1.

INTRODUCTION

A mobile battery charger circuit is a device that can automatically recharge a mobile phone’s
battery when the power in it gets low. Nowadays mobile phones have become an integral part of
everyone’s life and hence require frequent charging of battery owing to longer duration usage.

Battery chargers come as simple, trickle, timer based, intelligent, universal battery charger-
analyzers, fast, pulse, inductive, USB based, solar chargers and motion powered chargers. These
battery chargers also vary depending on the applications like mobile phone charger, battery
charger for vehicles, electric vehicle batteries chargers and charge stations.

Charging methods are classified into two categories: fast charge method and slow charge
method. Fast charge is a system used to recharge a battery in about two hours or less than this,
and the slow charge is a system used to recharge a battery throughout the night. Slow charging is
advantageous as it does not require any charge detection circuit. Moreover, it is cheap as well.
The only drawback of this charging system is that it takes maximum time to recharge a battery.

The charging protocol (how much voltage or current for how long, and what to do when
charging is complete, for instance) depends on the size and type of the battery being charged.
Some battery types have high tolerance for overcharging (i.e., continued charging after the
battery has been fully charged) and can be recharged by connection to a constant voltage source
or a constant current source, depending on battery type. Simple chargers of this type must be
manually disconnected at the end of the charge cycle, and some battery types absolutely require,
or may use a timer, to cut off charging current at some fixed time, approximately when charging
is complete. Other battery types cannot withstand over-charging, being damaged (reduced
capacity, reduced lifetime) or overheating or even exploding. The charger may have temperature
or voltage sensing circuits and a microprocessor controller to safely adjust the charging current
and voltage, determine the state of charge, and cut off at the end of charge.

A trickle charger provides a relatively small amount of current, only enough to counteract self-
discharge of a battery that is idle for a long time. Slow battery chargers may take several hours to
complete a charge. High-rate chargers may restore most capacity much faster, but high rate
chargers can be more than some battery types can tolerate. Such batteries require active

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EN Department, SRMGPC
monitoring of the battery to protect it from overcharging. Electric vehicles ideally need high-rate
chargers. For public access, installation of such chargers and the distribution support for them is
an issue in the proposed adoption of electric cars.

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EN Department, SRMGPC
 2. DESCRIPTION OF TOPIC

Mobile phones generally charge with 5v regulated DC supply, so basically we are going to build
a 5v regulated DC supply from 220 AC. This DC supply can be used to charge mobiles as well
as the power source for digital circuits, breadboard circuits, ICs, microcontrollers etc.

You can also build 6V DC, 9V, 12V, 15V etc by using proper transformer, capacitor and voltage
regulator. The basic concept remains the same, you just need to arrange a heat sink for higher
voltage and current.

The concept of being able to charge mobile phones on the go has been a pleasant help to almost
everyone in the pre-sent times. Ever since the increasing abilities and the de-creasing cost of
smart phones, their utility has increased but their power consumption is high. The present day
smart phones have a very large storage capacity and the parallelism with respect to apps
associated with them is increasing rapid-ly. Running many applications at a time causes the
phones to drain out quickly. Although increased charge consumption for a host of parallel and
quick applications is a good bargain, this also calls for the phone being charged frequently. As
power supply sockets are not available all the time, power banks come in handy.

The power banks available in the market do not have the ability to extend beyond a fixed number
of ports. The de-sign is rigid to a high extent. The cost of these power banks is comparatively
very high as well. Other than that, using the present day power banks, we cannot do much, other
than charging phones. Say, we need to use some other USB device like a USB light or music
player with USB connection. They cannot be done easily with them. In order to power those de-
vices, we will have to do so separately. The following article describes another innovative design
to construct a power bank that reduces these problems to a great extent.

