Design Optimization of Charger Based on PSPICE Simulation

The design of a high-frequency switching mode charger (HFSMC) was optimized using a PSPICE simulation of the charging system including a valve regulated lead-acid (VRLA) battery pack and the HFSMC. A high-frequency battery charging circuit model was developed to describe the battery dynamics when charging with DC current having high-frequency ripples. An IGBT circuit model, a high-frequency pulsed transformer coupling model and a silicon fast recovery diode model were also developed. Simulations were compared to laboratory measurements to verify the battery and system models. Simulation of the working states of an Fe-based nanocrystalline magnetic core used in the transformer shows that the transformer design can be optimized by adjusting the core gap and by employing an RC network. Further simulations show that the components in the output unit of the charger main circuit can also be optimized. Simulations also show that the battery dynamics including the inductance should be considered for design optimization of the HFSMC.