DC Fast Charger and Battery Management System for Electric Vehicles

International Journal of Scientific Research and Engineering Development-– Volume 3 - Issue 5, Sep - Oct 2020
Available at www.ijsred.com
ISSN : 2581-7175 ©IJSRED: All Rights are Reserved Page 171
DC Fast Charger and Battery Management System for Electric
Vehicle
Ashok D*, Aswin S*, Dhananandhan S*, Anita S*, Ganeshmoorthy G**
*(Department of Electrical and Electronics Engineering,R.M.K. Engineering College, RSM Nagar,
Kavaraipettai
Email: ashokjayan99@gmail.com, aswi16115.ee@rmkec.ac.in, dhan16124.ee@rmkec.ac.in,
saa.eee@rmkec.ac.in)
**(Assistant Manager,SamsungIndia ElectronicsPrivate Limited
Email:ganeshg_be@yahoo.com)
----------------------------------------************************----------------------------------
Abstract:
The idea of developing a DC fast charger for EV in order to reduce the cost of production by
manufacturing within our country. The charging mechanism is done in such a way to minimize the
charging time of electric vehicles. Increase in charging stations will make the people to believe in this type
of electric vehicles and the importance of it towards environment. PIC microcontroller is used to control
the charging and the voltage regulator is used to control the charging voltage. The lithium ion battery type
is used. The BMS manage the output, charging and discharging and provide notifications on the status of
the battery pack. The temperature sensor LM35 is used measure the battery temperature and if the
temperature of the battery rises abnormally the led and buzzer will alert to disconnect the battery charging.
Keywords — PIC microcontroller, Control the charging voltage, Lithium ion battery, Battery
Management System, LM35 temperature sensor
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I. INTRODUCTION
An Electric Vehicle (EV) is a vehicle propelled
by an electric motor, rather than a traditional petrol
or diesel engine. The electric motor is powered by
rechargeable batteries that can be charged using
household mains electricity via an EV charge point
at home or at a more powerful EV charge station at
work or in the street. There are a few types of EV
technology, the most common are plug-in electric
hybrid vehicles (PHEV), range extender electric
vehicles (REEVs) and battery electric vehicles
(BEVs). The BEVs are focused in this introduction.
Battery electric vehicles use electricity, which is
stored in a battery pack to power an electric motor
and turn the wheels. When depleted, the batteries
are recharged using grid electricity from a dedicated
charging unit. The EV is refueled by plugging it
into the charging unit or charging station, like
charging a mobile phone. The same technology
exists in hybrid vehicles, alongside a small petrol or
diesel engine that also connects to turn the wheels
when the battery is depleted. This powers the car at
cruising speed, and batteries either provide power
until depleted or extra power when accelerating.
Batteries can recharge themselves when the car is
decelerating or when plugged in. Hybrid technology
means less pollution from the exhaust pipe, and can
save money if the battery is charged before each
journey.
RESEARCH ARTICLE OPEN ACCESS

In the range extender vehicles, the petrol or diesel
engine only comes in when the battery is depleted,
and instead of supplying locomotion to the wheels
it instead recharges the battery which drives the car
forward through the electric motor. The combustion
engine is designed to be used on the odd occasions
that the journey is too far for the electric battery to
satisfy, and helps to alleviate some concerns with
range limitations of battery electric vehicles.
Due to their sustainability and cheaper running
costs, electric vehicles are likely to be the way of
the future. However, they require a slight change in
the vehicles in general. Currently, the fuel in car
when it runs out or if the fuel is getting low, arrive
to a petrol station, fill it back up and drive off.
However, electric vehicles aren’t really designed
for petrol station refills as they take a few hours to
recharge. To put it simply, this is similar in the way
how mobile phones and other gadgets will be
charged before using it.
The most important thing is a charging station
installed at your house, so that we can charge the
vehicle at home. Likewise, charging stations will
eventually be set up at destination points like car
parks and work places so that we can recharge the
vehicle while we are not using it, instead of sitting
at a petrol station for 4 hours. In fact, governing
bodies of the European Union have proposed that
all new and refurbished buildings with parking
space for more than 10 cars should have to have an
electric vehicle charging point on the premises.
There will still likely be charging points at petrol
stations but these will be rapid charge units to give
your electric vehicle a blast of power while having
a travel break.
Electric vehicles are predicted to be the next
disruptive market force for transportation and
technology. They have the potential to revolutionize
how energy is used, created and redirected. The
advent of electric cars has called for an
improvement in overall energy usage and
generation. They have shown how important it is to
find alternate sources of fuel and they can
positively affect the environment and society as a
whole. When these electric vehicles are started to
implement in our country the situation will change.
At a public parking facility, the electric vehicles
(EVs) that are parked at dedicated parking spaces
with charging points can enjoy charging services.
Installing charging points at many places will be
helpful to overcome this situational crisis.
This project proposes the idea of developing a
DC fast charger for EV in order to reduce the cost
of production by manufacturing within our country.
The charging mechanism is done in such a way to
minimize the charging time of electric vehicles.
Increase in charging stations will make the people
to believe in this type of electric vehicles and the
importance of it towards environment.
Battery Management Systems are the brains
behind battery packs. They manage the output,
charging and discharging and provide notifications
on the status of the battery pack. They also provide
critical safeguards to protect the batteries from
damage. The single most important function that a
battery management system performs is cell
protection. Lithium ion battery cells have two
critical design issues, overcharging them can get
damaged and cause overheating or even explode so
it is important to have battery management system
to provide over voltage protection. Lithium ion
cells can also be damaged if they are discharged
below a certain threshold, approximately 5 percent
of total capacity. If the cells are discharged below
this threshold their capacity can become
permanently reduced.
In this module, we are closely observing the
battery temperature using the temperature sensor
which is placed on each individual cell and
monitoring it. If the temperature rises above the
threshold limit the buzzer will ON and led starts to
glow which indicates a caution alert to shut down
the charging kit. The lithium ion cell battery
temperature, voltage and current values will be
displayed by the serial monitor. PIC microcontroller
are electronic circuits that can be programmed to
carry out vast range of tasks. They are programmed
to be timers or to control the production line and
much more. The voltage regulators are used to
control the supply voltage to the microcontroller at

