MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS AUTOMOTIVE ENGINEERING RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANSFORMER ADVISOR : Ph. LE THANH PHUC STUDENTS: HO QUANG HUY DAO DUY KHANG SKL010718 Ho Chi Minh City, June 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANSFORMER Student’s name: HO QUANG HUY 19145180 DAO DUY KHANG 19145149 Major: AUTOMOTIVE ENGINEERING Advisor: LE THANH PHUC Ph. Ho Chi Minh City, June 2023 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, ……………., ……, 2023 PROJECT ASSIGNMENT Ho Quang Huy Student name: _________________________ 19145180 Student ID: ___________________ Dao Duy Khang Student name: __________________________ 19145149 Student ID: ___________________ Student name: __________________________ Student ID: ___________________ Automotive Engineering Major: ________________________________ 19145CLA Class: ________________________ Le Thanh Phuc Ph. Advisor: ____________________________ (+84) 932 591 200 Phone number: _________________ 17/01/2023 Date of assignment: _____________________ 30/06/2023 Date of submission: _____________ Research and Design charging system for electric motorcycle 1.
Project title: _________________________________________________________ using pulse transformer _____________________________________________________________________ 2. Initial materials provided by the advisor: __________________________________ _____________________________________________________________________ General research about the topic; Design the circuit; 3. Content of the project: _________________________________________________ Real test with the voltage; Conclusion & recommendation. ______________________________________________________________________ Report; Test model; Soft file 4.
Final product: ________________________________________________________ CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) i THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, ……………, ……, 2023 ADVISOR’S EVALUATION SHEET Student name: HO QUANG HUY Student ID: 19145180 Student name: DAO DUY KHANG Student ID: 19145149 Student name:. Major: AUTOMOTIVE ENGINEERING Project title: RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANFORMER Advisor: LE THANH PHUC Ph. Content of the project:. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, ………………, ……, 2023 ADVISOR (Sign with full name) ii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, ……………., ……, 2023 PRE-DEFENSE EVALUATION SHEET Student name: HO QUANG HUY Student ID: 19145180 Student name: DAO DUY KHANG Student ID: 19145149 Student name:.
Major: AUTOMOTIVE ENGINEERING Project title: RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANFORMER Name of Reviewer:. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, ………………, ……, 2023 REVIEWER (Sign with full name) iii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, ……………., ……, 2023 EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name:. Name of Defense Committee Member:.
Content and workload of the project .) Ho Chi Minh City, ……………., ……, 2023 COMMITTEE MEMBER (Sign with full name) iv ACKNOWLEDGMENTS To complete this project, we would like to thank all the teachers at Ho Chi Minh City University of Technology and Education, especially the teachers of the Faculty for High-Quality Training for their enthusiastic teaching and support, imparting very valuable knowledge to us during our time at the school. Our group would like to express sincere thanks to Mr. Le Thanh Phuc - the instructor who enthusiastically supported, oriented, and suggested to the group during the process of completing the graduation thesis. He allowed us to work in a laboratory with full equipment to make the process of doing the research more convenient.
Besides, the group also thanked all members of Mr. Le Thanh Phuc's laboratory, above all, Mr. Nguyen Le Khuong Duy, for their enthusiastic support to help the group gain more knowledge to complete the topic. Once again, we would like to thank the teachers at Ho Chi Minh City University of Technology and Education and the teachers of the Faculty for High-Quality Training.
v ABSTRACT The input is a 220V AC power source that will be rectified and then generate a DC power source output suitable for charging Lithium-ion battery packs on electric motorcycles. Our group will research, design, and implement a circuit that handles the power after rectification and generates a DC power source that can meet the requirements for charging the Lithium-ion battery packs and can be adjusted based on the feedback signals. By comparing the pulse source types and performance capabilities, the team will design a circuit system using the Flyback pulse source. This regulator circuit along with the pulse source will produce a more stable, efficient power supply than other types of power sources.
After the research and implementation of the topic, our group learned the structure and operating principle of pulse sources and electronic components applied in the charging circuit. Based on the knowledge learned and the parameters of the components, our group designed the circuit and made the test circuit part by part for testing the performance of the components. And based on the testing results, the team conducts and tests the circuit in practice along with the design of the pulse transformer. After testing and adjusting, the output of the charging circuit has finally met the conditions to charge the battery packs currently in the lab.
The charging circuit has been tested with large and small loads and the results show that the circuit works quite stably. Key words: Flyback Converter, Pulse transformer, Pulse Width Modulation, MOSFET, Snubber Circuit, Lithium-ion, Electric motorcycles vi TABLE OF CONTENTS PROJECT ASSIGNMENT. i ADVISOR’S EVALUATION SHEET. ii PRE-DEFENSE EVALUATION SHEET.
iii EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER. vi TABLE OF CONTENTS. vii LIST OF TABLES. ix LIST OF FIGURES.
Objectives of the research. Object and scope of the research. Object of the research. Scope of the research.
3 Chapter 2: LITERATURE REVIEW. Pulse power supply. Elements used in pulse power supply. Lithium-Ion Battery.
Structure of Lithium-ion Battery 18650. Working principle of Lithium-ion battery. Charging and discharging characteristics of lithium-ion battery. Lithium-ion battery on Tesla Model S.
Electronic components used in the project. MOSFET Driver IR2103. Introduction to STM32CubeIDE. STM32CubeIDE workspace.
