S.
H JONDHALE POLYTECHNIC DOMBIVLI (WEST)
ACADEMIC YEAR 2023-24
TOPIC:- BUILD A BATTERY CHARGER CIRCUIT FOR CHARGING BATTERY OF 6V, 4AH.
SBMITTED BY :-
1113 Shlok Gunjal
1112 Lalit Dube
1119 Viraj Kumbhar
1111 Anmol Beldar
1101 Vedant Hire
UNDER THE GUIDANCE OF
Ms. HEMALI PATIL
IN PARTIAL FULFILLMENT FOR
THE AWARD OF THE DIPLOMA IN
ELECTRONIC AND TELECOMMUNICATIONS ENGINEERING OF
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
1
ACKNOWLEDGEMENT
WE WOULD LIKE TO EXPRESS
OUR SPECIAL THANKS OF GRATITUDE
TO OUR SUBJECT TEACHER
MS. HEMALI PATIL
WHO GAVE US THE OPPORTUNITY
TO DO THIS PROJECT ON
“BUILD A BATTERY CHARGER CIRCUIT
FOR CHARGING BATTERY OF 6V, 4AH.”
WHICH ALSO HELPED US IN
DOING A LOT OF RESEARCH
AND WE CAME TO KNOW ABOUT
BATTERY CHARGER AND THERE USES
WE ARE REALLY THANKS
TO GROUP MATES TO FINALIZING
THISP ROJECT WITHIN THE
LIMITED TIME FRAME
2
This is to certify That Mr./Ms. Group Roll No. / Name
1113 Shlok Gunjal
1112 Lalit Dube
1119 Viraj Kumbhar
1111 Anmol Beldar
1101 Vedant Hire
Of fourth semester of diploma in Electronic and Telecommunication Engineering of Institute
[Link] polytechnic. Dombivli (W) has completed the micro project satisfactorily In Subject
LIC for the Academic Year 2022-23 as prescribe in the curriculum
Place: Dombivli Date:
Suject Teacher HOD Principal
3
Index
Sr No. Topic Page No.
1 Introduction 5
2 Components Required 7
And their detail
4 Conclusion 20
5 Reference 21
4
Introduction
Battery chargers are essential devices for ensuring
the longevity and efficient operation of rechargeable
batteries. In this report, we focus on the design and
construction of a battery charger tailored for a 6V,
4AH battery. The aim is to provide a comprehensive
guide to creating a functional charger using
commonly available components.
The necessity for such a charger arises from the
ubiquity of 6V batteries in various applications,
ranging from small electronic devices to backup
power systems. By designing a charger specifically
for this battery type, users can ensure optimal
charging conditions, thus prolonging the battery’s
lifespan and maintaining its performance.
5
Key components selected for this project include a
105J 250V capacitor, KBL406 bridge diode rectifier,
resistors (1K and 390k ohms), a red LED indicator, a
2-pin AC socket, and a battery connector cable.
Each component plays a crucial role in the charging
process, from converting AC voltage to DC to
regulating the charging current and providing visual
feedback to the user.
This report will outline the design principles,
component selection rationale, and step-by-step
construction process for building the battery charger.
Additionally, safety considerations and potential
troubleshooting tips will be addressed to ensure a
successful and reliable charging solution for 6V, 4AH
batteries.
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Components Required
105J 250 V Capacitor
Diode 1N4007
Resistor 1K
Resistor 390k Ohms
Red LED
2 Pin AC Socket
Battery connector cable
7
Capacitor
The 105J capacitor is a type of ceramic capacitor
commonly used in electronic circuits for various
purposes, including smoothing, filtering, decoupling,
and timing applications. The “105” in its name
represents its capacitance value in Pico farads (pF),
where the first two digits (10) denote the significant
figures, and the third digit (5) represents the
multiplier (10^5). Therefore, the capacitance value of
a 105 capacitor is 10 * 10^5 pF, which equals
1,000,000 pF or 1 µF (microfarad).
The 250V rating Indicates the maximum voltage that
the capacitor can withstand without experiencing
damage. In this context, the 105J capacitor is rated
for a maximum voltage of 250 volts, making it
suitable for use in circuits where the voltage does
not exceed this value.
In the context of a battery charger circuit, the 105J
capacitor is typically used for smoothing the output
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voltage from the rectifier stage. It helps remove the
ripple component from the rectified AC voltage,
resulting in a more stable DC voltage suitable for
charging the battery. Additionally, it assists in filtering
out any high-frequency noise or transients that may
be present in the power supply, ensuring a clean and
consistent voltage output for the charging process.
9
Diode 1N4007
The 1N4007 diode is a widely used rectifier diode in
electronic circuits, especially in low-frequency
applications where high current and voltage handling
capabilities are required. It belongs to the 1N400x
series of rectifier diodes, with the “4007” denoting its
specific part number.
The 1N4007 diode is designed to handle a
maximum repetitive peak reverse voltage (Vrms) of
1000 volts, making it suitable for applications
involving relatively high voltage levels. Additionally, it
has a forward current rating (If) of 1 ampere, which
allows it to handle moderate levels of current flow
without experiencing damage.
10
In a battery charger circuit, the 1N4007 diode is
commonly used as part of a bridge rectifier
configuration to convert alternating current (AC)
voltage from a power source, such as mains
electricity, into direct current (DC) voltage. As a
rectifier diode, it allows current to flow in only one
direction while blocking it in the opposite direction,
thus converting the AC input into a pulsating DC
output.
