Opus - Revision history

WikiSysop: /* Opus Performance Evaluation */

2019-12-10T03:22:10Z

Opus Performance Evaluation

← Older revision		Revision as of 03:22, 10 December 2019
Line 40:		Line 40:
	[[File:Opus-chargepwm-1A.png\|thumb\|center\|400px\|Opus charging current waveform at 1A; PWM at 19.6Hz from 0 to ~1.3A.]]		[[File:Opus-chargepwm-1A.png\|thumb\|center\|400px\|Opus charging current waveform at 1A; PWM at 19.6Hz from 0 to ~1.3A.]]
	[[File:Opus-chargeramp-0-1A.png\|thumb\|center\|400px\|Opus charging current ramp up waveform to 1A; 720us settle time.]]		[[File:Opus-chargeramp-0-1A.png\|thumb\|center\|400px\|Opus charging current ramp up waveform to 1A; 720us settle time.]]
	[[~~File:~~File:Opus-dischargepwm-1A.png\|thumb\|center\|400px\|Opus discharging current waveform at 1A; PWM at 19.6Hz from 0 to ~2.85A.]]		[[File:Opus-dischargepwm-1A.png\|thumb\|center\|400px\|Opus discharging current waveform at 1A; PWM at 19.6Hz from 0 to ~2.85A.]]

	==BOM Cost Estimate==		==BOM Cost Estimate==

WikiSysop: /* Opus Performance Evaluation */

2019-12-10T03:21:56Z

Opus Performance Evaluation

← Older revision		Revision as of 03:21, 10 December 2019
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	===Opus Performance Evaluation===		===Opus Performance Evaluation===

			[[File:Opus-chargepwm-1A.png\|thumb\|center\|400px\|Opus charging current waveform at 1A; PWM at 19.6Hz from 0 to ~1.3A.]]
			[[File:Opus-chargeramp-0-1A.png\|thumb\|center\|400px\|Opus charging current ramp up waveform to 1A; 720us settle time.]]
			[[File:File:Opus-dischargepwm-1A.png\|thumb\|center\|400px\|Opus discharging current waveform at 1A; PWM at 19.6Hz from 0 to ~2.85A.]]

	==BOM Cost Estimate==		==BOM Cost Estimate==

WikiSysop at 18:43, 15 April 2019

2019-04-15T18:43:32Z

← Older revision		Revision as of 18:43, 15 April 2019
Line 1:		Line 1:
	This is an analysis/reverse engineering review of the Opus BT-C3100 v2.2 4-slot Li/Ni battery charger/tester.		This is an analysis/reverse engineering review of the Opus BT-C3100 v2.2 4-slot Li/Ni battery charger/tester.

	[[File:~~CCR_v1_Regen~~.jpg\|thumb\|right\|~~Fully functional v1 CCR prototype in regenerative configuration, testing Re-volt and Samsung 2600mAH cells~~.]]		[[File:Opus_internal.jpg\|thumb\|right\|Internal picture of the Opus tester.]]

	==List of Features==		==List of Features==

WikiSysop: /* BOM Cost Estimate */

2019-04-15T18:43:03Z

BOM Cost Estimate

← Older revision		Revision as of 18:43, 15 April 2019
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	\|- style="color:gray;text-align:left;"		\|- style="color:gray;text-align:left;"

	\|~~OPA335 Zero~~-~~Drift Amplifier (qty 2)~~		\|-}
	~~\|$2.42~~
	~~\|[https://lcsc.com/product-detail/Others_Texas-Instruments-TI-OPA335AIDBVR_C364887.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|MCP1402 MOSFET Driver (qty 4)~~
	~~\|$1.83~~
	~~\|[https://lcsc.com/product-detail/MOS-Drivers_MICROCHIP_MCP1402T-E-OT_MCP1402T-E-OT_C128573.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|STM32F103 "Blue Pill"~~
	~~\|$1.82~~
	~~\|[https://s.click.aliexpress.com/e/cWPSibTi Aliexpress]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|NCS199A1 Current Sense Amplifier (qty 2)~~
	~~\|$1.45~~
	~~\|[https://lcsc.com/product-detail/General-Purpose-Amplifiers_ON-Semicon_NCS199A1SQT2G_ON-Semicon-ON-NCS199A1SQT2G_C179595.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|18650 SMT Holder (qty 2)~~
	~~\|$1.23~~
	~~\|[http://s.aliexpress.com/nuqmae6r Aliexpress]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|N-channel MOSFET 13A 11.5mOhm SOIC-8 (qty 4)~~
	~~\|$0.52~~
	~~\|[https://lcsc.com/product-detail/MOSFET_Alpha-Omega-Semicon_AO4406AL_Alpha-Omega-Semicon-AOS-AO4406AL_C35349.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|rBOM (under $0.41)~~
	~~\|$4.76~~
	~~\|LCSC~~
	~~\|- style="color:green;text-align:left;"~~

