© 2022 JETIR August 2022, Volume 9, Issue 8 www.jetir.

org (ISSN-2349-5162)

Design of Fast Charger For Electric Vehicle

Prof.V.R.Ghatage 1
Mayuri Salunkhe2, Sayali Mande3, Onkar Kumbhar4, Rahul kadukar5

1 Assistant Professor, Sant Gajanan Maharaj College of Engineering Mahagaon

2,3,4,5 Students, Sant Gajanan Maharaj College of Engineering Mahagaon

Abstract: Depleting fossil fuels and pressing global warming getting increased day by day. Crude oil is being depleted at a rate of
challenges are wreaking havoc towards the sustainable future of 4 billion tons per year . If this depletion carries at the same rate,
mankind. To cater these alarming issues, renewable energy crude oil reserved at present in world will be finished within a few
sources and alternate means of energy harnessing have been years .Moreover, average CO2 emissions from conventional vehicle
investigated rigorously for last several decades. Similarly, (4.7 metric tons per year), plays a significant role towards the global
transportation sector has also seen paramount reforms with warming . Owing to these major factors, the demand for electric
electric vehicles now seen as potential competitors to vehicles (EVs), hybrid electric vehicles (HEVs) and plug-in hybrid
conventional internal combustion vehicles (ICEV). The major electric vehicles (PHEVs) is getting increased day by day.
challenge electric vehicles face today includes slothful battery HEVs attracted the consumers as the CO2 emissions for HEVs are
charging rates and less electric driving range. The range can be 25% less compared to the conventional vehicle . HEVs are also
extended by proper selection of electric motors. Ultrafast DC more efficient with efficiency around 75% compared to where
charging is concurrently pondered upon to ramp up the sluggish conventional vehicles are only 15% . Further, the running cost of
battery charging rates. Fast chargers technology has been helpful HEVs is nearly 50% less compared to that of conventional vehicle.
in greatly reducing the battery charging time. Different types of HEVs are also a better alternative for storage of grid energy, and
charging technologies and methods have been employed. This they have the potential to transfer power to grid to alleviate the peak
projects mainly focus on the combining the different technologies power demand, frequency regulation and also support renewable
and designing a Fast charger for EV’s. energy generation . However, the sales of HEVs are not growing in
Even with the advancement of the high technology nowadays, the the rate as expected due to some of its major drawbacks. Cost of
popularity of electric vehicle is still limited and unable to make it HEV is more compared to conventional vehicle. The reason for high
a common usage. The main reason is due to the limitation of the cost of HEVs is high-tech energy sources used in the vehicle,
battery pack which is bulky, heavy, slow charging, short lifespan batteries costs up to 50% of the total cost of an HEV. HEVs are
and toxicity hazardous. Among these problems, slow charging limited by its range and speed, and also high charging time for
speed becomes the main consideration when purchasing an batteries. At the same time, charging station infrastructure is also a
electric vehicle. Hence, different charging methods have to be major constraint for PHEVs. Main Energy sources for HEVs are
studied thoroughly to seek for the best solution to overcome these ICE, fuel cells, super capacitors, batteries. I-ion battery is commonly
problems. In today's competitive battery charging method, a lot of used in HEVs as well as EVs due to its several advantages over its
charger manufacturers claim that they can amazingly short charge counterparts (fuel cell, ultra-capacitors, Pb-acid, Ni-Cd, Ni-MH).A
times of 30 minutes or less. comparison study of different energy sources is a part of the present
In this project, different charging method such as Constant work as discussed in Section II. At present scenario , charging time
Voltage charging, Constant Current charging, Pulsed charge etc, is a major constraint for HEVs. As the charging scheme decides the
have been studied and compared to optimize the charging time life cycle, efficiency, and charging time of the batteries, it is very
suitable for different kind of battery pack. important to design a good charger. Recently, an optimal charging
scheme is proposed for the Li-ion battery .
.

II. LITERATURE SURVEY

I. INTRODUCTION
Various charging schemes for batteries are present in the literature
With the increasing usage of internal combustion engine (ICE) and practice. Details of some main charging schemes are presented
vehicles or conventional vehicles i.e., vehicles that use crude oil in this section
and its byproducts as fuel source, the demand for crude oil is A. Constant Voltage Charging Scheme:

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3. Constant voltage mode:

In this method of charging, battery is charged with DC In this mode of charging, battery is charged at constant voltage of
power supply till the battery voltage is reached to set-point 4.2 V. Constant current mode is not extended till 100 SoC because
voltage. Li-ion cells have 4.2+/-50mV as nominal set-point to avoid overheating, stress on the cells. Even though battery
voltage and maximum allowable charging current is 1C. This reaches 4.2 V it does not indicate that battery is fully charged so it
method of charging is preferred for Pb-acid batteries as each has to be further charged in constant voltage mode. During this
individual cell equalize the charge among them. Major drawback stage, current drops till 0.1C while charging is terminated.
of this method is battery does not get fully charged and time
required for charging is more than 2 hours. 4. Charge termination mode:
Normally charge termination is done by minimum charge current
method or timer method. In minimum current method, charge
B. Constant Current Charging Scheme: current is always monitored and as it reaches a value in range of
0.02C - 0.07C charging is terminated Despite its advantages, the
In this method of charging, battery is charged with drawback of this conventional charging to lithium ion batteries is it
uniformly constant current. If more number of cells are present in takes long time (at least more than 2 hours) to charge the battery
the battery this method of charging is not preferred to implement completely.
as some cells may get fully charged than others. This method is
not efficient and also leads to over stress on the cells. Drawback
of this method is maintaining low charge current leads to more
charging time. To implement fast charging to Li-ion batteries
using this method higher charging current is required. But when
charging current is too high the travel rate of Li-ions exceeds the
insertion rate of Li-ions into graphite layer. This leads deposition
of some Li-ions on the electrode layer instead of getting inserted
into the layers. This is called lithium plating. To overcome lithium
plating enough settling time for Li-ions has to be provided to get
inserted into vacant sites of graphite electrodes.