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EN Department, SRMGPC
 3. COMPONENTS USED

The components used in this project are:-

USB Cable:-
The USB cable is a versatile product and that is being used to deliver the current and voltage to
the phones and other devices used. The internal structure of USB [1] is as explained:

Fig1 : USB Cable

Vcc (DC)- This is the most important part used in the making of the power bank. The USB cable
works on specifically and only 5V. Any voltage greater than this will damage the device used
and any voltage lesser than this might not power it to a sufficient extent. This property of the
USB cable to handle 5V is highly advantageous, as, most of the phones charge within 5V. Alt-
hough the current ratings will vary, that can be adjusted by using the battery.

Ground- This connects to the ground of the circuit.

D+ and D- These are data wires. These are utilized when the USB cable is used to transfer data
from one device to the other. They do not play any role in charging of the phone. But, many of
the pre-sent day phones will not work if the D+ and D- pins are not given any value. Hence, they
are given a dummy value using the resistors and the phone is “tricked” into believing that it is
connected to an external device and hence charges.

Each one of the wires is connected to an internal pin inside the USB.
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EN Department, SRMGPC
IC 7805:-
This is a voltage regulator IC. This
regulates the input DC voltage
to 5V DC. This is the main voltage
conversion necessary to
power the phone. Most of the
phones are charged via the
USB cable. The USB cable, as
discussed earlier can handle
a maximum of 5V. This will be
got by the usage of IC 7805 [2]. In this IC, only the voltage will be regulated. The current how-
ever, will remain almost the same, with a very negligible drop. Most of the adapters used will
give 16 – 24V DC. This needs to be fed to the input of the IC and the output will be regulated to
5V (Fig 1) “[3], [4], [5]” which can be used to
charge the phone.

Fig2: Connection of IC 7805

All voltage sources cannot able to give fixed output due to fluctuations in the circuit. For getting
constant and steady output, the voltage regulators are implemented. The integrated circuits which
are used for the regulation of voltage are termed as voltage regulator ICs. Here, we can discuss
about IC 7805.

The voltage regulator IC 7805 is actually a member of 78xx series of voltage regulator ICs. It is
a fixed linear voltage regulator. The xx present in 78xx represents the value of the fixed output
voltage that the particular IC provides. For 7805 IC, it is +5V DC regulated power supply. This
regulator IC also adds a provision for a heat sink. The input voltage to this voltage regulator can
be up to 35V, and this IC can give a constant 5V for any value of input less than or equal to 35V
which is the threshold limit.

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EN Department, SRMGPC
 Fig3: LM7805 Pin diagram

PIN 1-INPUT

The function of this pin is to give the input voltage. It should be in the range of 7V to 35V. We
apply an unregulated voltage to this pin for regulation. For 7.2V input, the PIN achieves a
maximum efficiency.

PIN 2-GROUND

We connect the ground to this pin. For output and input, this pin is equally neutral (0V).

PIN 3-OUTPUT

This pin is used to take the regulated output.

Battery:-
The nine-volt battery, or 9-volt battery, is a common size of battery that was introduced for the
early transistor radios. It has a rectangular prism shape with rounded edges and a polarized snap
connector at the top. This type is commonly used in walkie-talkies, clocks and smoke detectors.

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EN Department, SRMGPC
 Fig4: 9 volt battery

The nine-volt battery format is commonly available in primary carbon-zinc and alkaline
chemistry, in primary lithium iron disulfide, and in rechargeable form in nickel-cadmium, nickel-
metal hydride and lithium-ion. Mercury-oxide batteries of this format, once common, have not
been manufactured in many years due to their mercury content. Most nine-volt alkaline batteries
are constructed of six individual 1.5 V LR61 cells enclosed in a wrapper.[3] These cells are
slightly smaller than LR8D425 AAAA cells and can be used in their place for some devices,
even though they are 3.5 mm shorter. Carbon-zinc types are made with six flat cells in a stack,
enclosed in a moisture-resistant wrapper to prevent drying. Primary lithium types are made with
three cells in series.The most common type of nine-volt battery is commonly referred to simply
as 9-volt, although there are less common nine-volt batteries of different sizes. The PP3 size
battery has height 48.5 mm, width 26.5 mm, depth 17.5 mm (or 1.9 in × 1.0 in × 0.68 in). Both
terminals are at one end and their centers are 1⁄2 inch (12.7 mm) apart.