	~~\|PCB~~
	~~\|$2.00~~
	~~\|JLCPCB~~
	~~\|- style="color:purple;text-align:left;"~~

	~~\|Assembly~~
	~~\|$7.10 - $31.70~~
	~~\|PCBgogo~~
	~~\|- style="color:black;text-align:center;"~~

	~~\|'''HW Component'''~~
	~~\|'''Cost'''~~
	~~\|'''Source'''~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|100x40x20 Aluminum Heatsink~~
	~~\|$3.02~~
	~~\|[https://www.ebay.com/itm/5pcs-Aluminum-Heat-Sink-100X40X20MM-100-40-20MM/163423637602?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 eBay]~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|40x40x20 5V Fan~~
	~~\|$1.60~~
	~~\|[https://www.ebay.com/itm/10-Pcs-5V-40mm-x-20mm-Cooling-Case-Fan-40x40x20mm-PC-Computer-Cooler-3D-Printer/251791125294 eBay]~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|Misc HW (Under $0.22)~~
	~~\|$0.42~~
	~~\|Aliexpress/eBay~~
	~~\|- style="color:red;text-align:left;"~~

	~~\|Total Price~~
	~~\|$52.41 (Assembly cost $317, batch qty 10)~~
	\|
	\|-

	\|}

WikiSysop: /* Opus Performance Evaluation */

2019-04-15T18:42:30Z

Opus Performance Evaluation

← Older revision		Revision as of 18:42, 15 April 2019
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	===Opus Performance Evaluation===		===Opus Performance Evaluation===
	~~[[File:Current_ramp_0-1A.png\|thumb\|center\|400px\|Charging mode ramp from 0 to 1A (CC).]]~~
	~~[[File:IR_current_pulse.png\|thumb\|center\|400px\|Discharge current pulse of 1A for measuring cell IR.]]~~

	The CCR v2 was assembled 2/15/19 and checked for basic operation cycle testing a Samsung 25R. Charging current is limited to approximately 2A due to power dissipation of the SOIC-8 P-channel MOSFETs. This may improve slightly with proper airflow routing using a 3D printed enclosure. Transient performance and current regulation were measured with a Rigol DS1052E. Discharge shows an overshoot of approximately 18% for 580us, and regulation of +/-3.8% at 1A. Charge shows no overshoot, and regulation of +/-3.9% at 1.5A.

	~~[[File:CCR_v2_Thermal_Charging3p5A180k.JPG\|thumb\|center\|400px\|Thermal image of the P-channel MOSFET at 180kHz switching frequency, 3.5A charging. Peak was 103 C from 12V supply.]]~~

	Further investigation showed the MOSFET driver was not able to produce sharp edges, causing higher switching losses at 360 kHz. Changing the code to operate the MOSFETs at 180 kHz allows charging at up to 3.5A.

	==BOM Cost Estimate==		==BOM Cost Estimate==

WikiSysop: /* CCR v1 Performance Evaluation */

2019-04-15T18:42:16Z

CCR v1 Performance Evaluation

← Older revision		Revision as of 18:42, 15 April 2019
Line 32:		Line 32:

	Discharge termination is when the Li-Ion battery reaches 2.70V at constant current. There is no rest period after discharge before charging begins.		Discharge termination is when the Li-Ion battery reaches 2.70V at constant current. There is no rest period after discharge before charging begins.

	~~===CCR v1 Performance Evaluation===~~
	~~[[File:CCR_v1_Efficiency.png\|thumb\|center\|400px\|Buck (charging)/Boost (discharging) converter efficiency for the CCR v1.0.]]~~
	~~[[File:Thermal_4V-1p5A.JPG\|thumb\|right\|Boost (discharging) mode operation at 1.5A, showing peak external transistor temperature of 57.8 C.]]~~

	===Microcontroller===		===Microcontroller===

WikiSysop: /* Resistor Discharger */

2019-04-15T18:42:07Z

Resistor Discharger

← Older revision		Revision as of 18:42, 15 April 2019
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	A simplified schematic of the circuit that discharges the battery is shown in the thumbnail below:		A simplified schematic of the circuit that discharges the battery is shown in the thumbnail below:

	[[File:~~Ccr_v20_boost_simple~~.png\|thumb\|center\|400px\|Simplified ~~boost~~ circuit schematic for the ~~CCR v2.0~~.]]		[[File:Opus_discharge_simple.png\|thumb\|center\|400px\|Simplified discharger circuit schematic for the Opus.]]