International Journal of Scientific Research and Engineering Development
©IJSRED: All Rights are Reserved
a constant voltage and thereby the battery starts
charging. The analog signals which is received
from the sensors is converted into digital signal
with the help of inbuilt ADC in the microcontroller.
II. BOCK DIAGRAM OF THE SYSTEM
The block diagram for DC fast charger
shown in Fig 1.
Fig 1. DC fast charger for EV
III. WORKING
A 230V AC supply is given to the step
transformer. In the step-down transformer, the AC
voltage is reduced from 230V to 12V.The bridge
rectifier is an Alternating Current(AC) to Direct
Current(DC) converter that rectifies
input to DC output. This rectifier circuit are widely
used in power supplies that provide necessary DC
voltage for the electronic devices.
capacitor is a device that allows passing the dc
component of the rectifier output. Thus, the ou
of the filter circuit will be a steady DC voltage.
A voltage regulator is a system designed to
automatically maintain a constant voltage
A voltage regulator may use a simple feed
design or may include negative feedback. Two
voltage regulators are used for various purposes.
fixed voltage regulator produces a fixed DC output
voltage, which is either positive or negative.
In other words, some fixed voltage regulators
produce positive fixed DC voltage values, while
International Journal of Scientific Research and Engineering Development-– Volume 3 - Issue
©IJSRED: All Rights are Reserved
a constant voltage and thereby the battery starts
ging. The analog signals which is received
from the sensors is converted into digital signal
with the help of inbuilt ADC in the microcontroller.
SYSTEM
fast charger for EV is
fast charger for EV
230V AC supply is given to the step-down
down transformer, the AC
voltage is reduced from 230V to 12V.The bridge
rectifier is an Alternating Current(AC) to Direct
Current(DC) converter that rectifies mains AC
input to DC output. This rectifier circuit are widely
used in power supplies that provide necessary DC
voltage for the electronic devices. The filter
capacitor is a device that allows passing the dc
component of the rectifier output. Thus, the output
of the filter circuit will be a steady DC voltage.
is a system designed to
voltage level.
may use a simple feed-forward
design or may include negative feedback. Two
lators are used for various purposes. A
fixed voltage regulator produces a fixed DC output
voltage, which is either positive or negative.
In other words, some fixed voltage regulators
produce positive fixed DC voltage values, while
others produce negative fixed DC voltage values.
An Adjustable/Variable Voltage Regulator
regulates the output voltage within a desired range
and can be adjustable within that range. Depending
on the range of voltage to be adjusted, there are
many types of adjustable voltage regu
two IC’s used are LM317T and LM7085.PIC
microcontroller is used here to carry out the vast
range of tasks and calibrate the obtained values
with the programmed values which are feed into IC
through coding. The series of three lithium ion cells
are used to produce the output voltage of 12V.A
printed circuit board (PCB) is an electronic circuit
used in devices to provide mechanical support and a
pathway to its electronic components. The
temperature sensor LM35 is used for measuring the
lithium ion battery temperature while charging. The
buzzer is used to indicate the abnormal rise in
battery temperature which alerts to safeguard the
charging kit. The led glows incase of any technical
malfunction in the kit. The serial 2x16 LCD is used
to display the battery temperature, voltage and
current values.
IV. HARDWARE MODULES
Microcontroller(PIC16F877A)
The microcontroller PIC16F877A is one of the
most renowned microcontrollers in th
has a total number of 40 pins and there are 33 pins
for input and output. It has a smaller 35 instructions
set. The operating voltage is between 4.2 volts to
5.5 volts and it can operate up to 20MHz frequency.
Step down transformer
The step down transformer is designed to reduce
the voltage from the primary
secondary winding. As a step
transformer converts high-voltage, low
power into low-voltage, high-current power.
transformer will step down the power supply
voltage from 230V to 12V. Then the secondary of
the potential transformer will be connected
precision rectifier. The advantages of using
precision rectifier is to give peak voltage output as
DC, rest of the circuits will give only RMS output.
Issue 5, Sep - Oct 2020
www.ijsred.com
Page 173
fixed DC voltage values.
An Adjustable/Variable Voltage Regulator
regulates the output voltage within a desired range
and can be adjustable within that range. Depending
on the range of voltage to be adjusted, there are
many types of adjustable voltage regulators. The
two IC’s used are LM317T and LM7085.PIC
microcontroller is used here to carry out the vast
range of tasks and calibrate the obtained values
with the programmed values which are feed into IC
through coding. The series of three lithium ion cells
are used to produce the output voltage of 12V.A
printed circuit board (PCB) is an electronic circuit
used in devices to provide mechanical support and a
pathway to its electronic components. The
temperature sensor LM35 is used for measuring the
battery temperature while charging. The
buzzer is used to indicate the abnormal rise in
battery temperature which alerts to safeguard the
charging kit. The led glows incase of any technical
malfunction in the kit. The serial 2x16 LCD is used
e battery temperature, voltage and
MODULES
(PIC16F877A)
microcontroller PIC16F877A is one of the
most renowned microcontrollers in the industry. It
has a total number of 40 pins and there are 33 pins
has a smaller 35 instructions
between 4.2 volts to
can operate up to 20MHz frequency.
is designed to reduce
the voltage from the primary winding to the
As a step-down unit, the
voltage, low-current
current power. The
transformer will step down the power supply
Then the secondary of
ial transformer will be connected to the
The advantages of using
give peak voltage output as
DC, rest of the circuits will give only RMS output.

