected to the negative terminal of the diode D1, and the positive terminal of the diode D1 is connected to the other end of the input side of the transformer T1. A capacitor C9 is connected in parallel across the two ends of resistor R48; A capacitor C27 is connected in parallel across the diode D1. The output port 4 of bridge rectifier BR1 is grounded; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R52. Resistors R52, R53, and R51 are connected in sequence. The other end of the resistor R51 is connected to port 2 of the PWM controller U2. Port 1 of the PWM controller U2 is connected to the collector of the optocoupler U4-A; Port 2 of PWM controller U2 is connected to the collector of optocoupler U9-A and the collector of optocoupler U14-B; The emitters of optocoupler U4-A, optocoupler U9-A, and optocoupler U14-B are grounded; A capacitor C10 is connected in parallel between the collector and emitter of the optocoupler U14-B; Port 3 of PWM controller U2 is connected to one end of capacitor C11, and the other end of capacitor C11 is grounded; Port 4 of PWM controller U2 is connected to one end of resistor R20, and the other end of resistor R20 is grounded; Port 5 of the PWM controller U2 is grounded; Port 8 of PWM controller U2 is connected to one end of capacitor C5, and the other end of capacitor C5 is grounded; Port 7 of PWM controller U2 is connected to one end of capacitor C20 and the positive terminal of capacitor C16, while the other end of capacitor C20 and the negative terminal of capacitor C20 are grounded. The positive terminal of capacitor C16 is connected to a 14V DC power supply; Port 6 of PWM controller U2 is connected to one end of resistor R22, and the other end of resistor R22 is connected to the base of transistor TR10 and the base of transistor TR9. The collector of transistor TR10 is connected to a 14V DC power supply. The emitter of transistor TR10 is connected to the emitter of transistor TR9 and one end of resistor R19. The collector of transistor TR9 is grounded; The other end of resistor R19 is connected to the cathode of diode D8. The positive terminal of diode D8 is connected to the gate of MOSFET Q9; The source of MOSFET Q9 is grounded; A resistor R16 is connected in parallel between the gate and source of MOSFET Q9; The drain of MOSFET Q9 is connected to one end of inductor L3-A, and the other end of inductor L3-A is connected to the anode of diode D1. Port 3 of PWM controller U2 is connected to one end of resistor R28, and the other end of resistor R28 is connected to the negative terminal of diode D12. The positive terminal of diode D12 is connected to one end of inductor L3-B, and one end of inductor L3-B is grounded; The positive terminal of diode D12 is connected to one end of resistor R35, and the other end of resistor R35 is grounded. The positive terminal of diode D12 is connected to one end of resistor R12, the other end of resistor R12 is connected to one end of capacitor C25, and the other end of capacitor C25 is grounded. The negative terminal of diode D12 is connected to one end of resistor R34, and the other end of resistor R34 is grounded.

[0007] As a further embodiment of this utility model: the two ends of the varistor MOV1 are respectively connected to one end of resistor R36 and one end of resistor R33, and resistors R36, R37 and R33 are connected in series in sequence; the two ends of the varistor MOV1 are respectively connected to one end of resistor R3 and one end of resistor R2, and resistors R3, R1 and R2 are connected in series in sequence.

[0008] As a further embodiment of this utility model: a capacitor C1 is connected in parallel across the two ends of the capacitor C7.

[0009] As a further embodiment of this invention, a capacitor C17 is connected in parallel between the collector and emitter of the optocoupler U4-A.

[0010] As a further embodiment of this utility model, a resistor R50 is connected in parallel across the two ends of the capacitor C10.

[0011] As a further embodiment of this invention, a resistor R15 is connected in parallel across the two ends of the diode D8.

[0012] As a further embodiment of this utility model, a resistor R32 is connected in parallel across the two ends of the resistor R34.

[0013] As a further aspect of this utility model, the PWM controller U2 is model NCP1252.

[0014] As a further embodiment of this utility model: both capacitor C7 and capacitor C1 are electrolytic capacitors, and the positive terminals of capacitor C7 and capacitor C1 are connected to the output port 1 of bridge rectifier BR1.

