摘要：為了有效地提升鉛酸蓄電池" title="鉛酸蓄電池" target="_blank">鉛酸蓄電池的使用壽命，同時(shí)實(shí)現(xiàn)對(duì)充電過(guò)程的監(jiān)控，設(shè)計(jì)出一種用單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" 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title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)" title="單片機(jī)">單片機(jī)控制的36 V鉛酸蓄電池充電電源。本電路采用反激式拓?fù)洌B續(xù)電流工作模式，電源管理IC設(shè)計(jì)在電源的副邊，由ELAN公司的EM78P258N單片機(jī)模擬，是用可編程器件模擬電源管理IC，實(shí)現(xiàn)智能電源低成本化的一次成功嘗試，通過(guò)對(duì)單片機(jī)的軟件設(shè)計(jì)實(shí)現(xiàn)了充電電源的狀態(tài)顯示、充電時(shí)間控制、報(bào)警、過(guò)溫保護(hù)、過(guò)壓保護(hù)、過(guò)流保護(hù)等功能。本充電器真正的實(shí)現(xiàn)了鉛酸蓄電池的三段式充電過(guò)程，其最高輸出功率可達(dá)90 W，效率約85％，成本不到20元，具有很高的市場(chǎng)競(jìng)爭(zhēng)力。
關(guān)鍵詞：鉛酸蓄電池；充電電源；單片機(jī)；電源管理IC

    鉛酸蓄電池由于其制造成本低，容量大，價(jià)格低廉而得到了廣泛的使用。但是，若使用不當(dāng)，其壽命將大大縮短。影響鉛酸蓄電池壽命的因素很多，而采用正確的充電方式，能有效延長(zhǎng)蓄電池的使用壽命。研究發(fā)現(xiàn)：電池充電過(guò)程對(duì)電池壽命影響最大，放電過(guò)程的影響較少。也就是說(shuō)，絕大多數(shù)的蓄電池不是用壞的，而是“充壞”的。由此可見(jiàn)，一個(gè)好的充電器對(duì)蓄電池的使用壽命具有舉足輕重的作用。
    目前比較被認(rèn)可的充電曲線如圖1所示。也即常說(shuō)的三階段充電法：在充電開(kāi)始和結(jié)束時(shí)采用恒電流充電，中間用恒電壓充電。當(dāng)電流衰減到預(yù)定值時(shí)，由第二階段轉(zhuǎn)換到第三階段。這種方法可以將出氣量減到最少，最大限度的保護(hù)蓄電池的壽命。

    傳統(tǒng)的3842式充電器性能可靠，價(jià)格低廉，但卻只能實(shí)現(xiàn)充電曲線的前兩個(gè)階段，無(wú)法實(shí)現(xiàn)浮充(涓流)階段，而且無(wú)法實(shí)現(xiàn)智能控制。市場(chǎng)上的一些所謂的智能充電器，又無(wú)一例外的價(jià)格高昂，沒(méi)有市場(chǎng)競(jìng)爭(zhēng)力。本文介紹了一種采用單片機(jī)做電源管理IC的智能充電器，可以真正的實(shí)現(xiàn)三段式充電過(guò)程，并且具有狀態(tài)顯示、充電時(shí)間控制、報(bào)警等功能，而且整機(jī)成本不到20元，極具市場(chǎng)競(jìng)爭(zhēng)力。