STM32CubeIDE programing workspace. 42 Chapter 3: CALCULATION AND DESIGN. Operating principle of the system. MOSFET gate resistor.
MOSFET drive circuit. Calculation and design circuit elements. MOSFET gate resistor calculation. Calculation of pulse transformer.
Snubber circuit calculation. 58 Chapter 4: EXPERIMENT RESULTS AND DISCUSSION. 61 Chapter 5: CONCLUSION AND RECOMMENDATION. 72 viii LIST OF TABLES Table 2.
Main specifications of 18650 Lithium-ion batteries. IR2103 lead definitions. Main specifications of optocoupler HCPL2631. Main specifications of optocoupler PC817.
Input factors and output goals. Pulse transformer specifications. 60-cell battery pack charging result…………………………………………68 ix LIST OF FIGURES Figure 2. Inductor Voltage/Current Relationship.
Basic Principle of PWM. Basic Flyback Converter Schematic. Current and Voltage in primary & secondary coil. Flyback Converter operation.
Waveforms of a discontinuous-mode flyback. Waveforms of a continuous-mode flyback. Structure of Lithium-ion battery. Lithium-ion battery charging process.
Lithium-ion battery discharging process. Charging characteristic of lithium-ion battery. Discharge Characteristics of NCR18650. A battery module on Tesla Model S 2012.
V-I characteristic of enhancement-mode MOSFET. IR2103 lead assignments. IR2103 input and output control pulse. Structure of optocoupler.
Types of optocoupler. Structure of STM32F103C8. Diode basic structure. Forward biased diode.
Reverse biased diode. Diode V-I characteristic curve. Different types of resistors. Structure and symbol of capacitor.
Different types of capacitors. Structure and symbols of inductors. LM7805 pinout diagram. Application circuit for LM7805.
Initial startup window of STM32CubeIDE. MCU/MPU Selector window. STM32CubeIDE naming window. Pinout & Configuration window.
PA0 Mode and Configuration. Timer Parameter Settings. PWM generation mode at PA0. Coding window of STM32CubeIDE.
Lithium-ion battery charger circuit using pulse transformer………………. Rectifier output waveform. RCD Snubber circuit. Drain pole voltage without snubber circuit.
Drain pole voltage with snubber circuit. Parasitic capacitances in MOSFET. VGS as a function of gate charge. MOSFET "on" process.
MOSFET "off" process. N-MOSFET driver circuit high (left) and low side (right). Waveform graph of DC voltage after input filter capacitor. Feedback circuit block.
Voltage divider circuit. Soldered charging circuit. Output PWM on pin A0. Output signal on pin 8 of optocoupler HCPL2631.
Output signal on pin 5 of IR2103 to trigger MOSFET. Output voltage with no load. Temperature of MOSFET with no load on the circuit. Test charging circuit with 220V-60W with filament bulb.
Initial voltage output of the 60-cell battery. Output voltage and current of charging circuit when connect to the battery pack. Output voltage of the battery pack after charging. Graph of charging result by time.
Temperature of MOSFET during charging. 69 xii Chapter 1: INTRODUCTION 1. Motivation A healthy transportation system and a national economy promote and support each other. An efficient transportation system of products and people – both public and personal – has become an important factor in the economic empowerment of a nation.
Conversely, as the economy grows it translates into increased traffic of goods and people. According to statistics by 2022 from the Vietnam Association of Motorcycle Manufacturers (VAMM), sales of the whole market have reached more than 3 million vehicles, an average of more than 8,000 units sold per day. It can be seen that, with the characteristics of economy, culture and infrastructure in Vietnam, motorbikes are still the most optimal and most popular means of transportation. On the other hand, all signals indicate that the trend of vehicle production in the world in general and Vietnam, in particular, is towards environmentally friendly vehicles, using energy sources that can be regenerated.
One of them is an electric vehicle. Combining humanistic, economic, social and market backgrounds, we have every reason to believe that electric motorbikes will soon become a dynamic future for Vietnamese people. However, the issue that many consumers are concerned about is: Are electric scooters safe to use and charge? How long does an electric motorcycle take to fully charge? Is there a way to make this process faster? And many more questions. To be able to replace traditional motorcycles, electric motorcycles need to ensure convenience and quickness - which are the strengths of traditional motorbikes.
To catch up with this changing trend, applying knowledge of automotive technology, especially automotive electronics, we decided to choose the topic of Research and design charging systems for electric motorcycles using pulse transformers as our graduation project. Domestic topics The article "Nghiên cứu ảnh hưởng của chế độ làm việc dòng điện liên tục và gián đoạn máy biến áp đối với bộ nguồn chuyển mạch cao tần" by Cao Xuan Tuyen and Nguyen Anh Tuan's team was published in the journal Science and Technology [1]. The authors have calculated, tested, and simulated the operation of transformers for high frequency switching power supplies in two working modes: continuous and intermittent current working mode. In this study, the Flyback converter was used to control the transformer and applied formulas to calculate the required parameters at three different output power levels with the same input power.
With the same input power source Vin = 9-15 (VDC), the team surveyed with output 𝑉𝑜𝑢𝑡 = +5 (VDC), 𝐼𝑜𝑢𝑡 = 1. Simulation of the power supply is performed by the 1 author's team using PSIM software. Based on the simulation results in two working modes, both working modes of the transformer are stable. Besides, the power supply working in intermittent current mode has better voltage quality than the other mode.
However, the circuit size working in intermittent current mode is smaller, requires more turns of wire, and in continuous current mode is larger in size with a smaller number of turns.