ELECTRO SERVICE (INDIA) started its operation with manufacturing of Transformers and Chokes for industrial applications in 1987. It is renowned manufacturer of smps battery charger, Transformer , toto rickshaw charger, Tuktuk Auto-Rickshaw Battery Charger etc

1. Welcome to
Technical
Presentation on
SMPS based
E-Rickshaw
Battery Charger
22 April 2016
1

2. E-Rickshaw runs on
electrical energy,
provided by a heavy
duty rechargeable
battery bank.
What is an E-Rickshaw?
22 April 2016
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3. 1) ECO friendly- that is ZERO Pollution & Noise less
2) Low running cost & perhaps lower maintenance cost
3) Lower initial investment compared to
Petrol/Diesel/CNG driven Auto Rickshaw
4) Though slightly larger in size, it accommodates more
passengers
5) Aesthetically better looking
Why E-Rickshaw? Auto versus Toto
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4. 1) DC motor of E-rickshaw (TOTO) runs in 48V DC
2) Generally 4X12V rechargeable mono block batteries
are used.
3) These batteries are heavy duty tubular type batteries
and require maintenance by periodic re-filling of
electrolyte ( acid & water)
Now Battery & Battery Charger
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5. 1) Tubular batteries have got high rate of discharging
capability, particularly during cranking.
2) It can also accept higher rate of charging current
(required for quick restoration) compared to sealed
maintenance free batteries (SMF VRLA batteries).
3) In a nutshell tubular batteries are suitable for heavy
duty CYCLIC use
Advantage Tubular Battery
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6. 1) Considering the space & weight constraints of the
vehicle, 88 to 120AH battery capacity has been
optimized, which can give around 80 KM per charge
cycle.
2) These batteries are used to its fullest capacity in
E-rickshaws and expected life is 250 to 300
charge/discharge cycles
Battery sizing & installation
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7. Role of Battery Charger
❖ Charging a discharged Battery by taking
electrical energy from the domestic
electrical supply grid ( single phase, 230V
AC )
❖ And to make the battery ready for next
cycle of discharge for the next run of the
Toto 22 April 2016
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8. Process of battery charging
☞ Battery Charging is a complex electro
chemical process, in which the discharged
electrical energy is replenished from the
electrical network.
☞ AND Quality of the charging process is
critical for the health & longevity of the
battery. 22 April 2016
8

9. Type of Battery Chargers
Four types of E-rickshaw battery chargers are
available in the market:
1. Transformer based with manual control
2. Transformer based but automatic control
3. SMPS based automatic but without
microcontroller
4. SMPS based with microcontroller
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10. Advantage of manual control
transformer charger
1. Cheap.
2. Suitable for quick charging by injecting
high rate of current by manual control
switch kept for current control.
3. Can be serviced by local electrician .
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11. Disadvantage of manual control
transformer charger
1. Bulky & heavy- not easy to carry and handle.
2. Energy-inefficient (consumes more power) .
3. Not provided with any electronic protection circuit.
4. Charging current varies with the input voltage
fluctuation. Battery gets damaged very easily in high
voltage area due to high current charging.
5. And takes long time to charge in low voltage area.
22 April 2016
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12. Disadvantage of auto control
transformer charger
1. It is bulky as before but no longer cheap due to
additional control circuitry.
2. It consumes more power because of crude technique of
auto control of charging current
3. It fails very often because of bad design, poor
workmanship and use of low quality electronics
4. No warranty & high repairing cost
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13. Switched mode power supply in
Battery charging application
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14. Few words about SMPS charger
☞ Switched mode power conversion technique has
become boon due to its reduced size & lower cost
☞ SMPS Battery chargers are very popular in Telecom
application as well as in UPS industry
☞ Most popular SMPS battery Chargers are cell phone
and laptop chargers.
22 April 2016
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15. Limitation of SMPS technique
☞ Reduced size of SMPS converters is due to
high frequency transfer of power since high
frequency ( 50Khz +) magnetic materials can
handle much higher power density.
☞ But, it can handle power only up to limited
capacity.
22 April 2016
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16. A brief outline about AC TO
DC conversion with
switched mode technique
Let us briefly refresh theory
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17. ❑A typical Switched Mode Power Supply
incorporates a front end AC-DC rectifier to
generate an unregulated DC input voltage.
❑A high frequency chopper (MOSFET/IGBT)
then chops the input DC Voltage.
❑After that a high frequency transformer
isolates, steps down and converts this square
wave DC to square wave AC output.
SMPS PRINCIPLE OF
OPERATION
22 April 201617