LED:-
The Light emitting diode is a two-lead semiconductor light source. In 1962, Nick Holonyak has
come up with an idea of light emitting diode, and he was working for the general electric
company. The LED is a special type of diode and they have similar electrical characteristics of a
PN junction diode. Hence the LED allows the flow of current in the forward direction and blocks
the current in the reverse direction. The LED occupies the small area which is less than the 1
mm2. The applications of LEDs used to make various electrical and electronic projects.

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EN Department, SRMGPC
 Fig5: LED Circuit diagram

Light emitting diode is a p-n junction diode. It is a specially doped diode and made up of a
special type of semiconductors. When the light emits in the forward biased, then it is called as a
light emitting diode. Light emitting diodes are made from a very thin layer of fairly heavily
doped semiconductor material and depending on the semiconductor material used and the
amount of doping, when forward biased an LED will emit a coloured light at a particular spectral
wavelength.When the diode is forward biased, electrons from the semiconductors conduction
band recombine with holes from the valence band releasing sufficient energy to produce photons
which emit a monochromatic (single colour) of light. Because of this thin layer a reasonable
number of these photons can leave the junction and radiate away producing a coloured light
output.

Then we can say that when operated in a forward biased direction Light Emitting Diodes are
semiconductor devices that convert electrical energy into light energy. The construction of a
Light Emitting Diode is very different from that of a normal signal diode. The PN junction of an
LED is surrounded by a transparent, hard plastic epoxy resin hemispherical shaped shell or body
which protects the LED from both vibration and shock. Unlike normal incandescent lamps and
bulbs which generate large amounts of heat when illuminated, the light emitting diode produces
a “cold” generation of light which leads to high efficiencies than the normal “light bulb” because
most of the generated energy radiates away within the visible spectrum. Because LEDs are solid-
state devices, they can be extremely small and durable and provide much longer lamp life than
normal light sources.

Different LED compounds emit light in specific regions of the visible light spectrum and
therefore produce different intensity levels. The exact choice of the semiconductor material used
will determine the overall wavelength of the photon light emissions and therefore the resulting
colour of the light emitted.

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EN Department, SRMGPC
Resistors:-
A resistor is a passive two-terminal electrical component that implements electrical resistance as
a circuit element. In electronic circuits, resistors are used to reduce current flow, adjust signal
levels, to divide voltages, bias active elements, and terminate transmission lines, among other
uses.

Fig5: Resistor

High-power resistors that can dissipate many watts of electrical power as heat, may be used as
part of motor controls, in power distribution systems, or as test loads for generators. Fixed
resistors have resistances that only change slightly with temperature, time or operating voltage.
Variable resistors can be used to adjust circuit elements (such as a volume control or a lamp
dimmer), or as sensing devices for heat, light, humidity, force, or chemical activity.

Connecting wires:-
Connecting wires are used as per requirement in the circuit. Connecting wires allows an
electrical current to travel from one point on a circuit to another because electricity needs a
medium through which it can move.

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EN Department, SRMGPC
 Fig6: Connecting wires

Most of the connecting wires are made up of copper or aluminum. Copper is cheap and good
conductivity. Instead of the copper, we can also use silver which has high conductivity but it is
too costly to use.

Capacitors:-
A capacitor is a passive two terminal electrical component that stores potential energy in electric
field. The effect of capacitor is called capacitance. In this minor project, total two capacitors are
being used each of 470 uF rating.

Fig7 : Capacitor

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EN Department, SRMGPC
 4. WORKING AND LAYOUT

A portable mobile charger with over voltage protection is presented in this project. The circuit
can be used to charge a mobile with the help of 4 AA batteries.As the components are discrete,
an over voltage protection system is also included in the event of failure of any component. The
working of the circuit is explained below.