	The battery positive goes through 2 0.12 ohm current sense resistors in parallel, through an SS34 schottky diode (3A, 40V, 0.4Vf at 2A), and into 6 5.1 ohm resistors in parallel (0.85 ohms equivalent), switched through an AO3400 N-channel MOSFET rated for up to 5.8A drain current, <33mOhm resistance at 4.5Vgs, and up to 1.4W power dissipation. The PWM rate for the MOSFET is 20 Hz. The peak battery current for a 4.2V Li-Ion battery is approximately 4A pulsed, accounting for voltage drops in the diode, FET, and current sense resistors.		The battery positive goes through 2 0.12 ohm current sense resistors in parallel, through an SS34 schottky diode (3A, 40V, 0.4Vf at 2A), and into 6 5.1 ohm resistors in parallel (0.85 ohms equivalent), switched through an AO3400 N-channel MOSFET rated for up to 5.8A drain current, <33mOhm resistance at 4.5Vgs, and up to 1.4W power dissipation. The PWM rate for the MOSFET is 20 Hz. The peak battery current for a 4.2V Li-Ion battery is approximately 4A pulsed, accounting for voltage drops in the diode, FET, and current sense resistors.

WikiSysop: /* List of Features */

2019-04-15T18:41:45Z

List of Features

← Older revision		Revision as of 18:41, 15 April 2019
Line 11:		Line 11:
	* Modes: Charge, Discharge, Discharge Test (C/D/C), Quick Test (IR), Discharge Refresh (10 cycles)		* Modes: Charge, Discharge, Discharge Test (C/D/C), Quick Test (IR), Discharge Refresh (10 cycles)
	* 6-7mA current resolution (4 digits), 10mV voltage resolution (3 digits), 1.64Hz update rate		* 6-7mA current resolution (4 digits), 10mV voltage resolution (3 digits), 1.64Hz update rate

			[[File:1a-vs-2a_chargetest_opus.png\|thumb\|center\|400px\|1A and 2A charge/discharge curves for the Opus.]]

	==Electronics==		==Electronics==

WikiSysop: /* Heatsink Sizing */

2019-04-15T18:40:57Z

Heatsink Sizing

← Older revision		Revision as of 18:40, 15 April 2019
Line 11:		Line 11:
	* Modes: Charge, Discharge, Discharge Test (C/D/C), Quick Test (IR), Discharge Refresh (10 cycles)		* Modes: Charge, Discharge, Discharge Test (C/D/C), Quick Test (IR), Discharge Refresh (10 cycles)
	* 6-7mA current resolution (4 digits), 10mV voltage resolution (3 digits), 1.64Hz update rate		* 6-7mA current resolution (4 digits), 10mV voltage resolution (3 digits), 1.64Hz update rate

	~~==Heatsink Sizing==~~

	~~...~~

	==Electronics==		==Electronics==

WikiSysop: /* Buck Converter (Charger) */

2019-04-15T18:38:57Z

Buck Converter (Charger)

← Older revision		Revision as of 18:38, 15 April 2019
Line 20:		Line 20:
	A simplified schematic of the buck converter that charges the battery from a 12V supply is shown in the thumbnail below:		A simplified schematic of the buck converter that charges the battery from a 12V supply is shown in the thumbnail below:

	[[File:~~Ccr_v20_buck_simple~~.png\|thumb\|center\|400px\|Simplified ~~buck~~ circuit schematic for the ~~CCR v2.0~~.]]		[[File:Opus_charge_simple.png\|thumb\|center\|400px\|Simplified charging circuit schematic for the Opus.]]

