AC/DC bidirectional battery charger/discharger Firmware/Hardware simulation

Thread Starter

Hasan2019

Joined Sep 5, 2019
44
Hi,

My project diagram is similar to this idea,
BAT_CHR.JPG

Lets say input is 3p 380VAC, 60Hz, Main Transformer MTR runs at 20kHz, DC output should be 50-147 v, charging current 100A. Should have CC and CV mode of operation.

I need to implement FW with following facilities,

1. Shunt/ Temperature sensing

2. 3v AC to 16 bit ADC having channel current and voltage

3. CAN/SPI/SCI protocol

4. PF correction, PI or PID control

5. PWM for high frequency switching.


Kindly suggest any simulation model/ EVM board/tools to understand the system.
 

Irving

Joined Jan 30, 2016
2,055
That's not a project idea, that's a full scale industrial design. What level of simulation are you looking for? Functional block, subfunction or component level?

What level of expertise do you have? Your 'facilities' list is a collection of low-level elements that completely ignores major design issues and are minor considerations in approaching a design of this magnitude.
 

Thread Starter

Hasan2019

Joined Sep 5, 2019
44
That's not a project idea, that's a full scale industrial design. What level of simulation are you looking for? Functional block, subfunction or component level?

What level of expertise do you have? Your 'facilities' list is a collection of low-level elements that completely ignores major design issues and are minor considerations in approaching a design of this magnitude.
First of all thanks a lot for reply.
Yeap, its a industrial project. Kind of very complex and versatile. Looking at your options all level are necessary. Lets talk about sub functional stage.
Lets say my expertise are 1% of you.
I have a prototype one that also can make money. Customized code has been made for many purpose, even register files are made separately.
Main issues are
1. Modified controller need updated F/W.
2. Somehow CAN protocol makes trouble to sending massage of device ID, Channel voltage and current of shunt.
3. Not considering input AC current.
 

Irving

Joined Jan 30, 2016
2,055
Hmm.. Where to start.. Let me say I have designed and built something similar, 1500W charger & electronic load for charging/discharging 24v/200Ah LiFePO4 battery packs, so it's not a beginner project.

What you're asking makes no sense to me. Either you designed & built this 'prototype' so have intimate knowledge of how it works, or you didn't, in which case you must have full documentation on how it was designed including schematics, test results, etc., and enough understanding & experience yourself, to work through the system to determine what changes need to be made.

No one can tell you how to resolve the issues you have, and no simulation can be developed thats relevant, without that level of detail.

Even the CANbus issue you have makes me wonder what the situation is. CAN protocol is easy, but why it should have any issues sounds like a design/implementation problem in the underlying hardware/firmware so resolving that needs intimate knowledge of the system. If you don't have that it's hard to see where you go from here...
 

Irving

Joined Jan 30, 2016
2,055
Why don't you post the schematics of what you have working (or not) and let's see if it's remotely possible to move forward from there...
 

Thread Starter

Hasan2019

Joined Sep 5, 2019
44
Hmm.. Where to start.. Let me say I have designed and built something similar, 1500W charger & electronic load for charging/discharging 24v/200Ah LiFePO4 battery packs, so it's not a beginner project.
If you dont mind could you share difficulties to perform this project. Starting from beginning from AUX TR 380/2V how do you interface AC analog input AC_V_R/S/T with help ac coupled rail to rail opamp TLC22741 or else? I do mean signal conditioning, setting offset. In my case it it will not exit 2V. Exhibiting high input impedance and low noise, is excellent for small-signal
conditioning for high-impedance sources. I can make ADC_AC_V_R/S/T. Buffer Op Amp to ADC Circuit Collection
Which controller/dsp/mcu do you use?

What you're asking makes no sense to me. Either you designed & built this 'prototype' so have intimate knowledge of how it works, or you didn't, in which case you must have full documentation on how it was designed including schematics, test results, etc., and enough understanding & experience yourself, to work through the system to determine what changes need to be made.
Good complement. Looks like you are interested share your knowledge. Do you think this research paper is meaningless .. see attachment.



No one can tell you how to resolve the issues you have, and no simulation can be developed thats relevant, without that level of detail.
Many of you are seeking knowledge from such forum.

Even the CANbus issue you have makes me wonder what the situation is. CAN protocol is easy, but why it should have any issues sounds like a design/implementation problem in the underlying hardware/firmware so resolving that needs intimate knowledge of the system. If you don't have that it's hard to see where you go from here...
Its challenging indeed. On your eyes it looks easy You may saw easy protocol that adapt system easily, but if the total system runs with a DSP instructions then it might not easy. I do mean in my case setting of CAN is easy but run with assembly code its not easy.
 

Attachments

kaindub

Joined Oct 28, 2019
87
Is this a college project?
If it’s a design to be commercialised, you face some hurdles.
There are many established suppliers of forklift chargers.The buyers of such a product are warehouse managers. They are very price conscious.
Even if you come up with a great product, how are you going to reach the buyers if the existing distribution channels are already taken.
If you have a great idea, pitch it to the existing charger manufacturers. But I bet they are already onto this idea.
Sorry to be Debbie downer, but this project it a lot of effort (time and money). It’s not your usual hobby type project.
 

Thread Starter

Hasan2019

Joined Sep 5, 2019
44
Is this a college project?
If it’s a design to be commercialised, you face some hurdles.
There are many established suppliers of forklift chargers.The buyers of such a product are warehouse managers. They are very price conscious.
Even if you come up with a great product, how are you going to reach the buyers if the existing distribution channels are already taken.
If you have a great idea, pitch it to the existing charger manufacturers. But I bet they are already onto this idea.
Sorry to be Debbie downer, but this project it a lot of effort (time and money). It’s not your usual hobby type project.
Well said.
Usually we love to run for unknown to explore it .We are keen to looking for impossiblies to make things possible.
Thousands of products are available in market but manufacturers wont "give up".
Any one can make money if he knows where to invest it. Most of us in this globe are not in starvation.
 
Last edited:
Top