Research and design charging system for electric motorcycle using pulse transformer

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS AUTOMOTIVE ENGINEERING RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANSFORMER ADVISOR : Ph.D LE THANH PHUC STUDENTS: HO QUANG HUY DAO DUY KHANG SKL010718 Ho Chi Minh City, June 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION PROJECT RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANSFORMER Student’s name: HO QUANG HUY 19145180 DAO DUY KHANG 19145149 Major: AUTOMOTIVE ENGINEERING Advisor: LE THANH PHUC Ph.D Ho Chi Minh City, June 2023 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, ……………., ……, 2023 PROJECT ASSIGNMENT Ho Quang Huy 19145180 Student name: _ Student ID: _ Dao Duy Khang 19145149 Student name: Student ID: _ Student name: Student ID: _ 19145CLA Automotive Engineering Major: Class: Le Thanh Phuc Ph.D Advisor: (+84) 932 591 200 Phone number: _ 17/01/2023 30/06/2023 Date of assignment: _ Date of submission: _ Research and Design charging system for electric motorcycle Project title: _ using pulse transformer _ Initial materials provided by the advisor: _ General research about the topic; Design the circuit; Content of the project: _ Real test with the voltage; Conclusion & recommendation Report; Test model; Soft file Final product: CHAIR OF THE PROGRAM ADVISOR (Sign with full name) (Sign with full name) i THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, ……………, ……, 2023 ADVISOR’S EVALUATION SHEET Student name: HO QUANG HUY Student ID: 19145180 Student name: DAO DUY KHANG Student ID: 19145149 Student name: Student ID: Major: AUTOMOTIVE ENGINEERING Project title: RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANFORMER Advisor: LE THANH PHUC Ph.D EVALUATION Content of the project: Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark: …………….… (In words: ) Ho Chi Minh City, ………………, ……, 2023 ADVISOR (Sign with full name) ii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, ……………., ……, 2023 PRE-DEFENSE EVALUATION SHEET Student name: HO QUANG HUY Student ID: 19145180 Student name: DAO DUY KHANG Student ID: 19145149 Student name: Student ID: Major: AUTOMOTIVE ENGINEERING Project title: RESEARCH AND DESIGN CHARGING SYSTEM FOR ELECTRIC MOTORCYCLE USING PULSE TRANFORMER Name of Reviewer: EVALUATION Content and workload of the project Strengths: Weaknesses: Approval for oral defense? (Approved or denied) Overall evaluation: (Excellent, Good, Fair, Poor) Mark: ……………… (In words: ) Ho Chi Minh City, ………………, ……, 2023 REVIEWER (Sign with full name) iii THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness Ho Chi Minh City, ……………., ……, 2023 EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: Student ID: Student name: Student ID: Student name: Student ID: Major: Project title: Name of Defense Committee Member: EVALUATION Content and workload of the project Strengths: Weaknesses: Overall evaluation: (Excellent, Good, Fair, Poor) Mark: ……………… (In words: ) Ho Chi Minh City, ……………., ……, 2023 COMMITTEE MEMBER (Sign with full name) iv ACKNOWLEDGMENTS To complete this project, we would like to thank all the teachers at Ho Chi Minh City University of Technology and Education, especially the teachers of the Faculty for High-Quality Training for their enthusiastic teaching and support, imparting very valuable knowledge to us during our time at the school Our group would like to express sincere thanks to Mr Le Thanh Phuc - the instructor who enthusiastically supported, oriented, and suggested to the group during the process of completing the graduation thesis He allowed us to work in a laboratory with full equipment to make the process of doing the research more convenient Besides, the group also thanked all members of Mr Le Thanh Phuc's laboratory, above all, Mr Nguyen Le Khuong Duy, for their enthusiastic support to help the group gain more knowledge to complete the topic this talent Once again, we would like to thank the teachers at Ho Chi Minh City University of Technology and Education and the teachers of the Faculty for High-Quality Training v ABSTRACT The input is a 220V AC power source that will be rectified and then generate a DC power source output suitable for charging Lithium-ion battery packs on electric motorcycles Our group will research, design, and implement a circuit that handles the power after rectification and generates a DC power source that can meet the requirements for charging the Lithium-ion battery packs and can be adjusted based on the feedback signals By comparing the pulse source types and performance capabilities, the team will design a circuit system using the Flyback pulse source This regulator circuit along with the pulse source will produce a more stable, efficient power supply than other types of power sources After the research and implementation of the topic, our group learned the structure and operating principle of pulse sources and electronic components applied in the charging circuit Based on the knowledge learned and the parameters of the components, our group designed the circuit and made the test circuit part by part for testing the performance of the components And based on the testing results, the team conducts and tests the circuit in practice along with the design of the pulse transformer After testing and adjusting, the output of the charging circuit has finally met the conditions to charge the battery packs currently in the lab The charging circuit has been tested with large and small loads and the results show that the circuit works quite stably Key words: Flyback Converter, Pulse transformer, Pulse Width Modulation, MOSFET, Snubber Circuit, Lithium-ion, Electric motorcycles vi TABLE OF CONTENTS PROJECT ASSIGNMENT i ADVISOR’S EVALUATION SHEET ii PRE-DEFENSE EVALUATION SHEET iii EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER iv ACKNOWLEDGMENTS v ABSTRACT vi TABLE OF CONTENTS vii LIST OF TABLES ix LIST OF FIGURES x Chapter 1: INTRODUCTION 1.1 Motivation 1.2 Research status 1.2.1 Domestic topics 1.2.2 International 1.3 Objectives of the research 1.4 Research methods 1.5 Object and scope of the research 1.5.1 Object of the research 1.5.2 Scope of the research 1.6 Expected result Chapter 2: LITERATURE REVIEW 2.1 Pulse power supply 2.1.1 Elements used in pulse power supply 2.1.2 Flyback Regulator 2.2 Lithium-Ion Battery 10 2.2.1 Structure of Lithium-ion Battery 18650 10 2.2.2 Working principle of Lithium-ion battery 12 2.2.3 Charging and discharging characteristics of lithium-ion battery 14 2.2.4 Lithium-ion battery on Tesla Model S 16 vii 2.3 Electronic components used in the project 17 2.3.1 MOSFET 17 2.3.2 MOSFET Driver IR2103 19 2.3.3 Optocoupler 21 2.3.4 Microcontroller STM32F103C8 25 2.3.5 Diode 28 2.3.6 Resistor 31 2.3.7 Capacitor 33 2.3.8 Inductor 35 2.3.9 Voltage regulator 36 2.4 STM32CubeIDE 38 2.4.1 Introduction to STM32CubeIDE 38 2.4.2 STM32CubeIDE workspace 38 2.4.3 STM32CubeIDE programing workspace 42 Chapter 3: CALCULATION AND DESIGN 44 3.1 System description 44 3.2 Operating principle of the system 44 3.2.1 Rectifier circuit 44 3.2.2 Snubber circuit 45 3.2.3 MOSFET gate resistor 47 3.2.4 MOSFET drive circuit 50 3.3 Calculation and design circuit elements 51 3.3.1 MOSFET gate resistor calculation 51 3.3.2 Calculation of pulse transformer 53 3.3.3 Snubber circuit calculation 58 3.3.4 Feedback circuit 58 Chapter 4: EXPERIMENT RESULTS AND DISCUSSION 61 Chapter 5: CONCLUSION AND RECOMMENDATION 70 REFERENCES 72 viii