[0015] Compared with the prior art, the present invention has at least the following beneficial effects: This invention uses a PWM controller U2 to adjust the control signal, and a bridge rectifier BR1 and a transformer T1 to adjust the output voltage according to the control signal, achieving an ultra-wide range of output voltage. This is very suitable for the charging characteristics of battery chargers, enabling charging from a minimum voltage of 0V. The switching power supply circuit ensures safe switching of the power supply circuit. The main power devices in the power supply circuit have strong current capability and low cost, thus perfectly complementing most of the shortcomings of the flyback topology. This greatly improves the output power of the flyback topology and also significantly improves efficiency. The current sampling circuit of this invention has almost no loss and no significant temperature rise, resulting in a very significant efficiency improvement. The flyback topology PWM of this invention, through pulse width modulation and reduced duty cycle, can achieve a full range of power output up to 1000W. Attached Figure Description

[0016] Figure 1 This is a system block diagram of a medium-to-high power battery charger.

[0017] Figure 2 This is a circuit diagram of the power supply circuit in a medium-to-high power battery charger.

[0018] Figure 3 This is a circuit diagram of a DC regulated power supply circuit in a medium-to-high power battery charger.

[0019] Figure 4 This is a circuit diagram of a signal processing circuit in a medium-to-high power battery charger.

[0020] Figure 5 This is a circuit diagram of a switching power supply circuit in a medium-to-high power battery charger. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model.

[0022] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," and "linked" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0023] Please see Figure 1-5 A medium-to-high power battery charger includes a power supply circuit, a DC regulated power supply circuit, a signal processing circuit, and a switching power supply circuit. One end of the power supply circuit is connected to external AC mains power, and the other end is connected to the DC regulated power supply circuit. The input terminals of the power supply circuit and the signal processing circuit are connected, and the output terminal of the signal processing circuit is connected to the DC regulated power supply circuit. The power supply circuit and the switching power supply circuit are also connected. The power supply circuit converts external power, such as AC mains power, into the stable voltage and current required by the device. The DC regulated power supply circuit achieves a stable DC voltage output. The signal processing circuit performs current / voltage conversion, signal amplification, and filtering, and is a typical circuit in the field of analog signal processing. The switching power supply circuit is a high-efficiency power conversion and voltage regulation device that regulates the output voltage by controlling a switching transistor and is widely used in power supply scenarios for electronic equipment.