1 電源設(shè)計(jì)方案
1．1 總體方案簡(jiǎn)介
    采用單片機(jī)做電源管理IC，瓶頸問(wèn)題是單片機(jī)的運(yùn)算速度較慢，當(dāng)負(fù)載出現(xiàn)突變時(shí)無(wú)法及時(shí)做出調(diào)節(jié)，而本例的負(fù)載是電池，給電池進(jìn)行充電的過(guò)程恰好不會(huì)出現(xiàn)負(fù)載突變這個(gè)問(wèn)題，這使得采用單片機(jī)作為電源管理IC成為可能。
    由于本電路的輸出功率小于100 W，所以采用反激式拓?fù)湫问剑醇な酵負(fù)渥畲蟮膬?yōu)點(diǎn)是不需要輸出濾波電感，這使得反激式拓?fù)涞某杀据^低，體積較小。電源管理IC設(shè)計(jì)在電路副邊，由ELAN品牌的EM78P258N單片機(jī)模擬，單片機(jī)的運(yùn)算頻率設(shè)定為8 MHz。EM78P258N是一款具有很高性價(jià)比的單片機(jī)，其工作頻率最高可達(dá)20 MHz(外接振蕩器模式)，內(nèi)部設(shè)置了4個(gè)12位精度的AD轉(zhuǎn)換器、2Kx13位片內(nèi)寄存器、3個(gè)八位、一個(gè)十六位計(jì)時(shí)器和一個(gè)PWM波形發(fā)生器，具有看門(mén)狗功能。電路的初級(jí)和次級(jí)由變壓器進(jìn)行隔離，變壓器不僅結(jié)構(gòu)簡(jiǎn)單，而且很容易實(shí)現(xiàn)初次級(jí)3 000VAC的抗電強(qiáng)度。該充電器最高輸出約可為45 V／2 A，并可根據(jù)實(shí)際需要進(jìn)行調(diào)節(jié)。本充電器的開(kāi)關(guān)頻率設(shè)為40 KHz，每個(gè)周期被等分為200個(gè)部分，PWM每次可以調(diào)節(jié)1／200個(gè)周期，即125 ns。
    本充電器的電路如圖2所示。市電輸入經(jīng)橋式整流后，形成約300 V直流電壓。本電路的整流濾波電路與通常有所不同，對(duì)蓄電池充電器來(lái)說(shuō)，整流后的100 Hz脈動(dòng)電流沒(méi)必要濾除干凈，100 Hz的脈動(dòng)電流對(duì)蓄電池充電不僅無(wú)害，反而有利，在一定程度上可起到脈沖充電的效果，使充電過(guò)程中蓄電池的化學(xué)反應(yīng)有緩沖的機(jī)會(huì)，防止連續(xù)大電流充電形成的極板硫化現(xiàn)象。