Overall, the 1N4007 diode plays a critical role in
ensuring the proper functioning of the rectification
stage in a battery charger circuit, enabling the
conversion of AC power into a form suitable for
charging batteries.
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Resistor
A 1K resistor, also known as a 1 kilo ohm resistor, is
a passive two-terminal electronic component that
restricts the flow of electric current. Its name
signifies its resistance value, which is 1000 ohms (1
kilo ohm).
In electronic circuits, resistors are used for various
purposes, including current limiting, voltage division,
biasing, and signal conditioning. The 1K resistor is a
commonly used value in circuits where moderate
resistance is required.
In the context of a battery charger circuit, a 1K
resistor might be used for current limiting or voltage
division purposes. For example, it could be used in
conjunction with other components to regulate the
charging current flowing into the battery, ensuring
that it remains within safe limits. Additionally,
resistors are often employed in voltage divider
networks to set reference voltages or bias certain
components within the circuit.
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Overall, the 1K resistor serves as a versatile
component in electronic design, providing control
over current and voltage levels in various circuit
configurations. In the specific context of a battery
charger circuit, it contributes to the overall
functionality and safety of the charging process.
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Red LED
A red LED, or Light Emitting Diode, is a
semiconductor device that emits red light when
current flows through it in the forward direction.
LEDs are widely used in electronic circuits for
indicating purposes, illumination, and visual
feedback.
In the context of a battery charger circuit, a red LED
is often utilized as an indicator to convey the
charging status to the user. Typically, the LED is
connected in parallel with a current-limiting resistor
across the battery terminals. When the battery is
being charged, the LED lights up, providing a visual
indication that charging is in progress. Once the
battery reaches full charge or when charging is
complete, the LED may turn off or exhibit a different
behaviour, such as blinking or dimming, depending
on the circuit design.
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Red LEDs are preferred for charging indicators due
to their visibility and distinct colour, which easily
distinguishes them from other indicators or status
lights in electronic devices. They are relatively low-
cost, energy-efficient, and have a long operational
life, making them suitable for various battery charger
applications.
Overall, the red LED serves as a simple yet effective
component in battery charger circuits, providing
users with a convenient way to monitor the charging
process and ensuring safe and efficient operation of
rechargeable batteries.
15
2 Pin AC Socket
A 2-pin AC socket is a type of electrical connector
designed to connect devices to an alternating
current (AC) power supply. It typically consists of two
pins that plug into corresponding slots in a power
outlet or receptacle.
In the context of a battery charger circuit, the 2-pin
AC socket serves as the interface between the
charger and the mains power supply. It allows the
charger to be plugged into a standard AC power
outlet, enabling the device to draw electrical power
for charging batteries.
The 2-pin configuration is commonly used in regions
where the electrical grid supplies power at a voltage
and frequency compatible with this type of
connector. The absence of a grounding pin simplifies
the design and reduces the size of the socket,
making it compact and convenient for portable
devices such as battery chargers.
16
When incorporating a 2-pin AC socket into a battery
charger circuit, proper insulation and safety features
should be considered to prevent electric shock
hazards and ensure compliance with relevant safety
standards. Additionally, the socket should be rated to
handle the voltage and current requirements of the
charger and the local power supply to ensure safe
and reliable operation.
17
Battery connector
A 6V, 4AH battery connector is a type of electrical
connector specifically designed to interface with a 6-
volt, 4-ampere-hour (AH) rechargeable battery. It
typically consists of two terminals or pins that allow
for the secure and reliable connection between the
battery and external devices, such as a charger or
load.
The connector’s design and pin configuration should
match the corresponding terminals on the battery to
ensure proper polarity and compatibility. Typically,
one terminal is designated for the positive (+)
connection, while the other terminal is for the
negative (-) connection.
When selecting or designing a connector for a 6V,
4AH battery, factors such as current carrying
capacity, insulation, durability, and ease of use
should be taken into consideration. The connector
should be capable of safely handling the maximum
current that the battery can deliver during charging
or discharging operations.
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Common types of connectors used for 6V, 4AH
batteries include barrel connectors, screw terminals,
and push-on connectors. The choice of connector
depends on the specific application requirements,
such as space constraints, ease of assembly, and
mechanical robustness.
Overall, a properly chosen and correctly installed
battery connector ensures efficient and safe
operation of devices powered by 6V, 4AH batteries,
including battery chargers and other electronic
systems.
19
Conclusion
The design and construction of a battery charger for
a 6V, 4AH battery involve careful selection and
integration of various components to ensure safe
and efficient charging. Components such as the
KBL406 bridge diode rectifier, 105J capacitor, 1K
resistor, red LED, 2-pin AC socket, and the battery
connector cable play critical roles in converting AC
voltage to DC, smoothing the output, regulating
current, and providing visual feedback to the user.
By understanding the functions and specifications of
each component, one can create a charger that
meets the specific requirements of the battery while
adhering to safety standards. Overall, a well-
designed charger facilitates reliable charging,
prolongs battery life, and enhances the usability of
devices powered by 6V, 4AH batteries.
20
Reference
• [Link]
• [Link]
component-7-basic-components-that-help-
power-our-world/
• [Link]
• [Link]
• [Link]
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