Welcome to

Technical Presentation on SMPS based E-Rickshaw

Battery Charger 22 April 2016

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E-Rickshaw runs on electrical energy,

provided by a heavy duty rechargeable

battery bank.

What is an E-Rickshaw?

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1) ECO friendly- that is ZERO Pollution & Noise less2) Low running cost & perhaps lower maintenance cost3) Lower initial investment compared to

Petrol/Diesel/CNG driven Auto Rickshaw4) Though slightly larger in size, it accommodates more

passengers5) Aesthetically better looking

Why E-Rickshaw? Auto versus Toto

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1) DC motor of E-rickshaw (TOTO) runs in 48V DC 2) Generally 4X12V rechargeable mono block batteries

are used.3) These batteries are heavy duty tubular type batteries

and require maintenance by periodic re-filling of electrolyte ( acid & water)

Now Battery & Battery Charger

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1) Tubular batteries have got high rate of discharging capability, particularly during cranking.

2) It can also accept higher rate of charging current (required for quick restoration) compared to sealed maintenance free batteries (SMF VRLA batteries).

3) In a nutshell tubular batteries are suitable for heavy duty CYCLIC use

Advantage Tubular Battery

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1) Considering the space & weight constraints of the vehicle, 88 to 120AH battery capacity has been optimized, which can give around 80 KM per charge cycle.

2) These batteries are used to its fullest capacity in E-rickshaws and expected life is 250 to 300 charge/discharge cycles

Battery sizing & installation

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Role of Battery Charger

❖ Charging a discharged Battery by taking electrical energy from the domestic electrical supply grid ( single phase, 230V AC )

❖ And to make the battery ready for next cycle of discharge for the next run of the Toto

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Process of battery charging

☞ Battery Charging is a complex electro chemical process, in which the discharged electrical energy is replenished from the electrical network.

☞ AND Quality of the charging process is critical for the health & longevity of the battery.

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Type of Battery Chargers

Four types of E-rickshaw battery chargers are available in the market:

1. Transformer based with manual control

2. Transformer based but automatic control

3. SMPS based automatic but without microcontroller

4. SMPS based with microcontroller 22 April 2016

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Advantage of manual control transformer charger

1. Cheap.

2. Suitable for quick charging by injecting high rate of current by manual control switch kept for current control.

3. Can be serviced by local electrician .

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Disadvantage of manual control transformer charger

1. Bulky & heavy- not easy to carry and handle.2. Energy-inefficient (consumes more power) .3. Not provided with any electronic protection circuit.4. Charging current varies with the input voltage

fluctuation. Battery gets damaged very easily in high voltage area due to high current charging.

5. And takes long time to charge in low voltage area.

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Disadvantage of auto control transformer charger

1. It is bulky as before but no longer cheap due to additional control circuitry.

2. It consumes more power because of crude technique of auto control of charging current

3. It fails very often because of bad design, poor workmanship and use of low quality electronics

4. No warranty & high repairing cost

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Switched mode power supply in Battery charging application

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Few words about SMPS charger

☞ Switched mode power conversion technique has become boon due to its reduced size & lower cost

☞ SMPS Battery chargers are very popular in Telecom application as well as in UPS industry

☞ Most popular SMPS battery Chargers are cell phone and laptop chargers.

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Limitation of SMPS technique

☞ Reduced size of SMPS converters is due to high frequency transfer of power since high frequency ( 50Khz +) magnetic materials can handle much higher power density.

☞ But, it can handle power only up to limited capacity.

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A brief outline about AC TO DC conversion with

switched mode technique

Let us briefly refresh theory

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❑A typical Switched Mode Power Supply incorporates a front end AC-DC rectifier to generate an unregulated DC input voltage.

❑A high frequency chopper (MOSFET/IGBT) then chops the input DC Voltage.

❑After that a high frequency transformer isolates, steps down and converts this square wave DC to square wave AC output.

SMPS PRINCIPLE OF OPERATION

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❑It is then rectified & filtered to generate a smooth ripple free output voltage.

❑Pulse Width Modulation technique is generally employed to regulate the charger output of a SMPS Charger

SMPS PRINCIPLE OF OPERATION

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AC INPUT

TYPICAL SCHEMEMATIC OF SMPS CONVERTER

RECTI-FIER SMPS TRANS-

FORMER

HFRECTIFIER

&FILTER DC

OUTPUT

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SMPS Advantage☞ COMPACT & LIGHT

☞ HIGH EFFICIENCY ( low consumption of power)

☞ LOW RIPPLE ( good for battery life)

☞ EXCELLENT REGULATION ( no variation in charging current)

☞ WIDE INPUT WINDOW (130-270V)- ( charging quality & time unaffected due input voltage fluctuation)

☞ LOWER COST

☞ RELIABLE & LOW COST OF REPAIRING22 April 2016

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Before that let us see what is present

market trend

We will elaborate on microcontroller advantage later

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End user’s perception about the Charger

❖ Charger should be 12A. It should charge a fully discharged battery within 8-10 hours

❖ It should indicate state of charge for rough estimation about the mileage capacity of the vehicle and they can run their TOTO even before full charge

❖ Charger should automatically stop and should not over charge the battery, which can damage the battery due to over heating

❖ Charger must have warranty & should not fail22 April 2016

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Dealer’s requirement

❖ Warranty & replacement service❖ Minimum failure❖Cheap & light weight❖On site servicing during post

warranty period

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Dealer’s requirement continues

❖ Should charge in low voltage area without sacrificing the time period

❖ Low power consumption or higher efficiency❖ It should indicate state of charge ❖ Attractive look, good packaging & bright

catalogue with user friendly instruction manual/sticker

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ESI charger is SMPS charger with

microcontroller based control

Let us see ESI charger’s feature

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ESI charger is programmed to meet all expected features & performance….like

✓ ESI Charger is 12A charger.