    單片機(jī)初始工作電壓，是由負(fù)載電池提供的，當(dāng)沒(méi)有接上負(fù)載電池時(shí)，本充電器不會(huì)工作。由于單片機(jī)EM78P258N芯片的采樣精度與它的供電的電源紋波有關(guān)，這里采用7805芯片給它供電。EM78P258N芯片輸出的PWM脈沖的高電平為5V，而IRF840的開(kāi)通電壓為4V，但由于EM78P25 8N芯片的輸出信號(hào)要先經(jīng)過(guò)放大電路，再經(jīng)過(guò)信號(hào)變壓器的耦合，才去驅(qū)動(dòng)開(kāi)關(guān)管IRF840，PWM波形難免會(huì)出現(xiàn)畸變。為了降低損耗，這里將信號(hào)放大電路的電壓設(shè)置為20 V，經(jīng)測(cè)試，此舉會(huì)大大提高電路的效率，此20 V電壓由7820芯片提供。7805芯片和7820芯片的輸入均接到本充電器的輸出端(圖2中未繪出)。EM78P258N芯片的6腳和7腳用來(lái)控制信號(hào)燈，通過(guò)觀察兩個(gè)信號(hào)燈的開(kāi)滅狀態(tài)就可以知道本電路工作在哪個(gè)階段下。11腳被設(shè)定為警報(bào)控制信號(hào)端，當(dāng)電池充電過(guò)程完成，或者充電器出現(xiàn)故障時(shí)，此腳控制警報(bào)器發(fā)出不同的報(bào)警聲。4個(gè)AD轉(zhuǎn)換器中，13腳用來(lái)采集電壓信號(hào)，14腳用來(lái)采集電流信號(hào)，1腳用來(lái)采集溫度信號(hào)，2腳閑置，可用于以后的功能升級(jí)。3腳用來(lái)監(jiān)控220VAC市電，當(dāng)充電器斷電后，單片機(jī)進(jìn)入休眠狀態(tài)。電流采樣電阻還可以完成假負(fù)載的功能。
    本電路在市電和蓄電池均聯(lián)接上后，才開(kāi)始工作，蓄電池和市電任一個(gè)斷開(kāi)，電路即停止工作，可靠性較好。
1．2 單片機(jī)軟件的設(shè)計(jì)
    由于EM78P258N芯片并不是專用的電源管理IC，所以在程序設(shè)計(jì)時(shí)，一定要盡可能將所有可能出現(xiàn)的工作狀態(tài)全部考慮到。由于單片機(jī)的運(yùn)算速度的限制(在本例中，一個(gè)指令周期為125 ns)，不可能實(shí)現(xiàn)特別準(zhǔn)確的電壓或電流輸出，但對(duì)于鉛酸電池來(lái)說(shuō)，適當(dāng)?shù)碾妷夯螂娏骷y波反而有利于消除極板硫化現(xiàn)象。
    軟件控制流程如圖3所示。當(dāng)蓄電池接上后，單片機(jī)開(kāi)始工作，初始化后，PWM緩慢打開(kāi)，然后檢測(cè)電流采樣電阻上的電壓，將電路的輸出電流控制到1．8～2 A之間，同時(shí)檢測(cè)輸出電壓并計(jì)時(shí)，如果電路輸出電壓到達(dá)42 V的時(shí)間小于10 s，就認(rèn)為這個(gè)電池本身就滿的，程序直接轉(zhuǎn)到涓流狀態(tài)。當(dāng)電路的輸出電壓達(dá)到43 V后，程序轉(zhuǎn)到恒壓充電階段，此階段將電路的輸出電壓控制到43～45 V之間，同時(shí)檢測(cè)輸出電流并計(jì)時(shí)，當(dāng)輸出電流小于200 mA時(shí)，程序轉(zhuǎn)到恒壓轉(zhuǎn)涓流階段。由于在恒壓階段，電池已經(jīng)被浮充到了44．6 V左右，而涓流階段的電壓要求為41．4 V左右，如果恒壓階段結(jié)束后直接轉(zhuǎn)到涓流階段，就會(huì)出現(xiàn)電池的電壓高于充電器輸出電壓的情況，充電電流為零，強(qiáng)迫程序結(jié)柬。所以在恒壓階段結(jié)束后，程序先進(jìn)入一個(gè)恒壓轉(zhuǎn)涓流階段，在此階段，將充電電流控制到80～100 mA之間，隨著充電電流的下降，電池兩端的電壓也會(huì)下降，當(dāng)電池兩端的電壓降至40 V以下時(shí)，程序轉(zhuǎn)到涓流階段繼續(xù)對(duì)電池進(jìn)行充電，從而真正實(shí)現(xiàn)了三段式的充電模式。涓流階段持續(xù)半小時(shí)或者充電電流小于50 mA后，單片機(jī)在蜂鳴提示后，進(jìn)行到睡眠狀態(tài)，充電過(guò)程結(jié)束。