Fig8 : Circuit Diagram

A 2A fuse can be used before IC 7805 to ensure that its input is cut off when over voltage
condition occurs.The output of 7805 is connected to a female USB connector and from which a
mobile can be charged. In the practical implementation, we used four 1.5V AA batteries that are
rated 1.5A.

When the switch is closed, power is drawn from the battery and current flows through the circuit.
The USB cable connected to the output terminal of IC 7805 is used to charge the phone through
its usb socket.
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EN Department, SRMGPC
PCB Layout:-

Fig: PCB Layout

5. ADVANTAGES AND DISADVANTAGES

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EN Department, SRMGPC
Advantages:-
 Portable: This is, in a word, a charger is portable. You can bring it in the office, or while
on vacation. It does not need sockets. So you can charge your phone even when you are
in travel or vacation in the woods. The portability will certainly help you stay away from
a terrible situation when the box runs out of life.
 Low cost: The cost of making this portable mobile battery charger is very less as
compared to normal battery chargers whuch is one of the important advantages of using
it.
 Simple construction: The circuit and PCB layout is very simple to understand.
 Fast charging.

Disadvantages:-
 Bulky: The model is bulky and large in construction as compared to normal battery
charger and power banks.
 Not wireless: In the age of wireless, the device uses a USB cable, which is still a minor
setback. The phone has to be connected to usb to charge which is not feasible all the time.
 Compatibility issues: Some phones may not be supported and might not charge. Due to
hardware comolexities some phones may even get damaged due to mismatch of charging
cycles.

6. CONCLUSION

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EN Department, SRMGPC
This design will help in reducing overall cost of the device and also help people by relaxing the
need of phone chargers and separate chargers for USB devices. It will definitely be helpful over
the days, as, the speed and advancements in phones are at an exponential rate which decreases
the charge of phones greatly. Hence, this calls for easier solutions to phone charg-ing. This will
also prove helpful to the newly emerging wear-able electronic gadgets as, the size and power
rating is ideal for that usage as well. Various power banks utilise the principle of portable battery
charging which are in huge demand. The cost effectiveness and simplicity of the model is bug
advantage over other bulky models.

7. FUTURE SCOPE

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EN Department, SRMGPC
This design will help in reducing overall cost of the device and also help people by relaxing the
need of phone chargers and separate chargers for USB devices. It will definitely be helpful over
the days, as, the speed and advancements in phones are at an exponential rate which decreases
the charge of phones greatly. Hence, this calls for easier solutions to phone charg-ing. This will
also prove helpful to the newly emerging wear-able electronic gadgets as, the size and power
rating is ideal for that usage as well.

The majority of electronic products—not just cell phones but also tablets, notebooks and many
others—utilize Lithium-ion batteries, whose potential dangers have been well-publicized lately.
For example, according to CBS News, a defect in the design of the Samsung Galaxy Note 7
smartphone caused its Li-ion battery to overheat—and in some cases burst into flames—resulting
in at least 13 reports of burns and 47 reports of property damage. In addition to the inherent risks
of Li-ion powered phones, Li-ion based portable chargers for cellphones have a separate
drawback: they can take hours to fully charge.

Portable and simple power bank has been the pursuit of people. One solution is to allow mobile
power bank to be attached to the phone. Mobile power bank and mobile phones as a whole is
possible. Mobile power bank can be used as a mobile phone shell or a protective cover, so that it
will be more convenient.

Diversity of mobile power banks seem to have become a new trend. Someone has developed
some features of the mobile power bank: electronic lighter .Even the capacity of power bank is
large, it will run out of time. In the outdoors, how to charge your mobile phone has become a
new problem. Solar power bank has appeared on the market. However, now, the solar energy
conversion rate is also very low. Therefore, it is urgent to find a new energy of power bank.

Science and technology change life. Smart phones should not be restricted by a small battery.
After all ,No demand ,no pursuit .

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EN Department, SRMGPC