Ka3842_lm358 electric car charger circuit

The charger is a device designed to replenish the battery of an electric bicycle with electrical energy. It typically consists of several key components, including a rectification and filtering circuit, a high-voltage switch, voltage conversion stage, constant current and constant voltage control circuits, and a charging management system. The primary function of the rectification and filtering circuit is to convert the 220V AC from the power grid into approximately 300V DC. This DC voltage is then processed through a high-voltage switching circuit, which converts it into a lower DC voltage suitable for charging the battery. The charging process is controlled by the charging control circuit, ensuring safe and efficient power delivery. The charger has two main connectors: one for connecting to the power supply (mains) and another for connecting to the battery. Additionally, there are two LED indicators that display the power status and the charging progress. **Ka3842_lm358 Electric Car Charger Circuit**

**Working Principle of Ka3842_lm358 Electric Car Charger Circuit** The 220V AC input passes through LF1 for bidirectional filtering. The diodes VD1â€“VD4 perform full-wave rectification, converting the AC into pulsating DC. This is further smoothed by capacitor C3 to produce a stable DC voltage of around 300V. This voltage is supplied to pin 7 of the pulse-width modulation IC1 (Ka3842) via resistor R4. Once the voltage at pin 7 exceeds 14V, the IC starts operating, generating PWM pulses from pin 6, which drive the power switch (a MOSFET). VT7 operates in a switching mode, allowing current to flow through the source and drain terminals of VT1, passing through resistor R7 and back to ground. During this phase, an induced voltage is generated across the 8â€“9 winding of the switching transformer T1. This voltage is used to provide a stable operating voltage for pin 7 of IC1 through VD6 and resistor R2. The oscillation frequency of IC1 is determined by external resistor R10 and capacitor C7 connected to pin 4. IC2 (TL431) serves as a precision reference voltage source, while IC4 (4N35 optocoupler) helps regulate the charging voltage. By adjusting the semi-variable potentiometer RP1 (510 ohms), the output voltage of the charger can be fine-tuned. LED1 acts as a power indicator, lighting up red when the charger is powered on. Once VT1 begins functioning, the secondary winding (6â€“5) of the transformer produces an output voltage that is rectified by fast recovery diode VD60 and filtered by capacitor C18 to obtain a stable 53V DC. This voltage is then used to charge the battery through diode VD70, which prevents reverse current flow. The remaining voltage is routed through current-limiting resistor R38, Zener diode VZD1, and filter capacitor C60 to provide a 12V power supply for the comparator IC3 (LM358). VD12 provides a reference voltage, which is divided by resistors R25, R26, and R27 and applied to pins 2 and 5 of IC3. During normal charging, the upper end of resistor R33 has a voltage between 0.18V and 0.2V. This voltage is fed to pin 3 of IC3 via resistor R10, causing the output at pin 1 to go high. This high signal is split into three outputs: one drives transistor VT2, activating the cooling fan; another lights the red LED in the dual-color LED (LED2); and the third is sent to pin 6 of IC6, which causes pin 7 to go low, turning off the green LED in LED2. At this point, the charger enters the constant current charging phase. When the battery voltage rises to about 44.2V, the charger transitions to the constant voltage charging mode, and the charging current gradually decreases. When the current drops to 200â€“300mA, the voltage at the top of R33 decreases, causing the voltage at pin 3 of IC3 to fall below that at pin 2. This results in a low-level output at pin 1, turning off the red LED and cutting off VT2, stopping the fan. IC3's pin 7 goes high, lighting the green LED in LED2, indicating that the battery is nearly full (though it may take an additional two hours to fully charge). This high level also feeds back to pin 1 of IC2, reducing the output voltage and entering the trickle charge mode (200â€“300mA). Adjusting the resistance of RP2 allows control over the transition from constant current to trickle charging.

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