A Project Report

On
48v Battery Charger
(EV - Charger)

(National Institute Of Technology Delhi)

 A
Project Report
On–

ELECTRIC VEHICLE CHARGING SOLUTIONS

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

B.TECH IN

ELECTRICAL ELECTRONICS ENGINEERING

SUBMITTED TO

NATIONAL INSTITUTE OF TECHNOLOGY DELHI

Under

UNDER THE GUIDANCE OF

Dr. ANMOL RATNA SAXENA

DEPARTMENT OF “ELECTRICAL ELECTRONICS
ENGINEERING”

NATIONAL INSTITUTE OF TECHNOLOGY

DELHI
Plot No. FA-7, Zone -P1 GT Karnal Road Delhi-110036

SUBMITTED BY :
1. 211230018 : DILKUSH MEENA
2. 211230058 : VICKEY KHAREDIYA
 ACKNOWLEDGEMENT

I would like to express my special thanks of gratitude to my project guide Dr. ANMOL
RATNASAXENA as well as our Director Dr. AJAY KUMAR SHARMAwho gave me the
golden opportunity to do this wonderful project on the topic 48v Battery Charger.
which also helped me in doing a lot of research and i came to know about so many
new things I am really thankful to them.

Date:-
Place :- NIT DELHI Submitted by:-
1. 211230018 : DILKUSH MEENA
2. 211230058 : VICKEY KHAREDIYA
 TABLE OF CONTENTS

Sl. CONTENT Page

No
1 TITLE 1
2 ACKNOWLEDGEMENT 3
3 ABSTRACT 5
5 LIST OF FIGURE 6
6 INTRODUCTION 7
7 WORKING OF EV CHARGER 9
8 HOW IT WORKS 10
9 BATTERY CHARGING PROCESS 11
10 WHERE TO CHARGE 13
11 SCHEMATIC AND PCB ASSEMBLY 14
12 CONCLUSION 16
13 FUTURE WORK 17
 ABSTRACT

Electric vehicles are a new and upcoming technology in the transportation and power sector
that have many benefits in terms of economic and environmental. This study presents a
comprehensive review and evaluation of various types of electric vehicles and its associated
equipment in particular 48v battery charger and charging station. A comparison is made on
the commercial and prototype electric vehicles in terms of electric range, battery size,
charger power and charging time. The various types of charging stations and standards used
for charging electric vehicles have been outlined and the impact of electric vehicle charging
on utility distribution system is also discussed.
 LIST OF FIGURE

Sl. FIGURES Page

No
1 EV CHARGER BLOCK DIAGRAM 8
2 HT45F5Q-X SPECIFICATIONS 8
3 BLOCK DIAGRAM OF HT45F5Q-2 9
4 BATTERY CHARGING CURVE 11
5 EV CHARGER SCHEMATIC FOR 48V/12A 14
6 EV CHARGER PCB ASSEMBLY 15
 INTRODUCTION

The popularity of electric vehicles (EVs) is increasing rapidly in India. According to a

survey, the EV market in India is estimated to increase from 3 million units in 2019 to 29
million units by 2027 with a CAGR of 21.1 per cent. As a result, demand for AC/DC 48v
Battery Chargers, the smart chargers for EVs, will also increase.

In order to charge the batteries efficiently, and to ensure their long life, we need a smart
battery management or charging system. To realise such an EV charging system, Holtek has
come up with smart Electric Vehicle Battery Charging Solutions based on their low-cost
ASSP flash microcontroller (MCU) HT45F5Q-X for charging EV batteries.

At present, three EV charger designs suitable for Indian market—with specifications of

48V/4A, 48V/12A and 48V/15A—are available for rapid development of the product.
This semiconductor-based smart charging system can support both lithium-ion as well as
lead-acid battery types.

Block diagram of the Electric Vehicle 48v Battery Charging Solutions is shown in Fig.1 .
Here, battery charger ASSP flash MCU HT45F5Q-X is the heart of EV charger circuitry, with
in-built operational amplifiers (OPAs) and digital-to-analogue converters (DACs) that are
necessary for battery charging function.
 Fig. 1: EV charger block diagram

Specifications of the battery charger flash MCU HT45F5Q-X series are shown in Fig. 2.
Designers can choose an appropriate MCU from HT45F5Q-X series according to their
application requirement.

