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Most robotists use alkaline batteries when primary batteries are called for and NiCd batteries when secondary batteries are needed.
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NiCd battery chargers are inexpensive. Typically it is not worth the time and effort to build a stand-alone charger for common-size batteries such as AAA, AA, C, D, and 9V. However, if one wishes to incorporate a built-in charger for a robot, then knowing how to build a custom battery charger is important. While most inexpensive chargers will charge batteries only at the C/10 rate, even after the batteries have received a full charge (14 h), the charger we will build will drop the current down to a C/30 rate after the batteries are fully charged. This is the recommended procedure for charging NiCd batteries. This will help ensure a long service life to your rechargeable battery. The following information will allow you to design a system for charging a custom NiCd battery pack. The prototype charger shown in Fig. 3.7 is a stand-alone unit for illustration purposes. The design can easily be placed inside a robot. The robot will need to have a power socket that connects to the power supply. In between the socket and power supply, you should add a double-pole double-throw (DPDT) switch. The DPDT switch connects the power supply to either the robot s circuitry or the charger. This prevents powering the robot, which would reduce the current flow to the batteries, while the batteries are being charged (see Fig. 3.7).
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3.7 DPDT switch controlling charging to battery pack
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Power
3.8 Basic power supply for charger circuit
The power for the charger may be supplied by either a standard transformer or a VDC plug-in wall transformer. I would choose a wall transformer because it supplies a DC voltage. If you are using a standard transformer, you must build the power supply, using a line cord, switch, fuse, bridge rectifier, and smoothing capacitor. In either case you should match the transformer (or wall transformer) power output to the battery pack you are charging. Matching the voltage and current to the battery pack reduces the power the LM317 must dissipate; for example, you wouldn t want to use a 12V transformer to charge a 6V battery pack. Figure 3.8 is a basic VDC power supply for the charger. The power supply can be made to provide either 6V, 12V, 18V, 24V, or 36V depending upon the transformer, bridge rectifier, and capacitor chosen. The charger circuit is illustrated in Fig. 3.9. It uses an LM317 voltage regulator and a current-limiting resistor. The resistance needed to be provided by the current-limiting resistor depends upon the current needed to charge the battery. Current-limiting resistor Most NiCd battery manufacturers recommend charging the battery at 1/10 of its rated capacity, referred to as C/10. So if an AA battery is rated at 0.850 Ah, it should be charged at 1/10 that capacity, or 85 mA, for 14 h. After the batteries are fully charged, manufacturers recommend dropping the current to around C/30 (1/30 of battery capacity) to keep them fully charged without overcharging or damaging the batteries in any way. For our example, we will configure the charger to recharge four C cells in series. Each C cell is rated at 2000 mA. So our C/10 rate is 200 mA. The typical voltage rating from this battery is approxi three
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3.9 Schematic of charger circuit
mately 1.3V (4 1.3V 5.2V). We can use a 6V transformer with at least a 200-mA output. To calculate the resistance to be provided by the current-limiting resistor, use the formula R 1.25/Icc where Icc is the desired current. Plugging in our 200 mA (0.2 A) yields 1.25/0.2 6.25 ohms The resistance of the current-limiting resistor for this charger should be around 6.25 ohms. In the schematic (Fig. 3.9), this resistor is labeled R2. Notice the R2 value listed in the schematic is 5 ohms. You should choose a common resistor value as close as possible to the calculated value. C/30 resistor To drop the current to a C/30 range, we add another resistor whose value is 2R, or about 12.5 ohms. In the schematic this resistor is labeled R3. Again a resistor with the closest value to the calculated value is used. In this case the value is 10 ohms. How the charger works The charger uses an LM317 voltage regulator as a constant current source. The C/10 current-limiting resistor is identified as R2 in the schematic (see Fig. 3.9). R2 you will notice is only 5 ohms as compared
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