✓ It ensures full charge of a fully discharged battery within 7-8 hours hours

✓ ESI charger indicates state of charge by multiple LEDs

✓ Charging process is indicated by a blinking LED

✓ On completion of charge ❖ Charging LED becomes steady

❖ And a buzzer also beeps intermittently to draw attention 22 April 2016

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ESI charger is programmed to meet all expected features & performance….like

✓ It operates in low voltage area without compromising charging period.

✓ ESI charger is efficient and consumes less power.

✓ Low ripple content.

✓ Excellent line and load (charge) regulation.22 April 2016

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ESI Charger is designed and programmed to enhance battery life

Beyond basics- the microcontroller topping

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ESI SPEIALITY-1

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➢ It keeps Battery healthy

➢Enhances battery life

beyond expectation

➢Prevents Battery from

premature death

DE-SULPHATION

De-sulphation of Battery

❖ Battery plates accumulate lead-sulphate crystals after each discharge cycle.

❖ These crystals are normally broken down during charging. But, in reality some part of these crystals remains on the plates and gets hardened in course of time.

❖ This drastically reduces the discharge efficiency or battery capacity.

❖ For which battery performance decreases resulting to early end of battery life.

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De-sulphation of Battery continues…………

❖ ESI charger incorporates a rapid pulse charging technique in the beginning, which totally breaks down all accumulated lead sulphate crystals.

❖ This pulse charging radically enhances battery life.

❖ This process also helps in equalization of electrolytic concentration (specific gravity).

❖ Equalizing or cell balancing keeps all the cells in more or less same state of health.

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ESI SPEIALITY-2

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➢ ESI charger does not over charge the old battery

➢ Thus prevents over heating

➢Helps battery to retain its efficiency

➢ Eliminates the possibility of early end of life of battery

TimerOver-ride

Voltage sensed termination of charging

❖ Battery voltage increases with the charge❖ Charging process normally terminates by sensing

battery voltage.❖ That is when battery voltage reaches a preset level

electronic control circuit either reduces the charging current or terminates the charging process totally.

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Limitation of voltage sensed termination

❖ This voltage sensing fails after some time due to age or poor maintenance of battery.

❖ When battery gets old or behaves like an old battery due to ill maintenance, charging voltage fails to reach the desired set level of sensing required for termination of charging process.

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Battery over heating and failure

☞ As a result battery receives a high rate of charging current ( that is excess charge) beyond its capacity of absorption.

☞ This causes over heating and reduces battery life drastically.

☞ Hence premature DEATH (of the Battery) is inevitable.

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To overcome this catastrophe…………

❖ ESI charger introduces a smart technique by starting a TIMER when charging voltage reaches 60% voltage level.

❖ Timer elapsed time is set corresponding to the time normally required by a new/healthy battery to reach 100% charge level from this level of 60% state of charge 22 April 2016

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A full proof solution for termination

✓ Microcontroller works here like an watch dog

✓ It also continuously senses charge voltage level

✓ IF voltage level reaches before the preset elapsed time it goes to end of charge process.

✓ ELSE charging reaches end of charge level as soon as timer stops.

✓ Hence NO OVER HEATING of aged or ill maintained battery. Battery efficiency is maintained.

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ESI SPEIALITY-3

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➢Charging indication with blinking

LED

➢State of charge by multiple LEDs

➢End of charge notification by

buzzer & steady glow of charging LED

➢Visual alert for

aging/handicapped battery

USER FRIENDLY STATUSDISPLAY

Product Image

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ESI SPEIALITY-4

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➢ ESI provides comprehensive warranty for six months

➢ ESI extends component cost servicing up to one year

➢ ESI will repair its product up to five years from its date of manufacturing

POST WARRANTY SUPPORT

ESI SPEIALITY/ADVANTAGE-5

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➢ ESI is an ISO 9000-2008 company since the last 10 years

➢ ESI is in the Battery Charger business since the last 20 years

➢ ESI is an 100% Indian company

➢ We design in-house from white paper and do not copy paste from others

ASSURANCEFROM

An ISOINDUSTRY

◻ At ESI we test each & every finished good and maintain a comprehensive record

◻ All the Test Instruments are calibrated in NABL accredited Laboratory

◻ Product Type Tests are carried out at ERTL, National Test House and SAMEER

Quality Assurance

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◻ At ESI we test each & every finished good and maintain a comprehensive record

◻ All the Test Instruments are calibrated in NABL accredited Laboratory

◻ Product Type Tests are carried out at ERTL, National Test House and SAMEER

Quality Assurance

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◻ We are here to clarify your queries .

◻ We look forward to do business with you .

◻ Please contact :■ Somen Ghosh, CEO

■ M- 9903993911/9331036892

■ Email: somengosh@esielectro.com

■ URL- www.esielcectro.com

Thank you For yourPatience

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