Rectifier
A rectifier is an electrical device comprises of
one or more diodes which allow the flow of current
only in one direction. It basically converts
alternating current into direct current. The rectifier
which is used here is 1N4007G SOD57.
Fixed voltage regulator
The voltage regulator is used to regulate voltage
level. When a steady, reliable voltage is needed,
then voltage regulator is the preferred device. It
generates a fixed output voltage that remains
constant for any changes in an input voltage or load
conditions. It acts as a buffer for protecting
components from damages. The voltage regulator
which is used here is LM7805.
Variable voltage regulator
Variable Voltage Regulator regulates the output
voltage within a desired range and can be adjustable
within that range. Depending on the range of
voltage to be adjusted, there are many types of
adjustable voltage regulators. The adjustable
voltage regulator which is used here is LM317T.
Temperature sensor
LM35 is a temperature measuring device having
an analog output voltage proportional to the
temperature. It provides output voltage in Celsius. It
does not require any external calibration circuitry.
The sensitivity of LM35 is 10 mV/degree Celsius.
Liquid Crystal Display
LCD stands for Liquid Crystal Display which is
wide spread use replacing LEDs. A model used
here is low cost LCD which can display messages
in two lines with 16 characters each. It can also
display the alphabets, Greek letters, punctuation
marks, mathematical symbols and also the user
defined symbols.
V. CONCLUSIONS
The proposed DC fast charger will ensure the
knowledge regarding electric vehicle battery
management system. Electric vehicle industry has
seen in recent years is not only extremely
welcomed, but highly necessary in light of the
increasing global greenhouse gas levels. Due to the
economic, social, and environmental causes, the
benefits of electric vehicles far surpass the costs.
Moreover, the cost of the electric vehicle is
relatively high now when compared with the
normal gasoline powered vehicles. The only way to
overcome this problem is manufacturing the
electronic components related to electric vehicle
industry in India and marketing its reliability. This
will reduce the cost of the electric vehicles. Also
making incentivized and empowered to drive an
electric-powered vehicle will rise to better change.
REFERENCES
[1] R. S. Morris, B. G. Dixon, T. Gennett, R. Raffaelle, M. J. Heben,
“High-energy fast rechargeable Li-ion battery” Power Sources, vol.
138, pp. 277-280, 2018.
[2] M. Fukino, N. Irie, H. Ito, Development of an electric vehicle with fast
charging system, pp. 25-32, 2017.
[3] Luca Buccolini, Adrianna Ricci, Cristiano Scavongelli, Giuseppe
DeMaso-Gentile, Simone Orcioni, Massimo “Battery Management
System”, pp. 1-6, 2016.
[4] Huang Shaofang, "Electric vehicle charger (station) of harmonic" in
Jiaotong University, Beijing, vol. 2, pp. 56-58, 2008.

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