    在單片機(jī)的整個(gè)工作過(guò)程，充電器的輸出電壓和輸出電流一直被監(jiān)控，如果單片機(jī)的程序末完成，蓄電池即被取下，這時(shí)開(kāi)關(guān)管開(kāi)通時(shí)儲(chǔ)存在變壓器里的能量無(wú)法被充分釋放，長(zhǎng)時(shí)間后會(huì)導(dǎo)致變壓器的磁飽和，繼而燒毀充電器。所以在程序中，設(shè)定當(dāng)充電電流為零，充電過(guò)程即強(qiáng)制結(jié)束。如果檢測(cè)到充電器的輸出電壓過(guò)高或輸出電流過(guò)大，充電程序也會(huì)強(qiáng)制結(jié)束，保護(hù)蓄電池不會(huì)損壞。
    在程序中，各階段的執(zhí)行時(shí)間均被記錄，如果充電時(shí)間過(guò)長(zhǎng)或充電時(shí)間過(guò)短，均會(huì)跳至對(duì)應(yīng)的程序段，或點(diǎn)亮信號(hào)燈，或蜂鳴報(bào)警，或強(qiáng)制結(jié)束程序，這使得充電狀態(tài)一目了然。
1．3 變壓器設(shè)計(jì)簡(jiǎn)介
    由于電池的充電電流不可以為零，所以本充電器必須工作在連續(xù)工作模式下，反激變壓器即使工作在電流連續(xù)模式，盡管總安匝不會(huì)停留在零，但是，對(duì)于反激變壓器的每個(gè)線圈來(lái)說(shuō)，線圈電流總是處于斷續(xù)狀態(tài)。當(dāng)然電流(安匝)斷續(xù)更是如此。這是因?yàn)殚_(kāi)關(guān)期間，電流(安匝)在初級(jí)和次級(jí)之間來(lái)回轉(zhuǎn)換，即初級(jí)安匝減少時(shí)，次級(jí)安匝等量增加，反之亦然。雖然總安匝是連續(xù)的，紋波很小，但每個(gè)線圈的電流交
替由零到最高峰值之間變化。無(wú)論什么工作模式，線圈交流損耗大。
    為了降低成本，本例中使用的開(kāi)關(guān)器件是IRF840(500 V、8 A)，這使得變壓器的匝數(shù)比不可能太大，因?yàn)槭须娊?jīng)整流濾波后的電壓約為300VDC，充電器的最高輸出電壓約為45VDC，設(shè)計(jì)時(shí)設(shè)定匝數(shù)比N1／N2為2，這樣IRF840芯片約有100VDC的漏感尖峰裕度，降幅較為可靠。
    變壓器的初級(jí)和次級(jí)的伏秒數(shù)要保持平衡，由此可推算出開(kāi)關(guān)管的最大開(kāi)通時(shí)間
   
    式中，為變壓器原邊的最低輸入電壓，T為開(kāi)關(guān)周期，VO為輸出電壓，N1為初級(jí)匝數(shù)，N2為次級(jí)匝數(shù)，這里忽略了電路中開(kāi)關(guān)管和二極管的導(dǎo)通壓降。
    假設(shè)充電器的效率為80％，充電器的輸出功率為100 W，由于開(kāi)關(guān)管的最大導(dǎo)通時(shí)間出現(xiàn)在輸入電壓最低的時(shí)候，可推得變壓器的初級(jí)電感量
   
    式中，PO為輸出功率。
    為保證本充電器可以可靠的工作在連續(xù)電流模式下，經(jīng)調(diào)試，變壓器的實(shí)際參數(shù)如下：磁芯采用TDK的PC40EER40磁芯，磁芯芯柱的氣隙設(shè)為1．58 mm，骨架采用排距25 mm、針距5 mm、6x6針的立式骨架。初級(jí)繞組用0．64mm高強(qiáng)度漆包線繞97匝，電感量780 μH；次級(jí)繞組用0．64 mm高強(qiáng)度漆包線三線并繞50匝，電感量為208 μH。初次級(jí)之間墊入3層聚脂薄膜，不浸漆。

2 總結(jié)
    經(jīng)測(cè)試，本充電器的最高輸出功率可達(dá)90 W，效率約85％，整機(jī)成本約20元人民幣，具有很強(qiáng)的市場(chǎng)競(jìng)爭(zhēng)力。
    由于單片機(jī)的運(yùn)算速度的限制，使用單片機(jī)模擬電源管理IC無(wú)法做到使反饋環(huán)路非常穩(wěn)定，這給電路的熱設(shè)計(jì)增加了難度。如果要優(yōu)化熱設(shè)計(jì)，可采用給單片機(jī)外置振蕩器，將其工作頻率提高到20 MHz的方法，也可以將恒流充電階段再分成若干個(gè)階段，隨著充電器輸出電壓的提高，逐漸的降低輸出電流以降低輸出功率，以延長(zhǎng)充電時(shí)間為代價(jià)來(lái)降低充電器的發(fā)熱量，可以大幅降低充電器的工作溫度。
    本設(shè)計(jì)是采用單片機(jī)模擬電源管理IC，實(shí)現(xiàn)電源智能化的一次成功嘗試，通過(guò)本次嘗試，相信可以大大擴(kuò)展智能化電源的設(shè)計(jì)思路。