18. ❑It is then rectified & filtered to generate a
smooth ripple free output voltage.
❑Pulse Width Modulation technique is
generally employed to regulate the charger
output of a SMPS Charger
SMPS PRINCIPLE OF OPERATION
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19. AC INPUT
TYPICAL SCHEMEMATIC OF SMPS CONVERTER
RECTI-
FIER
SMPS TRANS-
FORMER
HF
RECTIFIER
&
FILTER DC
OUTPUT
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20. SMPS Advantage
☞ COMPACT & LIGHT
☞ HIGH EFFICIENCY ( low consumption of power)
☞ LOW RIPPLE ( good for battery life)
☞ EXCELLENT REGULATION ( no variation in charging
current)
☞ WIDE INPUT WINDOW (130-270V)- ( charging quality &
time unaffected due input voltage fluctuation)
☞ LOWER COST
☞ RELIABLE & LOW COST OF REPAIRING22 April 2016
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21. Before that let us see
what is present
market trend
We will elaborate on microcontroller advantage later
22 April 2016
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22. End user’s perception about the
Charger
❖ Charger should be 12A. It should charge a fully
discharged battery within 8-10 hours
❖ It should indicate state of charge for rough
estimation about the mileage capacity of the
vehicle and they can run their TOTO even before
full charge
❖ Charger should automatically stop and should not
over charge the battery, which can damage the
battery due to over heating
❖ Charger must have warranty & should not fail22 April 2016
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23. Dealer’s requirement
❖ Warranty & replacement service
❖ Minimum failure
❖ Cheap & light weight
❖ On site servicing during post
warranty period
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24. Dealer’s requirement continues
❖ Should charge in low voltage area without
sacrificing the time period
❖ Low power consumption or higher efficiency
❖ It should indicate state of charge
❖ Attractive look, good packaging & bright
catalogue with user friendly instruction
manual/sticker
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25. ESI charger is SMPS
charger with
microcontroller based
control
Let us see ESI charger’s feature
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26. ESI charger is programmed to meet all
expected features & performance….like
✓ ESI Charger is 12A charger.
✓ It ensures full charge of a fully discharged battery
within 7-8 hours hours
✓ ESI charger indicates state of charge by multiple
LEDs
✓ Charging process is indicated by a blinking LED
✓ On completion of charge
❖ Charging LED becomes steady
❖ And a buzzer also beeps intermittently to draw attention
22 April 2016
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27. ESI charger is programmed to meet all
expected features & performance….like
✓ It operates in low voltage area without
compromising charging period.
✓ ESI charger is efficient and consumes less
power.
✓ Low ripple content.
✓ Excellent line and load (charge) regulation.
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28. ESI Charger is designed and
programmed to enhance battery life
Beyond basics- the microcontroller topping
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29. ESI SPEIALITY-1
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➢It keeps Battery healthy
➢Enhances battery life
beyond expectation
➢Prevents Battery from
premature death
DE-
SULPHATION