[0024] The power supply circuit includes resistor R10, switch K4-B, fuse F1, resistors R36, R37, and R33, varistor MOV1, resistors R3, R1, and R2, capacitor C4, bridge rectifier BR1, capacitors C7, C1, and C9, resistor R48, capacitor C27, diode D1, transformer T1 input side, resistors R52, R53, and R51, optocoupler U4-A, capacitor C17, optocoupler U9-A, optocoupler U14-B, capacitor C10, resistor R50, and capacitor C11, PWM controller U2, resistor R20, capacitor C5, capacitor C20, capacitor C16, resistor R22, transistor TR10, transistor TR9, resistor R19, resistor R15, diode D8, resistor R16, MOSFET Q9, and inductor L3-A. One end of switch K4-B in the power circuit is connected to the live wire of the mains power; the other end of switch K4-B is connected to one end of varistor MOV1. The neutral wire of the mains power is connected to one end of the fuse F1, and the other end of the fuse F1 is connected to the other end of the varistor MOV1. Resistors R36, R37, and R33 are connected in series, and the two ends of the series combination of resistors R36, R37, and R33 are connected in parallel across the two ends of the varistor MOV1. Resistors R3, R1, and R2 are connected in series, and the two ends of the series combination of resistors R3, R1, and R2 are connected in parallel across the two ends of the varistor MOV1. A capacitor C4 is connected in parallel across the two ends of the varistor MOV1; The two ends of the varistor MOV1 are connected to the two input ports 2 and the two output ports 3 of the bridge rectifier BR1. The two output ports 1 and 4 of the bridge rectifier BR1 are connected in parallel with a capacitor C7. A capacitor C1 is connected in parallel across capacitor C7. The output port 1 of the bridge rectifier BR1 is connected to one end of the input side of the transformer T1; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R48, the other end of the resistor R48 is connected to the negative terminal of the diode D1, and the positive terminal of the diode D1 is connected to the other end of the input side of the transformer T1. A capacitor C9 is connected in parallel across the two ends of resistor R48; A capacitor C27 is connected in parallel across the diode D1. The output port 4 of bridge rectifier BR1 is grounded; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R52. Resistors R52, R53, and R51 are connected in sequence. The other end of the resistor R51 is connected to port 2 of the PWM controller U2. Port 1 of the PWM controller U2 is connected to the collector of the optocoupler U4-A; A capacitor C17 is connected in parallel between the collector and emitter of the optocoupler U4-A; Port 2 of PWM controller U2 is connected to the collector of optocoupler U9-A and the collector of optocoupler U14-B; The emitters of optocoupler U4-A, optocoupler U9-A, and optocoupler U14-B are grounded; A capacitor C10 is connected in parallel between the collector and emitter of the optocoupler U14-B; A resistor R50 is connected in parallel across the two ends of capacitor C10; Port 3 of PWM controller U2 is connected to one end of capacitor C11, and the other end of capacitor C11 is grounded; Port 4 of PWM controller U2 is connected to one end of resistor R20, and the other end of resistor R20 is grounded; Port 5 of the PWM controller U2 is grounded; Port 8 of PWM controller U2 is connected to one end of capacitor C5, and the other end of capacitor C5 is grounded; Port 7 of PWM controller U2 is connected to one end of capacitor C20 and the positive terminal of capacitor C16, while the other end of capacitor C20 and the negative terminal of capacitor C20 are grounded. The positive terminal of capacitor C16 is connected to a 14V DC power supply; Port 6 of PWM controller U2 is connected to one end of resistor R22, and the other end of resistor R22 is connected to the base of transistor TR10 and the base of transistor TR9. The collector of transistor TR10 is connected to a 14V DC power supply. The emitter of transistor TR10 is connected to the emitter of transistor TR9 and one end of resistor R19. The collector of transistor TR9 is grounded; The other end of resistor R19 is connected to the cathode of diode D8. A resistor R15 is connected in parallel across the two ends of diode D8; The positive terminal of diode D8 is connected to the gate of MOSFET Q9; The source of MOSFET Q9 is grounded; A resistor R16 is connected in parallel between the gate and source of MOSFET Q9; The drain of MOSFET Q9 is connected to one end of inductor L3-A, and the other end of inductor L3-A is connected to the anode of diode D1. Port 3 of PWM controller U2 is connected to one end of resistor R28, and the other end of resistor R28 is connected to the negative terminal of diode D12. The positive terminal of diode D12 is connected to one end of inductor L3-B, and one end of inductor L3-B is grounded; The positive terminal of diode D12 is connected to one end of resistor R35, and the other end of resistor R35 is grounded. The positive terminal of diode D12 is connected to one end of resistor R12, the other end of resistor R12 is connected to one end of capacitor C25, and the other end of capacitor C25 is grounded. The cathode of diode D12 is connected to one end of resistor R34, and the other end of resistor R34 is grounded. A resistor R32 is connected in parallel across the two ends of resistor R34; The PWM controller U2 is model NCP1252; Both capacitors C7 and C1 are electrolytic capacitors. The positive terminals of both capacitors C7 and C1 are connected to output port 1 of bridge rectifier BR1. This invention uses IGBTs as the main power device. Due to their superior current capability and lower cost, IGBTs perfectly compensate for most of the shortcomings of flyback topologies. Power output can even be extended to around 1000W. Traditional flyback topologies are only suitable for small to medium power designs, mainly because the primary peak current of flybacks is relatively large. Beyond 1000W, they heavily rely on the current capability of the power MOSFETs, making the cost of MOSFETs quite high for high-power applications.

[0025] This invention uses a current transformer as the primary current sensor, effectively reducing the on-state loss on the primary side and improving the conversion efficiency by nearly 1%. Traditional flyback power supplies use resistor sampling for primary current detection, which results in significant power loss due to high current at high power levels and causes severe heat generation.

