On-board Protection device for battery charger

Abstract: The goal of the thesis is to document the implementation of an On-board Protection Device that is to be used for On-board charging system in Electrical Vehicles. On-board Protection Device is a protection part of the On-board charging system which communicates via CAN communication with the main charger unit. It includes basic fault detection hardware such as Ground Fault Monitoring, Residual Current Device and Main microcontroller for interface to and from peripheral fault monitoring devices and external communication networks. The Control logic is implemented inside a microcontroller, which also communicates with input channels and control output signals to circuit breaker which connects charger unit with supply. The microcontroller also send periodically the necessary data and status information about the peripheral protection devices to battery charger and also initiates close or open commands to circuit breaker, if there is any fault. The thesis outlines the details of the protection device system design that can be helpful in utilizing or upgrading this system. The thesis is presented in two parts- The first part documents the design of Residual Current Device with 6mA leakage current and Ground Fault Monitoring device. The suggested solution is simulated by Pspice and is tested in the laboratory. The principle of protection devices is demonstrated through the experimental results. The second part documents the main logic part, implemented using TI Stellaris LM3S9B92 microcontroller, which has the required peripheral components to interface with different protection hardware and also has inbuilt CAN bus peripheral to communicate different CAN bus messages over CAN network. The control logic is first simulated in MATLAB using SIMULINK and STATEFLOW toolbox and then the actual implementation on the Evaluation Kit EKK-LM3S9B92 is described.