30. De-sulphation of Battery
❖ Battery plates accumulate lead-sulphate crystals after
each discharge cycle.
❖ These crystals are normally broken down during
charging. But, in reality some part of these crystals
remains on the plates and gets hardened in course of
time.
❖ This drastically reduces the discharge efficiency or
battery capacity.
❖ For which battery performance decreases resulting to
early end of battery life. 22 April 2016
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31. De-sulphation of Battery continues…………
❖ ESI charger incorporates a rapid pulse
charging technique in the beginning, which
totally breaks down all accumulated lead
sulphate crystals.
❖ This pulse charging radically enhances battery
life.
❖ This process also helps in equalization of
electrolytic concentration (specific gravity).
❖ Equalizing or cell balancing keeps all the cells22 April 2016
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32. ESI SPEIALITY-2
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➢ESI charger does not over
charge the old battery
➢Thus prevents over heating
➢Helps battery to retain its
efficiency
➢Eliminates the possibility of
Timer
Over-ride

33. Voltage sensed termination of charging
❖ Battery voltage increases with the charge
❖ Charging process normally terminates by sensing
battery voltage.
❖ That is when battery voltage reaches a preset level
electronic control circuit either reduces the charging
current or terminates the charging process totally.
22 April 2016
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34. Limitation of voltage sensed termination
❖ This voltage sensing fails after some time due to age
or poor maintenance of battery.
❖ When battery gets old or behaves like an old battery
due to ill maintenance, charging voltage fails to reach
the desired set level of sensing required for
termination of charging process.
22 April 2016
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35. Battery over heating and failure
☞As a result battery receives a high rate of charging
current ( that is excess charge) beyond its capacity of
absorption.
☞ This causes over heating and reduces battery life
drastically.
☞Hence premature DEATH (of the Battery) is22 April 2016
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36. To overcome this catastrophe…………
❖ ESI charger introduces a smart technique
by starting a TIMER when charging voltage
reaches 60% voltage level.
❖ Timer elapsed time is set corresponding to
the time normally required by a
new/healthy battery to reach 100%
charge level from this level of 60% state of
charge 22 April 2016
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37. A full proof solution for termination
✓ Microcontroller works here like an watch dog
✓ It also continuously senses charge voltage level
✓ IF voltage level reaches before the preset elapsed
time it goes to end of charge process.
✓ ELSE charging reaches end of charge level as
soon as timer stops.
✓ Hence NO OVER HEATING of aged or ill22 April 2016
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38. ESI SPEIALITY-3
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➢Charging indication with blinking
LED
➢State of charge by multiple LEDs
➢End of charge notification by
buzzer & steady glow of charging
LED
USER
FRIENDLY
STATUS
DISPLAY

39. Product Image
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40. ESI SPEIALITY-4
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➢ESI provides comprehensive
warranty for six months
➢ESI extends component cost
servicing up to one year
➢ESI will repair its product up to
five years from its date of
manufacturing
POST
WARRANTY
SUPPORT

41. ESI SPEIALITY/ADVANTAGE-5
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➢ESI is an ISO 9000-2008
company since the last 10
years
➢ESI is in the Battery Charger
business since the last 20 years
➢ESI is an 100% Indian company
➢ We design in-house from white
paper and do not copy paste
ASSURANCEF
ROM
An ISO
INDUSTRY

42. ◻ At ESI we test each & every finished good and
maintain a comprehensive record
◻ All the Test Instruments are calibrated in NABL
accredited Laboratory
◻ Product Type Tests are carried out at ERTL,
National Test House and SAMEER
Quality Assurance
22 April 2016
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43. ◻ At ESI we test each & every finished good and
maintain a comprehensive record
◻ All the Test Instruments are calibrated in NABL
accredited Laboratory
◻ Product Type Tests are carried out at ERTL,
National Test House and SAMEER
Quality Assurance
22 April 2016
43

44. 22 April 2016
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◻ We are here to clarify your queries .
◻ We look forward to do business with you .
◻ Please contact :
■ Somen Ghosh, CEO
■ M- 9903993911/9331036892
■ Email: somengosh@esielectro.com
■ URL- www.esielcectro.com

45. Thank you
For your
Patience
22 April 2016
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