[0026] This invention employs a dual-power supply structure consisting of a main power supply and an auxiliary power supply. The main power supply provides the required output power, while the auxiliary power supply provides a stable voltage to all chips, ensuring stable operation under various conditions and providing sufficient turn-on current to inductive devices such as fans and relays. Traditional solutions typically use the auxiliary winding of the main power supply to power each circuit. This voltage is significantly affected by changes in the output load and is prone to malfunctions under certain conditions. For example, when the terminal battery voltage is too low, the charging voltage will also be low, causing the supply voltage to each circuit to drop accordingly. This results in the circuits not operating under optimal conditions, easily leading to abnormal states and affecting circuit reliability.

[0027] This invention employs a flyback topology, and the output voltage is regulated via PWM, enabling an ultra-wide output voltage range, making it ideal for the charging characteristics of battery chargers. For example, when a battery is over-discharged, a low-voltage, low-current activation charging is required; this invention can achieve charging from a minimum voltage of 0V.

[0028] This invention employs a flyback topology for the design of a high-power battery charger. This topology can achieve a wide range of voltage input (85V-265V input) and a wide range of voltage output (0V-88V) without the need for an active PFC circuit. Due to its simple structure and absence of a PFC circuit, it has a lower overall cost and higher cost-effectiveness.

[0029] This invention uses a flyback topology, which is currently the mainstream application in low-power power supplies under 1000W.

[0030] Traditional flyback topology power supplies using power MOSFETs are generally limited to power outputs up to 200W. This charger innovatively adopts a new type of high-frequency IGBT power device, which can greatly increase power output and efficiency. This invention has almost no losses and no significant temperature rise, and the efficiency improvement is very obvious. The flyback topology PWM of this invention can achieve full-range output of power supplies up to 1000W by reducing the duty cycle through pulse width modulation.

[0031] This utility model charger has an independent auxiliary power supply, which provides stable and reliable power to the fan, power chip, and relay. When abnormalities such as reverse battery connection or short circuit are required, the main power circuit can be quickly shut down, effectively reducing the risk of abnormal conditions.

[0032] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects; the scope of this invention is defined by the appended claims rather than the foregoing description; and thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0033] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution; this narrative style is merely for clarity; those skilled in the art should consider the specification as a whole; the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A medium-to-high power battery charger, characterized in that, It includes a power supply circuit, a DC regulated power supply circuit, a signal processing circuit, and a switching power supply circuit; the power supply circuit is connected to the external mains power, and the power supply circuit is connected to the DC regulated power supply circuit through a bridge rectifier BR1, a transformer T1, and the switching power supply circuit; the power supply circuit is connected to the switching power supply circuit; the power supply circuit is connected to the input terminal of the signal processing circuit through an internally installed PWM controller U2, and the output terminal of the signal processing circuit is connected to the DC regulated power supply circuit.