Fig. 2: HT45F5Q-X specifications

The features and working of EV charger solution for 48V/12A specification is briefly
explained below. This EV charger design utilises HT45F5Q-2 MCU for implementing
battery charging control function.
The MCU incorporates a battery charging module, which can be utilised for closed-loop
charging control with constant voltage and constant current for efficiently charging a battery.
Internal block diagram of MCU HT45F5Q-2 is shown in Fig. 3.

Fig. 3: Block diagram of HT45F5Q-2

The battery charging module in HT45F5Q-2 has built-in OPAs and DACs that are needed
for charging process. Therefore the design reduces the need for external components like
shunt regulators, OPAs and DACs, which are commonly used in conventional battery
charging circuits. As a result, the peripheral circuit is compact and simple, resulting in a
smaller PCB area and low overall cost.

Working of 48v Battery Charger

Input power to the 48v battery charger is an AC voltage in the range of 170V to 300V.
The 48v battery charger uses a half-bridge LLC resonant converter design, because of its
high-power and high-efficiency characteristics, to obtain DC power for charging the
battery.
The design utilises a rectifier circuit for converting input AC voltage to high-voltage DC
output, and it also has an electromagnetic interference (EMI) filter to eliminate high-
frequency noise from input power source. A pulse-width modulation (PWM) controller IC,
like UC3525, can be used for driving the MOSFETs of half-bridge LLC converter.

The battery charging process is supervised by the MCU HT45F5Q-2. It monitors the
battery voltage and charging current levels and gives feedback to the PWM controller IC.
Based on the feedback, the PWM controller varies the duty cycle of its PWM signal and
drives the MOSFET circuit to obtain variable output voltage and current for charging the
battery.

For better protection, HT45F5Q-2 is isolated from rest of the circuit (i.e., high-voltage
components) using a photo-coupler. Battery-level LED indicators are provided for knowing
the charging status.

How it Works?

• 4 Major Items:
1 Motor
The vehicle has one or more motors. Depending on size and performance, the total power
ranges between 15 and 200 kW.
Example: 48 kW (65 hp) for a small 4-seater sedan.
2 Batteries
Battery technology has made very significant progress in recent years. Lead has gradually
been replaced by other, more efficient compounds. Research continues with a view to
improving capacity and reducing weight .The most common technology at present is
lithium-ion .These new batteries have no memory effect and can therefore be charged
without having to be completely empty beforehand. They are present in telephones, laptop
computers, and some aircraft, as well as in electric vehicles.
3 On-board charger
The vehicle is fitted with one battery charger supplied in AC by the charging station that
defines the maximum charging current available. In some vehicles the battery charger may
also be supplied in DC by the charging station.
4 Charging inlet
The vehicle is fitted with at least one inlet for AC charging. In some vehicles the inlet can
also be used for DC fast charging or is completed by a second inlet for DC fast charging.

Battery charging process

The change in charging voltage and current during the charging process is graphically
illustrated in Fig. 4. If the battery voltage is too low when connected for charging, low
charging current (i.e., trickle charge (TC)) will be set initially and charging process will start.

Fig. 4: Battery charging curve

When the battery voltage increases to a pre-defined level (Vu), constant voltage (CV) and
constant current (CC) is applied for charging and continued until the battery is fully charged.
Battery is considered to be fully charged when voltage reaches VOFF. When charging
current drops to Iu, final voltage (FV) is set. The voltage, current and temperature control
process in this EV charger are explained below.

(a) Voltage control

The charging voltage is decided based on the initial voltage of battery when it is connected
for charging. As the charging progresses, charging voltage changes accordingly and, finally,
when battery is fully charged, the final voltage is set. The charging-voltage decision levels
for 48V/12A battery charger are explained below.

• If Battery Voltage <36V, TC(0.6A) Charging, Voltage Setting FV(56V)

• If Battery Voltage <40V, TC(0.6A) Charging, Voltage Setting CV(58V)
• If Battery Voltage >40V, CC(12.0A) Charging, Voltage Setting CV(58V)
• When fully charged, voltage is set to FV(56V). If battery voltage is lower than FV,
the charging current will be reset to CC (12.0A).

(b) Current control

Charging current is set depending on the battery voltage. Initially, if the battery voltage is too
less, trickle-charge current would be set for charging the battery. Once battery voltage
reaches certain level, constant current is supplied for charging, until battery is charged fully.
The charging-current decision levels for 48V/12A battery charger are listed below.