To implement fast charging to Li-ion batteries using this

method higher charging current is required. But when charging
current is too high the travel rate of Li-ions exceeds the insertion
rate of Li-ionsinto graphite layer. This leads deposition of some
Li-ions on the electrode layer instead of getting inserted into the
layers. This is called lithium plating. To overcome lithium plating
enough settling time for Li ions has to be provided to get inserted III. WORKING
into vacant sites of graphite electrodes. Higher charging currents
also decrease charging efficiency due to joule heating. Joule • The 230 V AC power the readily available Source is
heating is also known as ohmic heating and resistive heating. This Coverted to 12 V DC using Step Down Transformer and
heating is occurred because of the flow of electric current through Bridge Rectifier Circuit or Directly a DC source can be
internal resistance of battery. Due to these reasons, fast charging used.
is not possible using this charging scheme. 12 V DC is used as an input to Buck Converter.
The DSP TMS320F28335 is used as controller
C. Constant Current Constant Voltage charging:
A current sensor ACS712 (20A rating) is used to measure
The conventional charging technique employed for charging current. The measured current is used to calculate SoC by
of Li-ion batteries is constant current constant voltage (CCCV) Arduino UNO platform. The SoC is estimated using
charging since it is easy to implement, efficient and has its own equation , where ‘Q’ is the amount of charge present in the
advantages. In this CCCV technique there are found different battery and ‘Qmax’ is maximum charge that can be injected
stages as shown in Fig. into battery .
Reference current generated from Arduino UNO will be in
1. Pre-charge mode: form of digital signal i.e, as ‘5’or ‘0’. An analog signal of
In this mode of charging, deeply discharged cells (voltage below 1.5 V magnitude is given as 1 kHz pulse with 30% duty
3V) are charged with 10% of full charge current. This mode is cycle. So, a low pass RC filter is used to obtain average
important to avoid overheating of the cells until it is able to accept value of that signal.Current sensed using ACS712 sensor
full charge current. and obtained reference current from low pass RC filter are
given as analog signals to DSP TMS320F28335. PI
2. Constant current mode: controller is implemented in DSP TMS320F28335. The
In this mode of charging, normally battery is below 1C rate until output of the PI controller and sequence generator are used
the battery reaches 4.2 V. If high charging current rates are to generate PWM pulses of 20 kHz.
implemented, cell voltage rises more rapidly and constant current
stage become shorter but overall charging time doesn’t reduce.

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IV. METHODOLOGY operation of processor.

A. Diagram: 4. Voltage Regulator : A circuit that create and maintain

a fixed output voltage irrespective of changes to the
input or load condition.

5. Current Sensor : It measures current flow using

magnetic field to detect the current and generate the
proportional output.

DESIGN OF SYSTEM

SoC

Components
Battery
Voltage
L
1. Rectifier : a convention OBC (on board charging +

Li-ion Iref
C
system) has bridge rectifier to convert Ac voltage to Battery
Generator

Dc.

2. Ripple Monitoring : Ripple monitoring circuit may

mea

+
Comparator PI
generate information indicative of falling Controller
™

component in power supply. re f

Sequnece
3. Control Circuit : Control circuit is component of Generator

computer central processing unit , that directs the Charging circuit to implement five level charging scheme.

V. ADVANTAGES

• Reduce the battery charging time.

• Faster operation
• Battery life is not affected.

• Reduced size
• Energy saving
• Low cost
• Quick charge
• Bettery temperature under permissible limit

VI. CONCLUSION

In this project, it is expected to reduce the conventional battery

charging time required to charger a Li-ion battery in EV’s.

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VII. FUTURE SCOPE Science, University Tunku Abdul Rahman,Setapak Kuala
Lumpur, 53100
Future work might be:
• To further reduce the charging time to as minimal as 3)IEEE Paper “A Robust, Intelligent CC-CV Fast Charger for
possible. Aging Lithium Batteries” by Lan-Rong Dung Department of
Electrical and Computer Engineering National Chiao Tung
• To reduce the cost of the charger and make it more University Hsinchu, Taiwan lennon@faculty.nctu.edu.tw
robust.
4) IEEE Paper “Fast Charger for Li-ion Batteries Based on
• To design a potable charger which can be used for any Battery Temperature” by A. Hadi*, I. Said, M. Mansor, H.
battery type irrespective of its ratings. Hussain Department of Electrical Power Universiti Tenaga
Nasional, Selangor, Malaysia *hadigan@yahoo.com

REFERENCES 5)IEEE Paper “Experiments Study on Fast Charge Technology

forLithium-ion Electric Vehicle Batteries” by BAI Ya-shuang1,2,
1) IEEE Paper “Electric Vehicle Battery Technologies” by ZHANG Cheng-ning 1. School of Mechanical and Vehicular
Kwo Young, Caisheng Wang, Le Yi Wang, and Kai Engineering, Beijing Institute of Technology, Beijing 100081,
Strunz China;2. North China Institute of Aerospace Engineering,
LangFang HeBei, 065000,China)
2) IEEE Paper “Ultra Fast Charging System On Lithium Ion
Battery” by C.K.Leong ,YH Can, C.D Can, Z. Y Phuan, M.K
Yoong, B.K Cheah. K. W Chew Faculty Of Engineering And

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