2. A medium-to-high power battery charger according to claim 1, characterized in that, The power supply circuit includes switch K4-B, fuse F1, varistor MOV1, bridge rectifier BR1, transformer T1 input side, optocoupler U4-A, optocoupler U9-A, optocoupler U14-B, PWM controller U2, transistor TR10, transistor TR9, diode D8, MOSFET Q9 and inductor L3-A; One end of switch K4-B in the power circuit is connected to the live wire of the mains power; the other end of switch K4-B is connected to one end of varistor MOV1. The neutral wire of the mains power is connected to one end of the fuse F1, and the other end of the fuse F1 is connected to the other end of the varistor MOV1. A capacitor C4 is connected in parallel across the two ends of the varistor MOV1; The two ends of the varistor MOV1 are connected to the two input ports 2 and the two output ports 3 of the bridge rectifier BR1. The two output ports 1 and 4 of the bridge rectifier BR1 are connected in parallel with capacitor C7. The output port 1 of the bridge rectifier BR1 is connected to one end of the input side of the transformer T1; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R48, the other end of the resistor R48 is connected to the negative terminal of the diode D1, and the positive terminal of the diode D1 is connected to the other end of the input side of the transformer T1. A capacitor C9 is connected in parallel across the two ends of resistor R48; A capacitor C27 is connected in parallel across the diode D1. The output port 4 of bridge rectifier BR1 is grounded; The output port 1 of the bridge rectifier BR1 is connected to one end of the resistor R52. Resistors R52, R53, and R51 are connected in sequence. The other end of the resistor R51 is connected to port 2 of the PWM controller U2. Port 1 of the PWM controller U2 is connected to the collector of the optocoupler U4-A; Port 2 of PWM controller U2 is connected to the collector of optocoupler U9-A and the collector of optocoupler U14-B; The emitters of optocoupler U4-A, optocoupler U9-A, and optocoupler U14-B are grounded; A capacitor C10 is connected in parallel between the collector and emitter of the optocoupler U14-B; Port 3 of PWM controller U2 is connected to one end of capacitor C11, and the other end of capacitor C11 is grounded; Port 4 of PWM controller U2 is connected to one end of resistor R20, and the other end of resistor R20 is grounded; Port 5 of the PWM controller U2 is grounded; Port 8 of PWM controller U2 is connected to one end of capacitor C5, and the other end of capacitor C5 is grounded; Port 7 of PWM controller U2 is connected to one end of capacitor C20 and the positive terminal of capacitor C16, while the other end of capacitor C20 and the negative terminal of capacitor C20 are grounded. The positive terminal of capacitor C16 is connected to a 14V DC power supply; Port 6 of PWM controller U2 is connected to one end of resistor R22, and the other end of resistor R22 is connected to the base of transistor TR10 and the base of transistor TR9. The collector of transistor TR10 is connected to a 14V DC power supply. The emitter of transistor TR10 is connected to the emitter of transistor TR9 and one end of resistor R19. The collector of transistor TR9 is grounded; The other end of resistor R19 is connected to the cathode of diode D8. The positive terminal of diode D8 is connected to the gate of MOSFET Q9; The source of MOSFET Q9 is grounded; A resistor R16 is connected in parallel between the gate and source of MOSFET Q9; The drain of MOSFET Q9 is connected to one end of inductor L3-A, and the other end of inductor L3-A is connected to the anode of diode D1. Port 3 of PWM controller U2 is connected to one end of resistor R28, and the other end of resistor R28 is connected to the negative terminal of diode D12. The positive terminal of diode D12 is connected to one end of inductor L3-B, and one end of inductor L3-B is grounded; The positive terminal of diode D12 is connected to one end of resistor R35, and the other end of resistor R35 is grounded. The positive terminal of diode D12 is connected to one end of resistor R12, the other end of resistor R12 is connected to one end of capacitor C25, and the other end of capacitor C25 is grounded. The negative terminal of diode D12 is connected to one end of resistor R34, and the other end of resistor R34 is grounded.

3. A medium-to-high power battery charger according to claim 2, characterized in that, The two ends of the varistor MOV1 are connected to one end of resistor R36 and one end of resistor R33 respectively, and resistors R36, R37 and R33 are connected in series. The two ends of the varistor MOV1 are connected to one end of resistor R3 and one end of resistor R2 respectively, and resistors R3, R1 and R2 are connected in series.

4. A medium-to-high power battery charger according to claim 3, characterized in that, A capacitor C1 is connected in parallel across the two ends of the capacitor C7.

5. A medium-to-high power battery charger according to claim 4, characterized in that, The collector and emitter of the optocoupler U4-A are connected in parallel with a capacitor C17.

6. A medium-to-high power battery charger according to claim 5, characterized in that, A resistor R50 is connected in parallel across the two ends of the capacitor C10.

7. A medium-to-high power battery charger according to claim 6, characterized in that, A resistor R15 is connected in parallel across the two ends of the diode D8.

8. A medium-to-high power battery charger according to claim 7, characterized in that, A resistor R32 is connected in parallel across the two ends of the resistor R34.

9. A medium-to-high power battery charger according to claim 8, characterized in that, The PWM controller U2 is model NCP1252.

10. A medium-to-high power battery charger according to claim 9, characterized in that, Both capacitors C7 and C1 are electrolytic capacitors, and the positive terminals of both capacitors C7 and C1 are connected to the output port 1 of the bridge rectifier BR1.

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