• Recharging Current <1.2A, determine the end of charging

• Recharging Current >0.2A, determine the start of charging

(c) Over-temperature protection

The EV charger has a negative temperature coefficient (NTC) thermistor to monitor the
temperature and a fan to regulate the heat. When temperature increases, the fan is
automatically switched on to dissipate the heat; it gets switched off when the temperature is
reduced to the lower set threshold. Also, the fan turns on when charging current is high and
turns off when charging current is low.

• When NTC temperature >110°C, the charging current will be reduced to 50 per
cent of charging current and will be monitored periodically
(d) LED indications for charging status

These are listed below.

• TC charge, red light flashes slowly (0.3 sec on, 0.3 sec off)
• CC, CV charge, red light flashes quickly (0.1 sec on, 0.1 sec off)
• When not charging, green light is on
• When charging time exceeds eight hours, red and green lights are bright

(e) Charging duration

When charging duration is exceeded (duration depends on battery capacity), the voltage
drops to FV, the current is reduced to TC, and charger repeatedly monitors the battery
voltage.

Where to charge
• At home
A charging station for private use installed in the garage.

• At home — condominium
A charging station for indoor or outdoor use, installed in a private parking place.
• At work
More and more companies have installed charging stations in their own parking areas. They have a choice of
whether users can charge their batteries for free or pay a fee.Municipal fleets and th fleets of delivery services,
as well as government departments generally have parking areas fully equipped to charge their electric
vehicles.
• In private parking area
To meet new customer demands, the operators of public and semipublic parking areas (for instance,
commercial buildings, shopping malls, restaurants, hotels, hospitals, etc.), frequently offer EV charging
services. Charging stations can generally be accessed with a badge or a mobile app based on various
commercial conditions.Municipalities and car park managers are now developing these services.
• On street
Involved in new green mobility deployment, municipalities are giving access to a network of charging stations
located on the street or in public parking areas. Charging stations can generally be accessed with a badge or
thanks to a Smartphone App., based on various commercial conditions.Electric car sharing is another service
offer that municipalities now promote. Charging station networks allow combined use by car-sharing services
and electric vehicle drivers.
• At service station
Service stations equipped for fast charging are appearing at test locations in some countries. Customers use
the less than 30 minutes charging time to take a break or shop in the supermarket.
Schematic and PCB assembly
The schematic of 48v battery charger design for 48V/12A type is shown in Fig. 5 for
reference and its PCB assembly is shown in Fig. 6.

Fig. 5: EV charger schematic for 48V/12A

The ASSP flash MCU HT45F5Q-2 can also be used for designing higher-wattage solutions.
It offers a programmable option for setting parameter thresholds, which makes it very
convenient for EV charger designs. Holtek provides technical resources such as block
diagram, application circuits, PCB files, source code, etc to help designers in rapid product
development and speed up time-to-market.
 Fig. 6: EV charger PCB assembly

EV charger development platform for HT45F5Q-X series will also be available soon. Using
this software tool, users would be able to easily select the charging voltage/current and other
parameters to create a program. This application will also be able to generate a program
containing a standard charging process, thereby significantly simplifying the development
process.
 CONCLUSION

Electric vehicles are expected to enter the world market such that by 2030, 10%
of the vehicles will be of EV type. To have a better understanding on EV
technology, this study outlines the various types of EV, battery chargers and
charging stations. A comprehensive review has also been made on the standards
currently adopted for charging EV worldwide. For better understanding on the
state of the art EV technology,a comparison is made on the commercial and
prototype electric vehicles in terms of electric range, battery size, charger power
and charging time.
 FUTURE WORK

While many countries still have some homework to do in terms of increasing and
improving the existing EV Charging infrastructure, some innovative alternatives
and the willingness of local governments to invest in an EV future will definitely
play a key role in the success of electric vehicles. We need to ensure reliable
access to charging infrastructure to keep accelerating the acquisition of electric
vehicles. In the same way that platforms have been developed for people to profit
on their personal assets by sharing them with strangers (Uber, Airbnb),
personal/home EV chargers may become “shared” assets to make sure everyone
can get a charge.
 REFERENCE

1 https://www.electronicsforu.com/electronics-projects/electronics-design-guides/electric-vehicle-battery-charging-
solutions

2 https://www.studocu.com/en-us/document/campbell-university/english-fundamentals/a-project-report-on-
electric-vehicle-charging-solutions/29051337

3 https://www.energy.ca.gov/sites/default/files/2021-06/CEC-500-2018-020.pdf

4 https://www.osti.gov/etdeweb/servlets/purl/20183285

5 https://www.electronicsforu.com/electronics-projects/eee-projects-ideas
For project