	The input is decoupled with a 1000uF/16V electrolytic capacitor, plus 10uF of MLCC for each cell. The charger consists of a EUP3484 340kHz 3A synchronous buck converter, which steps down the 12V to either 3.273V (in Ni* battery mode) or 6.326V (in Li* battery mode), with a 15uH inductor and 220uF 10V electrolytic output capacitor. This is switched through an AO3419 P-channel MOSFET rated for up to 3.5A drain current, <102mOhm resistance at 4.5Vgs, and up to 1.4W power dissipation. This ~20Hz PWM switched output is then fed through an SS34 schottky diode (3A, 40V, 0.4Vf at 2A), and 2 0.12 Ohm current sense resistors in parallel to the battery positive terminal.		The input is decoupled with a 1000uF/16V electrolytic capacitor, plus 10uF of MLCC for each cell. The charger consists of a EUP3484 340kHz 3A synchronous buck converter, which steps down the 12V to either 3.273V (in Ni* battery mode) or 6.326V (in Li* battery mode), with a 15uH inductor and 220uF 10V electrolytic output capacitor. This is switched through an AO3419 P-channel MOSFET rated for up to 3.5A drain current, <102mOhm resistance at 4.5Vgs, and up to 1.4W power dissipation. This ~20Hz PWM switched output is then fed through an SS34 schottky diode (3A, 40V, 0.4Vf at 2A), and 2 0.12 Ohm current sense resistors in parallel to the battery positive terminal.

← Older revision		Revision as of 18:43, 15 April 2019
Line 46:		Line 46:
	\|- style="color:gray;text-align:left;"		\|- style="color:gray;text-align:left;"

	\|~~OPA335 Zero~~-~~Drift Amplifier (qty 2)~~		\|-}
	~~\|$2.42~~
	~~\|[https://lcsc.com/product-detail/Others_Texas-Instruments-TI-OPA335AIDBVR_C364887.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|MCP1402 MOSFET Driver (qty 4)~~
	~~\|$1.83~~
	~~\|[https://lcsc.com/product-detail/MOS-Drivers_MICROCHIP_MCP1402T-E-OT_MCP1402T-E-OT_C128573.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|STM32F103 "Blue Pill"~~
	~~\|$1.82~~
	~~\|[https://s.click.aliexpress.com/e/cWPSibTi Aliexpress]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|NCS199A1 Current Sense Amplifier (qty 2)~~
	~~\|$1.45~~
	~~\|[https://lcsc.com/product-detail/General-Purpose-Amplifiers_ON-Semicon_NCS199A1SQT2G_ON-Semicon-ON-NCS199A1SQT2G_C179595.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|18650 SMT Holder (qty 2)~~
	~~\|$1.23~~
	~~\|[http://s.aliexpress.com/nuqmae6r Aliexpress]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|N-channel MOSFET 13A 11.5mOhm SOIC-8 (qty 4)~~
	~~\|$0.52~~
	~~\|[https://lcsc.com/product-detail/MOSFET_Alpha-Omega-Semicon_AO4406AL_Alpha-Omega-Semicon-AOS-AO4406AL_C35349.html LCSC]~~
	~~\|- style="color:gray;text-align:left;"~~

	~~\|rBOM (under $0.41)~~
	~~\|$4.76~~
	~~\|LCSC~~
	~~\|- style="color:green;text-align:left;"~~

	~~\|PCB~~
	~~\|$2.00~~
	~~\|JLCPCB~~
	~~\|- style="color:purple;text-align:left;"~~

	~~\|Assembly~~
	~~\|$7.10 - $31.70~~
	~~\|PCBgogo~~
	~~\|- style="color:black;text-align:center;"~~

	~~\|'''HW Component'''~~
	~~\|'''Cost'''~~
	~~\|'''Source'''~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|100x40x20 Aluminum Heatsink~~
	~~\|$3.02~~
	~~\|[https://www.ebay.com/itm/5pcs-Aluminum-Heat-Sink-100X40X20MM-100-40-20MM/163423637602?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 eBay]~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|40x40x20 5V Fan~~
	~~\|$1.60~~
	~~\|[https://www.ebay.com/itm/10-Pcs-5V-40mm-x-20mm-Cooling-Case-Fan-40x40x20mm-PC-Computer-Cooler-3D-Printer/251791125294 eBay]~~
	~~\|- style="color:blue;text-align:left;"~~

	~~\|Misc HW (Under $0.22)~~
	~~\|$0.42~~
	~~\|Aliexpress/eBay~~
	~~\|- style="color:red;text-align:left;"~~

	~~\|Total Price~~
	~~\|$52.41 (Assembly cost $317, batch qty 10)~~
	\|
	\|-

	\|}